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
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POLARIS PREDATOR 500 ATV Service Repair Workshop Manual
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Description
Fix your Polaris Predator 500 ATV yourself with this complete Service Repair Workshop Manual. Rebuild the engine, service the fuel system, adjust the transmission, replace brake components, and tackle electrical repairs without guessing. Every procedure, specification, and wiring diagram you need is here.
Access detailed engine work, suspension tuning, clutch service, and factory maintenance schedules instantly. Stop paying shop rates for jobs you can do in your garage. Buy once, download now, start working.
