2006 Polaris Predator 500 Factory Service & Work Shop Manual

1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL 2006 PREDATOR 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL 2006 PREDATOR - TROY LEE DESIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2006 PREDATOR 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 2006 PREDATOR 500 - TROY LEE DESIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 ‘WHERE USED’ TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SPECIAL TOOL LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 COVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. ENGINE DESIGNATION NUMBER ES50PLE - Single, Water Cooled, Electric Start, Manual 5-Speed, DOHC 4 Stroke VIN IDENTIFICATION UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION 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 LOCATION This information can be found on the clutch housing on the right side of engine. (A) PAINT CODE PAINTED PART COLOR POLARIS NUMBER Frame Vapor Silver P-385 Frame Matte’ Black P-458 } Machine Model Number Identification } } } A 06 GJ 50 AA Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine 4 X A G J 5 0 A * 5 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Emissions } Check Digit* Model Year Body Style Plant No* Individual Serial Number * -This could be either a number or a letter Powertrain

1.3 GENERAL INFORMATION PUBLICATION NUMBERS NOTE: Other Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. 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. STANDARD TORQUE SPECIFICATIONS 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 in. 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 Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2006 PREDATOR A06GJ50AA 9920183 9920184 9920185 2006 PREDATOR Troy Lee Design A06GJ50AB 9920183 9920184 9920185 Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

1.4 GENERAL INFORMATION SPECIFICATIONS MODEL 2006 PREDATOR 500 MODEL NUMBER:A06GJ50AA ENGINE MODEL:ES50PLE021 MODEL 2006 PREDATOR - TROY LEE DESIGNS MODEL NUMBER:A06GJ50AB ENGINE MODEL:ES50PLE031 Category 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 Oil Capacity 2.5 qts./2.37 ltr Coolant Capacity 2.25 qts./2.1 ltr Fuel Capacity 3.25 gal./12.3 ltr Category 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 412 lbs./187 kg Oil Capacity 2.25 qts./2.1 ltr Coolant Capacity 2.25 qts./2.1 ltr Fuel Capacity 3.25 gal./12.3 ltr Optional Accessories Shown

1.5 GENERAL INFORMATION 2006 PREDATOR 500 MODEL NUMBER:A06GJ50AA ENGINE MODEL:ES50PLE021 JETTING CHART Engine Platform Fuji DOHC 4 stroke Engine Model Number 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 160 o F (71 o 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 6CGY07–60-3 Needle Jet O–OM Pilot Screw 2.5 Turns Out (Initial setting, May Pilot Air Jet 110 Float Height 13 mm (0.51”) Fuel Delivery Fuel Pump Fuel Requirement 87 Octane (minimum) Electrical Alternator Output 200W @ 3000 RPM Voltage Regulator 3-Phase Lights: Main Headlights Dual Bean 35 watts / 35 watts Tail LED Brake 26.9 watts Neutral / Hot / Reverse 1 watt (ea.) Ignition System DC/CDI Ignition RPM Limit 9100 + 100 / Reverse 5000 + 100 Ignition Timing 30 o + 3 o BTDC@ 3500 RPM Spark plug / Gap NGK DCPR8E/ .035 in./ 0.9 mm Battery / Model / Amp Hr Maintenance-Free 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 38 Axle Runout - Maximum .020” (.51 mm) Gear Ratio : 1st 2nd 3rd 4th 5th Rev 2.43 1.61 1.29 1.09 0.92 2.07 Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm) 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 ‘Piggy Back’ Shock Rear Travel 11 in. / 27.94 cm Ground Clearance 4.5 in. / 11.43 cm Shock Preload Adjustment Front / Rear Front - Spring tension - Std. Rear - Fox Dual Clicker - Std. Turning Radius 67 in. / 170.18 cm Toe Out 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Wheel Size - Front 21x7-10 Wheel Size - Rear 20x11-9 Front Tire Make / Model / Size 21x7-10 Rear Tire Make / Model / Size 20x11-9 Recommended Air Pressure F / R 4 psi Front 4 psi Rear Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Altitude AMBIENT TEMPERATURE Below 40 o F Below 5 o C +40 o F to +80 o F +5 o C to +28 o C Meters (Feet) 0-1800 (0-6000) 155 150 above 1800 (above 6000) 147.5 142.5

1.6 GENERAL INFORMATION 2006 PREDATOR 500 - TROY LEE DESIGNS MODEL NUMBER:A06GJ50AB ENGINE MODEL:ES50PLE031 JETTING CHART Engine Platform Fuji DOHC 4 stroke Engine Model Number 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 6CGY07-60-3 Needle Jet O-OM Pilot Screw 2.5 Turns Out (Initial setting, May Pilot Air Jet 110 Float Height 13 mm (0.51") Fuel Delivery Fuel Pump Fuel Requirement 87 Octane (minimum) Electrical Alternator Output 200 w @ 3000 RPM Voltage Regulator 3-Phase Lights : Main Headlights Dual Beam 35 watts / 35 watts Tail LED Brake 26.9 watts Neutral / Hot / Reverse 1 watt (ea.) Ignition System DC/CDI Ignition RPM Limit 9100 ± 100 / Reverse 5000 ± 100 Ignition Timing 30 o + 3 o BTDC @ 3500 RPM Spark plug / Gap NGK DCPR8E/ .035 in./ 0.9 mm Battery / Model / Amp Hr Maintenance-Free 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 38 Axle Runout - Maximum .020” (.51 mm) Gear Ratio : 1st 2nd 3rd 4th 5th Rev 2.36 1.87 1.53 1.24 0.93 2.07 Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm) 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 Podium X w/piggyback reservoir Front Travel 10 in. / 25.4 cm Rear Suspension Style / Shock Linkless Swing Arm / Fox Podium X ‘Piggy Back’ Schock Rear Travel 11 in. / 27.94 cm Ground Clearance 4.5 in. / 11.43 cm Shock Preload Adjustment Front / Rear Front - Spring tension - Std. Rear - Fox Dual Clicker - Std. Turning Radius 67 in. / 170.18 cm Toe Out 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Wheel Size - Front 21x7-10 Wheel Size - Rear 20x10-9 Front Tire Make / Model / Size 21x7-10 Rear Tire Make / Model / Size 20x10-9 Recommended Air Pressure F / R 4 psi Front 4 psi Rear Brake - Front Dual Hydraulic Disc Brake - Rear Single Hydraulic Disc Altitude AMBIENT TEMPERATURE Below 40 o F Below 5 o C +40 o F to +80 o F +5 o C to +28 o C Meters (Feet) 0-1800 (0-6000) 155 150 above 1800 (above 6000) 147.5 142.5

1.7 GENERAL INFORMATION SPECIAL TOOLS ‘WHERE USED’ TABLE *Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657). PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN 8712100 or 8712500 Tachometer 2,7 2200634 Valve Seat Reconditioning Kit 3 PU-45257 Valve Spring Compressor 3 PA-46075 Flywheel Puller 3 PA-46087 Crankcase Separator 3 2870390 Piston Support Block 3 2872105 Water Pump Mechanical Seal Puller 3 PA-45958 Cam Chain Tensioner Assembly Tool 3 PA-46076 MAG End Crankshaft Nut Remover/Installer 3 PA-46077 MAG End Crankshaft Installer 3 2871283 Crankshaft/Water Pump Seal Install Kit 3 5131135 Water Pump Install Kit 3 PA-46502 Valve Spring Compressor 3 2870975 Mity Vac™ Pressure Test Tool 3,4 2872314 Carburetor Float Adjustment Tool 4 2870623 Shock Absorber Spring Compression Tool 5 7052069 Charging Needle 5 2200421 Gas Shock Recharging Kit 5 2871352 Shock Rod Holding Tool 5 2871351 Fox™ Shock IFP Depth Tool 5 2870386 Piston Pin Puller 6 PV-43568 Fluke™ 77 Digital Multimeter 7 2870630 Timing Light 7

1.8 GENERAL INFORMATION SPECIAL TOOL LISTING Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Tools shown may not apply to a particular vehicle. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine Tools PU-45432 - Caliper or A Basic Caliper Basic Micrometer PA-46502 - Valve Spring Compressor PA-46087 - Crankcase Separator PA-46075 - Flywheel Puller PA-45958 - Cam Chain Tensioner Tool Standard Tools and Engine Tools 2870569 - Crankshaft True Kit 2870386 - Piston Pin Puller PA-46076 Mag End Crank Nut Remover/Install PA-46077 - Mag End Crankshaft Installer PV-43527 Oil Filter Wrench 5131135 - Water Pump Install Tool 2870390 - Piston Support Block

1.9 GENERAL INFORMATION Standard Tools and Engine Tools 2870303 - Hone Kit 2870305 - Stone Replacement Kit 2870588 - Hone Oil (12 OZ.) 2200634 - Valve Seat Reconditioning Kit 2870459 - Dial Indicator PV-35667-A - Cylinder Leak down Tester 2872105 - Water Pump Seal Puller 2871283 - Crank/Water Pump Seal Install Kit Suspension Tools 2871351 - Shock IFP Depth Tool 2871071 - Shock Body Holding Tool 2870772 - 1.75” Wrench 2870623 - Shock Spring Compressor

1.10 GENERAL INFORMATION Fuel & Brake Systems 2870975 - Mity Vac™ Electrical Tools PV-43568 - Fluke™ 77 Multimeter PV-39617 - Current Clamp 2870836 - Battery Hydrometer 8712500 - PV-39951-A - Tachometer Tachometer Electrical Tools 2870630 - Timing Light 2871745 - Static Timing Light Harness 2460761 - Hall Sensor Probe Harness PV-39991 - Peak Reading Adapter PV-37453 - Christie™ Se-Sulfating Multi-Battery Charger PV-63070 - Christie™ Multi-Battery Charger

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2006 Polaris Predator 500 Factory Service & Work Shop Manual

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