2003-2006 Polaris Predator 500 Service & Repair Manual

2003 PREDATOR SERVICE MANUAL 2003 PREDATOR SERVICE MANUAL PN 9918062 PN 9918062 2003 PREDATOR 500 SERVICE MANUAL PN 9918062 2003 PREDATOR 500 SERVICE MANUAL PN 9918062

2003 PREDATOR SERVICE MANUAL Foreword ThismanualisdesignedprimarilyforusebycertifiedPolarisMasterServiceDealertechniciansinaproperly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Someproceduresoutlinedinthismanualrequireasoundknowledgeofmechanicaltheory,tooluse,andshop proceduresinordertoperformtheworksafelyandcorrectly. Techniciansshouldreadthetextandbefamiliar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Thismanualincludesproceduresformaintenanceoperations,componentidentificationandunitrepair,along with service specifications for the 2003 Polaris Predator ATV. Comments or suggestions about this manual maybedirectedto: ServicePublicationsDept.@PolarisSalesInc.2100Hwy55MedinaMinnesota55340. 2003 Polaris Predator ATV Service Manual (PN 9918062) ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvement in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY ISINVOLVED! DANGER FailuretofollowDANGERinstructionswillresultinsevereinjuryordeathtotheoperator,bystanderorperson inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation FOX, Registered Trademark of Fox Shox Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc.

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

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2003-2006 Polaris Predator 500 Service & Repair Manual

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