Polaris PREDATOR 2003 Service Manual
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Polaris PREDATOR 2003 Service Manual

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

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Summary of Contents for Polaris PREDATOR 2003

  • Page 1 2003 PREDATOR SERVICE MANUAL 2003 PREDATOR SERVICE MANUAL PN 9918062 PN 9918062...
  • Page 2 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.
  • Page 3 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.
  • Page 4 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...

  • Page 6: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION Model Identification ..... . . Serial Number Location ....Publication Numbers .

  • Page 7: Model Identification

    Individual Serial No. a number or a letter Engine Plant No.* Check Digit* Powertrain UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION Whenever corresponding with Polaris about a particular issue, the machine model number and serial number important vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B)

  • Page 8: Publication Numbers

    GENERAL INFORMATION PUBLICATION NUMBERS Year Model Model No. Owner’s Parts Parts Manual PN Manual PN Micro Fiche PN PREDATOR PREDATOR A03GJ50CA A03GJ50CA 2003 2003 9917574 9917574 9917576 9917576 9917577 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.

  • Page 9: Predator Models

    GENERAL INFORMATION PREDATOR MODELS PREDATOR 500 TROY LEE LIMITED EDITION PREDATOR 500...
  • Page 10 GENERAL INFORMATION 2003 PREDATOR 500 MODEL: ..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...

  • Page 11: Maintenance

    GENERAL INFORMATION 2003 PREDATOR 500 MODEL: ..MODEL NUMBER: A03GJ50AA ENGINE MODEL: ES50PLE01 Engine Drivetrain Platform Fuji DOHC 4 stroke Transmission Type Manual 5 speed Engine Model Number ES50PLE01 Main Sprocket - - # Tooth Engine Displacement 499cc Rear Sprocket - - # Tooth...
  • Page 12 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 13: Conversion Table

    GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.

  • Page 14: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8 or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 15 GENERAL INFORMATION NOTES 1.10...
  • Page 16 MAINTENANCE CHAPTER 2 MAINTENANCE Periodic Maintenance Chart ....2.2-2.3 Pre-Ride Inspection ..... . Lubricant and Maintenance Product Numbers 2.5 Special Tools .

  • Page 17: Periodic Maintenance Chart

    Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause. E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. ENGINE / COOLING / CONTROLS Item...
  • Page 18 MAINTENANCE PERIODIC MAINTENANCE CHART CONT’D ELECTRICAL Item Maintenance Interval Remarks (Whichever comes first) Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security. " Apply Dielectric grease to connectors that are subjected to water, mud, etc.

  • Page 19: Pre-Ride Inspection

    Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir. 2.22 Sight glass should appear dark when installed, indicating proper fluid level.
  • Page 20 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Engine Lubricant 2874414 Engine Oil (Quart) PS 4 Synthetic (4--Cycle) 2874415 Engine Oil (Gallon) PS 4 Synthetic (4--Cycle) Grease / Specialized Lubricants 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz.

  • Page 21: Special Tools

    Gas Shock Recharging Kit 2871352 Shock Rod Holding Tool 2871351 Foxt Shock IFP Depth Tool 2870386 Piston Pin Puller PV- -43568 Fluket77 Digital Multimeter 2870630 Timing Light *Special Tools Can be ordered through a Polaris Dealer or SPX Corporation (1--800--328--6657).
  • Page 22 2 years or 200 hours.© See Ch. 6. Drive Chain Polaris Chain Lube Apply to chain link plates and rollers. As required* * More often under severe use, such as operation in mud, water, sand or under severe loads.
  • Page 23 Every 6 months or 50 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (continuous operation in water, mud or sand) Use grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease. ¢...

  • Page 24: Clutch Freeplay Adjustment

    MAINTENANCE CLUTCH ADJUSTMENT To remove the ETC cover: 1. Use a medium flat blade screwdriver and insert Clutch Lever Freeplay blade into the pocket of the cover starting on the 1. Measure clutch lever freeplay between the perch #1 position. and the lever (A).

  • Page 25: Idle Speed Adjustment

    MAINTENANCE CARBURETOR PILOT SCREW IDLE SPEED ADJUSTMENT ADJUSTMENT BSR Carburetor FRONT (Engine) Idle Screw Ill.3 Pilot Screw Ill.2 1. Start engine and warm it up thoroughly. NOTE: Pilot screw is covered by a welsh plug. Plug 2. Adjust idle speed by turning the idle adjustment removal will be required to perform these procedures.

  • Page 26: Fuel System

    MAINTENANCE NOTE: Be sure the engine is at operating loss of consciousness or death in a temperature. See Idle Speed Adjustment. short time. Never drain the float bowl when the 4. Loosen lock nut on in-line cable adjuster (Ill. 1). engine is hot.

  • Page 27: Compression Test

    MAINTENANCE 5. Reverse the procedures to install the fuel valve. A cylinder leakdown test is the best indication of engine condition. Follow manufacturer’s instructions 6. Start engine and inspect for leaks. to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may CARBURETOR DRAINING dislodge and leak).

  • Page 28: Battery Maintenance

    MAINTENANCE SPARK PLUG INSPECTION Recommended Spark Plug: Spark Plug Removal and Replacement NGK DCPR8E 1. Turn the fuel valve to OFF. Spark Plug Torque: 2. Remove the front cab. 14 Ft. Lbs. (19 Nm) 3. Move the fuel valve hose clamp (1) forward and gently remove the hose from the fuel valve fitting Spark Plug Gap on the gas tank.
  • Page 29 BATTERY TERMINALS/BOLTS NEVER attempt to add electrolyte or water to a Maintenance- -Free battery. Doing so will damage Use Polaris corrosion resistant Dielectric Grease (PN the case and shorten the life of the battery. Refer 2871329) on battery bolts. to the Battery Maintenance Video (PN 9917987)

  • Page 30: Liquid Cooling System

    Dielectric Grease Overheating of engine could occur if air is not fully purged from system. (PN 2871329) Polaris Premium 60/40 anti--freeze is premixed and ready to use. Do not dilute with water. 4. Connect the battery cables. COOLANT STRENGTH / TYPE...

  • Page 31: Cooling System Hoses

    MAINTENANCE COOLING SYSTEM HOSES 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as Inspect all hoses for cracks, deterioration, abrasion or required for freeze protection in your area.

  • Page 32: Cooling System Pressure Test

    MAINTENANCE COOLING SYSTEM PRESSURE TEST See Chapter 3 for testing procedures. RADIATOR SCREEN REMOVAL 1. Remove the 4 screws retaining the radiator screen for access to the radiator fins when cleaning. Ill.1 Installation: 8. Reinstall crankcase breather filter, pre--filter and air filter into air box.

  • Page 33: Crankcase Breather Filter

    (8-9 Nm). NOTE: The long bolt must be placed in the forward hole. 18. Remove the dipstick and fill the oil tank with 2.25 quarts (1.9 l) of Polaris PS--4 Engine Oil (PN 2874414). 19. Place gear selector in neutral and set parking brake.

  • Page 34: Wheel Alignment

    Polaris recommends from string surement steering component repair and adjustment be to rim at should be performed by an authorized Polaris MSD- -certi- front and 0--1/16 (0 to fied technician when replacing worn or dam- rear of rim. .0625 cm) aged steering parts.

  • Page 35: Body/Suspension

    MAINTENANCE METHOD 2: CHALK STEERING INSPECTION / TIE ROD ENDS AND HUBS / 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and To check for play in the tie rod end, secure handlebars in this position. NOTE: The grasp the steering tie rod, pull in all steering post arm “frog”...

  • Page 36: Brakes

    MAINTENANCE CAMBER AND CASTER EXHAUST PIPE The camber and caster are non-adjustable. WARNING TOE ALIGNMENT G Do not perform clean out immediately after the engine has been run, as the ex- ADJUSTMENT haust system becomes very hot. Serious burns could result from contact with ex- If toe alignment is incorrect, measure the distance haust components.

  • Page 37: Brake System Inspection

    Inspect brakes in accordance with the maintenance schedule and before each ride. Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. Use Polaris DOT 3 Brake Fluid (PN 2870990). Sight Parking Brake 3/64 Glass Lock (.1cm)
  • Page 38 (C) should not exceed 11.875 inches (30 cm). Exceeding this length may cause SPROCKET INSPECTION the spring to unseat from the shock body. Polaris ATV drive chains are equipped with O-ring FRONT sealed permanently greased pins and rollers. The Setting...
  • Page 39 MAINTENANCE SPROCKET INSPECTION Inspect the sprocket for worn, broken or bent teeth. If there is space between outside Master Link edge of the mas- ter link and plate, Do not back the plate press plate out slightly. in too far. Inspect chain for excessive wear, missing o--rings, etc.
  • Page 40 MAINTENANCE 3. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. 4. Tighten the eccentric locking bolts to 45 ft. lbs. (61 Nm). CAUTION: DO NOT OVER-TIGHTEN ECCENTRIC CLAMP BOLTS. PRE-MATURE BEARING FAILURE MAY RESULT. ADJUSTMENT PROCEDURE - SWINGARM / REAR AXLE SHOCK REBOUND AND...

  • Page 41: Wheel Removal/Installation

    MAINTENANCE It has eight possible positions ranging from position 1 contact the gas tank or any other part of the (softest) to 8 (firmest). The compression damping is machine when turned fully to the left or right. factory set at position 4. To adjust, turn the clicker 3.

  • Page 42: Tire Inspection

    MAINTENANCE Improperly installed wheels could affect vehicle WARNING handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into Operating your ATV with worn tires, improperly taper on wheel. inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.
  • Page 43 MAINTENANCE NOTES 2.28...
  • Page 44 ENGINE CHAPTER 3 ENGINE Torque Specifications ......3.2-3.3 ES50PL Service Data ......3.3-3.4 Special Tools .

  • Page 45: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Thread ES50PL Ft. Lbs. (Nm) Blind Plug (Crankcase) 1/8 PT 6.6-11.1 (9-15 Nm) Blind Plug (Oil Filter Cover) 1/4 PT 12.5-17 (17-23 Nm) Bearing Stop Plates 8.1-9.6 (11-13 Nm) Camshaft Chain Tensioner Blade Bolt 10-12.2 (13.5-16.5 Nm) Camshaft Chain Tensioner 6.6-8.1 (9-11 Nm)

  • Page 46: Es50Pl Service Data

    ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Thread ES50PL Ft. Lbs. (Nm) Valve Cover 6.6-8.1 (9-11 Nm) Water Pump Impeller 6.6-8.1 (9-11 Nm) Water Pump Housing Cover 6.6-8.1 (9-11 Nm) ES50PL ENGINE SERVICE DATA Cylinder Head / Valve ES50PL Camshaft Cam lobe height 1.667-1.671 (42.35-42.45 mm) Limit 1.655 (42.05 mm)
  • Page 47 ENGINE ES50PL ENGINE SERVICE DATA Valve Spring Overall length Inner 1.575 (40.0 mm) Limit = --.079 (--2.0 mm) Outer 1.650 (41.9 mm) Squareness Inner .067- (1.7 mm) Outer .071 (1.8 mm) Cylinder / Piston / Connecting Rod EH50PL12 Cylinder Surface warpage limit (mating with .002 (.05 mm) cylinder head) Cylinder bore...

  • Page 48: Special Tools

    ENGINE SPECIAL TOOLS PISTON IDENTIFICATION The piston may or may not have an identification PART NUMBER TOOL DESCRIPTION mark for piston placement. If the piston has an 2872105 Water Pump Mechanical Seal Puller identification mark, follow the directions for piston placement below.

  • Page 49: Cooling System Specifications

    2. The radiator cap relief pressure is 13 psi. for all engine damage. Polaris Premium 60/40 models. Replace if cap releases at less than 13 Antifreeze/Coolant (PN 2871323) is recommended psi.

  • Page 50: Engine Removal

    ENGINE ACCESSIBLE COMPONENTS ENGINE REMOVAL The following components can be serviced or 1. Thoroughly clean the ATV engine and chassis. removed with the engine installed in the frame: 2. Clean work area. 3. Support the ATV with jackstands under the Flywheel footrests at a height sufficient to raise the rear Alternator/Stator...

  • Page 51: Engine Installation Notes

    ENGINE INSTALLATION NOTES Engine Break In Period The break in period for a Polaris ATV engine is defined After the engine is installed in the frame, review this as the first ten hours of operation, or the time it takes checklist and perform all steps that apply: to use two full tanks of gasoline.

  • Page 52: Es50Pl Engine Lubrication

    SUPPORT CRANKSHAFT Oil Pressure Specification: HERE. 20 PSI @ 5500 RPM, Polaris PS--4 Synthetic (Engine Hot) 2. To correct a situation like the one shown in the illustration, squeeze the crankshaft at points A. OIL PRESSURE TEST (Use tool from alignment kit).

  • Page 53: Oil Pump Priming

    ENGINE OIL PUMP PRIMING At this point, the oil is diverted in three directions. Oil is supplied to the crankshaft through a pto side oil PROCEDURE passage, lubricating the crank bearings, crankpin, piston, cylinder and connecting rod bearings. NOTE:Oil pump priming procedures must be delivery pipe supplies oil to the top of the cylinder head performed whenever the oil hose connection and the transmission main shaft.

  • Page 54: Es50Pl Lubrication/Oil Flow

    ENGINE ES50PL OIL FLOW ES50PL OIL FLOW CHART To p of Oil Tank Oil Pump Crankcase (Clutch Side) Crankcase (Mag Side) Oil Tank Oil Hose (Scavenging) Oil Gallery Oil Gallery Oil Hose Oil Strainer Crankcase (Mag Side) Crankcase Oil Gallery Cam Chain Cylinder Crankcase (Clutch Side)
  • Page 55 ENGINE ES50PL ENGINE EXPLODED VIEWS Cylinder/Cylinder Head Crankcase/Transmission Valve Train Crankshaft and Piston 3.12...

  • Page 56: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY 6. If tensioner remains in place, tap lightly on tensioner body with a soft face hammer and REFER TO PAGE 3.6- - 3.7 FOR ENGINE remove tensioner. CAUTION: The assembly is under spring tension. Maintain inward pressure REMOVAL / INSTALLATION NOTES while removing.
  • Page 57 ENGINE 4. To retract the plunger, rotate the special tool 3. Remove the 8 bolts securing the cam tower clockwise while holding the tensioner stationary. assembly and remove the cover. You may also hold the special tool stationary and 4. To free the cam assembly, lift one cam assembly rotate the tensioner assembly counter--clockwise and slightly rotate it while removing the chain from if desired.
  • Page 58 ENGINE 1. Check release cam (A) for smooth operation 5. Measure ID of camshaft journal bore. throughout the entire range of movement. The spring (B) should hold the cam against the stop. Camshaft Journal I.D.: In this position, the actuator (C) will be held outward in the compression release mode.

  • Page 59: Cylinder Head

    ENGINE CYLINDER HEAD CYLINDER HEAD INSPECTION DISASSEMBLY WARNING: Wear eye protection during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 2. Remove the valve buckets (A). NOTE: Keep all parts in order with respect to their location in the cylinder head.

  • Page 60: Valve Inspection

    ENGINE 4. Using Valve Spring Compressor (PA- -46502) (A), compress the valve springs and remove the split keepers. NOTE: To prevent loss of tension, do not compress the valve springs more than necessary. 8. Remove the valve seals. NOTE: Replace seals whenever the cylinder head is disassembled.

  • Page 61: Cylinder Head Assembly

    ENGINE CYLINDER HEAD ASSEMBLY 3. Check end of valve stem for flaring, pitting, wear or damage (A). CAUTION: Wear eye protection during assembly. NOTE: Assemble the valves one at a time to maintain proper order. 1. Install new valve seals on valve guides. 4.
  • Page 62 ENGINE 6. Place retainer on springs and install valve spring compressor. Compress springs only enough to allow split keeper installation and prevent loss of spring tension. Install split keepers with the gap even on both sides. 7. Repeat procedure for remaining valves. 8.
  • Page 63 ENGINE ES50PL Adjusting Pad Selection Matrix 1. Measure valve clearance at TDC (Compression stroke) using thickness gauge with original adjusting pad installed. 2. Reference the measurement and the 3 digits marked on the existing adjusting pad on the matrix below 3.

  • Page 64: Piston Removal

    ENGINE CYLINDER/PISTON REMOVAL 4. Rock cylinder forward and backward and lift it from the crankcase, exposing the piston and AND INSPECTION connecting rod. Support piston with Piston Support Block (PN 2870390). NOTE: Follow engine disassembly procedures to 5. Remove dowel pins from crankcase. remove valve cover, camshafts and cylinder head.

  • Page 65: Cylinder Inspection

    ENGINE 5. The oil control ring is a three piece design consisting 5. Record measurements. If cylinder is tapered or of a top and bottom steel rail and center expander out of round beyond specification, the cylinder section. Remove the top rail first followed by the must be replaced.
  • Page 66 ENGINE PISTON/ROD INSPECTION 3. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if 1. Measure piston pin bore. ring-to-groove clearance exceeds service limits. Piston Ring Piston Pin Bore Feeler Gauge...
  • Page 67 ENGINE PISTON RING INSTALLED CRANKCASE DISASSEMBLY AND INSPECTION NOTE: The starter motor, starter drive gears, 1. Place each piston ring inside cylinder using piston flywheel, stator, cam chain and sprockets can be to push ring squarely into place. serviced with the engine in the frame. NOTE: Crankcase and transmission components cannot be serviced in the frame.
  • Page 68 ENGINE 5. Measure the ID of the bushing in the stator 3. Removing the flywheel exposes the starter drive housing (A) and the crankcase and record. main gear and one way clutch, which is mounted Measure in two directions 90 apart to determine on the flywheel.
  • Page 69 ENGINE CRANKSHAFT NUT REMOVAL 3. Inspect or replace the crankshaft oil seal anytime the clutch cover is removed for service. Install 1. Remove the stator--side crankshaft nut using MAG with the seal lip pointed in toward the cover. End Crankshaft Nut Remover/Installer (PN PA- -46076) while using a suitable holding fixture to keep the crankshaft from turning.
  • Page 70 ENGINE 6. Remove the clutch plates and friction discs, 9. Installation: Reverse the procedures. Using a keeping them in order. Inspect the pressure new nut, torque the clutch basket retaining nut to plates for wear and warpage. Inspect the friction 66- -81 Ft Lbs.
  • Page 71 ENGINE 2. Remove the 3 bolts holding the oil pump cover. 5. Replace any component that is found to be Inspect the inside of the cover for wear or scoring. damaged or worn. OIL PUMP CLEARANCE Limits are same as Standard Body Feed/ .006--.008I...

  • Page 72: Crankcase Separation

    ENGINE CRANKCASE SEPARATION CAM CHAIN/TENSIONER BLADE REMOVAL 1. Remove flange bolts (12) from magneto side 1. Remove bolt securing tensioner pivot blade to crankcase evenly in a criss-cross pattern. crankcase (A). 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas.

  • Page 73: Transmission

    ENGINE TRANSMISSION 3. Inspect the shaft support bearings in the crankcase halves. Replace if any roughness or REMOVAL/INSPECTION wear is felt. See page 3.33 for crankcase bearing inspection/removal. 1. Remove the shift forks, shift fork tubes and shift 4. To reassemble, reverse the procedures using the drum from the transmission assembly.
  • Page 74 ENGINE 2. Insert the “M” and R” shift forks (face up). 2. Remove the crankshaft bearing retainer screws using a impact driver. (A). NOTE: Screw threads contain locking agent. Heating of screws is required for removal. Use caution and wear proper safety equipment...

  • Page 75: Crankshaft Runout Inspection

    ENGINE 6. Using Crankshaft Installer 3. Place the crankshaft in a truing stand or V-blocks (PA- -46077), draw the crankshaft into the bearing and measure the runout on both ends with a dial assembly by sliding the collar and thrustwasher indicator.

  • Page 76: Crankcase

    ENGINE CRANKCASE BEARING 1. Install the bearings so the numbers are visible. 2. Drive or press new bearings into the crankcases, INSPECTION/REMOVAL/ using the proper driver. CAUTION: Press only on INSTALLATION outer race of bearing to prevent bearing damage. PUMP SHAFT OIL SEAL/ WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE DISASSEMBLED)
  • Page 77 ENGINE WATER PUMP MECHANICAL SEAL REMOVAL Water Pump Mechanical Seal Puller: (PN 2872105) Replacement T- -Handle: T-Handle (PN 2872106) CAUTION: Main Puller Body Improper or careless use of this tool or Ill. 2 procedure can result in a bent water pump shaft.

  • Page 78: Crankcase Reassembly

    ENGINE 6. Turn the puller T-Handle clockwise until it contacts the water pump shaft. Continue rotating Align balancer shaft and until the remaining portion of mechanical seal has water pump shaft grooves been removed from the cases. (Ill. 5). Ill. 5 Align tube with notch in case 7.
  • Page 79 ENGINE 4. Check to make sure the rings rotate freely in the CAUTION: Circlips become deformed during the groove when compressed removal process. Do not re-use old circlips. Do not compress the new clip more than necessary upon installation to prevent loss of radial tension. Severe Ring Profile engine damage may result if circlips are re-used or deformed during installation.
  • Page 80 ENGINE CYLINDER HEAD 3. Apply clean engine oil to the ring compressor and install compressor according INSTALLATION manufacturers instructions. CAUTION: Verify all ring end gaps are correctly located. Clean the gasket surfaces on the cylinder head and cylinder. Remove all traces of old gasket material. Refer to disassembly photos.

  • Page 81: Camshaft Timing

    ENGINE CAM CHAIN INSTALLATION NOTE: The camshafts, crankshaft sprocket and clutch basket must be removed to perform this Align sprocket timing mark procedure. and brass colored chain link 1. Install the cam chain by dropping it down through the chain room and over the crankshaft sprocket. Align brass colored chainlink and sprocket marks with Top Dead Center (TDC) mark 4.

  • Page 82: Cam Timing

    ENGINE 6. Re--check all cam timing marks to verify proper cam timing, and install the cam tower. Tighten the bolts evenly in a criss--cross pattern to specification. Do not rotate engine until the tensioner has been installed to avoid chain slip and loss of timing reference.
  • Page 83 ENGINE EXHAUST INTAKE HEAD COVER FITTING SURFACE AT CYLINDER HEAD TIMING MARK TIMING PLATE (COLD) TIMING MARK 3.40...
  • Page 84 Rinse thoroughly, dry with compressed air, spots, roughness, and uneven surface. If any of the and oil the bore immediately with Polaris 4 Cycle above conditions exist, the valve seat must be Lubricant to prevent the formation of surface rust.
  • Page 85 ENGINE 5. Using valve guide driver, drive guides out of the cylinder head from the combustion chamber side. Be careful not to damage guide bore or valve seat when removing guides. 6. Place cylinder head on cylinder head table. NOTE: Be sure cylinder head is still at 212 F (100 C) before installing new guides.
  • Page 86 ENGINE If the contact area of the cutter is in the Valve Seat Width: same place, the valve guide is distorted from improper installation and must be Intake Std: .028I (.7 mm) replaced. Be sure the cylinder head is at Limit: .055I (1.4 mm) the proper temperature and replace the Exhaust...

  • Page 87: Troubleshooting

    ENGINE TROUBLESHOOTING Piston Failure - Scoring Lack of lubrication Engine Turns Over But Fails to Start Dirt entering engine through cracks in air filter or ducts No fuel Engine oil dirty or contaminated Dirt in fuel line or filter Fuel will not pass through fuel valve Excessive Smoke and Carbon Buildup Fuel pump inoperative/restricted Excessive piston-to-cylinder clearance...

  • Page 88: Spark Plug Fouling Checklist

    ENGINE SPARK PLUG FOULING COOLING SYSTEM TROUBLESHOOTING Spark plug cap loose or faulty Choke cable adjustment Overheating plunger/cable sticking Low coolant level Foreign material on choke plunger Air in cooling system seat or plunger Wrong type of coolant Incorrect spark plug heat range or Faulty pressure cap or system leaks Restricted system (mud or debris in Carburetor inlet needle and seat...
  • Page 89 ENGINE NOTES 3.46...
  • Page 90 FUEL SYSTEM/CARBURETION CHAPTER 4 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BSR 42 Carburetor Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 91 FUEL SYSTEM/CARBURETION BSR 42 CARBURETOR EXPLODED VIEW Ref. Description Ref. Description Ref. Description Ref. Description 1. Cover, Diaphragm 17. O-Ring 33. Ring 49. E-Ring 2. Spring 18. Cover 34. Holder, Jet 50. Cap 3. Diaphragm 19. Screw 35. Jet, Needle 51.

  • Page 92: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Vent Line Tank Cap Fuel Tank Fuel Valve Fuel Line Impulse Line Fuel Pump FUEL FLOW Fuel Tank Fuel Tank Vent Fuel Screens Fuel Valve Fuel Pump (Filter Built In) Carburetor Vent Engine Carburetor L Located on upper frame...

  • Page 93: Carburetor Jetting

    In higher elevations and higher temperatures, the air is less dense with reduced oxygen. Polaris ATV Carburetors are calibrated for an altitude 0-6000 ft. (0-1800 meters) and ambient temperatures between +40 and +80 F (+5 to +26...

  • Page 94: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main Main routed.
  • Page 95 FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.

  • Page 96: Assembly, Cv Carburetor

    FUEL SYSTEM/CARBURETION FLOAT SYSTEM Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.

  • Page 97: Carburetor Cleaning

    FUEL SYSTEM/CARBURETION CARBURETOR DISASSEMBLY CONT’D NOTE: The starter jet is removeable. Upon disassembly, place the parts in a container for safe 2. Remove float bowl. Remove the float pin screw. keeping. The float and float pin can be removed. Starter Jet Pilot Screw Float Pin Remove Screw...

  • Page 98: Carburetor Inspection

    FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION 1. Inspect jet needle and needle jet for wear. Look for discoloration, shiny spots, or an area that looks different than the rest of the needle. The middle to upper portion of the needle contacts the needle jet and is the most likely wear point.

  • Page 99: Needle & Seat Leakage Test

    FUEL SYSTEM/CARBURETION FLOAT HEIGHT ADJUSTMENT Float Too Far Inward 1. Ilustration 1: Place the the throttle side of the carburetor on a level surface to remove weight from float arm. In this position, the float tongue will rest slightly outward. Float Outward Ill.

  • Page 100: Fuel Level

    FUEL SYSTEM/CARBURETION FUEL PUMP fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. If not, inspect needle and seat and seat O-ring. The Predator 500 is equipped with a pressure regulated fuel pump (1-3 PSI). The pump is located in the front fender cavity of the machine.

  • Page 101: Troubleshooting

    FUEL SYSTEM/CARBURETION and check the surfaces for damage. Replace Float level too high diaphragms and gaskets as a set. Poor fuel quality (old fuel) 4. Reassemble the pump in the reverse order of Loose jets disassembly. Tighten all screws evenly. Worn jet needle/needle jet or other carburetor parts TROUBLESHOOTING...
  • Page 102 BODY / STEERING / SUSPENSION CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools ..Body Assembly, Exploded View ....Steering Assembly, Exploded View .
  • Page 103 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS 2871352 Shock Rod Holding Tool PART NUMBER TOOL 2871199 Seal Sleeve DESCRIPTION Installation Tool Kit Front A-Arm Attaching Bolt 30 ft. lbs. 2870872 Shock Spanner (41 Nm) Wrench Front A-Arm Ball Joint Stud 35 ft.

  • Page 104: Body Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW A. Seat I. Grab Bar B. Seat Release Latch J. Fuel Tank Support C. Rear Cab K. Rear Frame L. Foot Peg D. Side Panel M. Rock Guard E. Front Cover N.

  • Page 105: Steering Assembly, Exploded View

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY, EXPLODED VIEW A. HANDLEBAR B. BLOCK CLAMPS C. STEERING BUSHINGS D. STEERING POST E. CENTERLINK F. IDLER ASSEMBLY G. STEERING MOUNT BLOCK H. TIE ROD ASSEMBLY I. UPPER A--ARM J. LOWER A--ARM K. STEERING KNUCKLE L.

  • Page 106: Front Hub Removal

    BODY / STEERING / SUSPENSION FRONT HUB REMOVAL / DISASSEMBLY 1. Elevate front end and safely support machine under footrest / frame area. Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 107: Front Hub Assembly/Installation

    BODY / STEERING / SUSPENSION FRONT HUB ASSEMBLY 9. Place a shop towel on hub to protect surface. Carefully pry seal out of hub. 1. Drive or press one new bearing into hub using a bearing driver. Seal Seals (2) Tapered Spacer Bearings (2) 10.

  • Page 108: Front Hub Installation

    BODY / STEERING / SUSPENSION FRONT HUB INSTALLATION Front Wheel Torque 1. Apply grease to spindle. 2. Inspect spindle and bearing surface for wear or damage. Install the inner spacer. Front Wheel Nuts (4) 30 ft. lbs. (41 Nm) Inner Spacer Front Spindle Nut 40 ft.

  • Page 109: Steering Knuckle Removal/Installation

    BODY / STEERING / SUSPENSION STEERING KNUCKLE 5. Place the upper and lower A--arms into the steering knuckle. REMOVAL / INSTALLATION 6. Install the castle nuts onto the upper and lower A--arms. Torque the nuts to 25 ft.lbs. (35 Nm). Removal 7.
  • Page 110 BODY / STEERING / SUSPENSION Press Press Ball Joint Ball Joint Driver Driver 6. After the new ball joint is installed into the A--arm, install a NEW retaining ring. Upon A--arm installation onto the steering knuckle, install a Correct NEW cotter key also. Driver Placement NEW Cotter Key Nut &...

  • Page 111: Front Hub Exploded View

    BODY / STEERING / SUSPENSION FRONT HUB EXPLODED VIEW Ref. Qty. Description 2 Hub, Dust Cover 2 Nut, Castle 2 Pin, Cotter 2 Washer 2 Spacer, Outer 2 Seal 2 Bearing, Ball, Sealed 2 Hub, Wheel, Front, Indy Red 8 Stud 2 Spacer, Tapered 2 Bearing, Ball 2 Seal...

  • Page 112: A-Arm Replacement

    BODY / STEERING / SUSPENSION A-ARM REPLACEMENT Use new cotter pins upon reassembly. Install Use new bolts upon reassembly. with open end toward rear of machine. A. Spring B. IFP Shock C. Upper A--Arm D. Bolt E. A--Arm Shaft F. Bolt G.

  • Page 113: Concentric Swing Arm Removal

    BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM REMOVAL A. Chain Slide G. Washer B. Mount Bolt H. Nylok Nut C. Spacer I. Chain Guide D. Seal J. Sprocket Guard E. Needle Bearing K. Swing Arm Bolt & Nut F. Thrust Bushing L.

  • Page 114: Rear Axle Removal/Disassembly

    BODY / STEERING / SUSPENSION REAR AXLE REMOVAL/DISASSEMBLY 1. Securely support rear of machine with rear wheels off the floor. Remove rear wheels and hubs. 4. Loosen the hex screw (A) to loosen the axle nut. Turn the axle nut (D) counter clockwise with a 1 3/4”...
  • Page 115 BODY / STEERING / SUSPENSION 6. Remove the four bolts that secure the brake disc 9. Remove the O--ring (G) from the axle assembly. (C) to the rear disc hub and remove the brake disc. NOTE: It is not necessary to remove the brake disc at this time, only remove it if needed.

  • Page 116: Rear Axle Installation

    BODY / STEERING / SUSPENSION 13. With the axle out, remove the retaining ring (I) and sprocket hub (J) from the axle. 5. Install the mounting bracket (E) and retaining ring (F). Be sure to properly align the bracket (E) and bushing (I) upon installation.
  • Page 117 9. Install the brake disc if previously removed. 14. Lubricate the axle housing through the grease Torque the brake disc nuts to 16- -19 ft. lbs. fitting with Polaris All Season Grease (PN (22- -26 Nm). Torque the hex pinch bolt to 50 2871423).

  • Page 118: Rear Swing Arm / Axle Exploded View

    BODY / STEERING / SUSPENSION REAR SWING ARM / AXLE EXPLODED VIEW 1 Chain, 94P 1 Link, Connector Qty Desciption 1 Bushing, Caliper 2 Seal 1 Bracket, Caliper Mount 2 O-Ring 1 Ring, External 2 Bearing, Cone, Taper 4 Nut, Nylok 2 Bearing, Cup, Taper 1 Disc, Brake 1 Housing, Axle, Rear...

  • Page 119: Steering Post Assembly/Decal Replacement

    BODY / STEERING / SUSPENSION STEERING POST ASSEMBLY 10--12 ft. lbs. (14--16 Nm) 17 ft. lbs. (23 Nm) Grease Fitting 30 ft. lbs. (41 Nm) 30 ft. lbs. (41 Nm) 1. Torque to 50 ft. lbs. 2. Align cotter pin hole. 3.
  • Page 120 BODY / STEERING / SUSPENSION FRONT SHOCK SERVICE Shown below is an example of how valving stacks are arranged. The table on page 5.20 contains optional valving specifications and piston orifice sizes. Parts in boxed area are an example of typical valving. * Note direction of valve piston before disassembly.
  • Page 121 BODY / STEERING / SUSPENSION BODY / STEERING / SUSPENSION Optional Valving Listed By Shock Part Number Refer to the appropriate parts manual for a complete listing of Foxt shock parts. Shock Travel Limiting Spacer (1/4 ) - Part Number 5431355 Valve Washer Part Numbers Part No.
  • Page 122 BODY / STEERING / SUSPENSION SHOCK DISASSEMBLY Keep the parts in order as they are disassembled. Note the direction and position of all internal parts for 1. Remove spring and bushings from shock eyes. reassembly. Thoroughly wash shocks in a parts washer or with soap and water to remove dirt and other debris.
  • Page 123 BODY / STEERING / SUSPENSION 3. Remove valve and sealing O-ring from body cap. 6. Pull shock rod and piston straight out to avoid seal or valve damage. Be prepared to catch piston ring when removing the damper rod/valve piston. 4.
  • Page 124 BODY / STEERING / SUSPENSION 9. If bearing cap and/or seals are to be replaced, 4. Lubricate new seals and O-ring with Polaris shock remove nut, washer, and valve piston with valving oil and install. Be sure the seals are seated washers and set aside.
  • Page 125 BODY / STEERING / SUSPENSION 8. Position shock in vise with Body Clamp Tool . Clean body clamp tool before installing. 12. Carefully clean all parts thoroughly with electrical contact cleaner or solvent and dry with compressed air. Inspect shock body for scratches or wear. Shock Body Clamp Tool REASSEMBLY (PN 2871071)
  • Page 126 BODY / STEERING / SUSPENSION 3. Screw in bearing cap by hand until O-ring is fully CAUTION: seated. Do not over-tighten vise or bearing cap may be damaged. 9. Unscrew body cap and remove. 4. Invert shock and mount bearing cap flats lightly in vise.
  • Page 127 BODY / STEERING / SUSPENSION 12. Insert IFP tool and slowly push IFP to specified depth. Place a shop towel over the end of IFP tool to catch any spilled shock oil. 15. Reinstall body cap with a new O-ring and tighten by hand.
  • Page 128 BODY / STEERING / SUSPENSION 17. Set the nitrogen tank pressure regulator to 200 - 19. As a final check, push the damper rod through a 205 PSI. full stroke. The damper rod must bottom out at full travel, and then slowly rise to full extension. Shaft movement must be smooth and consistent throughout the entire compression and rebound stroke, without binding or loss of damping.
  • Page 129 BODY / STEERING / SUSPENSION FRONT SHOCK EXPLODED VIEW Ref. Qty Description Ref. Qty Description 1 Nylon Preload Ring 1 Body Cap 1 Floating Piston 1 O--Ring 1 External Bearing 1 O--Ring 1 Screw, O--ring 1 Body 1 Screw 1 Back Up Plate 4 Air Valve 1 Piston 1 Bushing...
  • Page 130 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE Special Tools Required: Body Holding Tool (PN 2871017) When performing maintenance on Foxt shocks, use Charging Needle (PN 7052069) the Gas Shock Recharging Kit (PN 2200421), as it Gas Shock Recharging Kit (PN 2200421) contains the necessary valves, pressure gauge, and Foxt Shock IFP Tool (PN 2871351) fittings to deflate and pressurize shocks.
  • Page 131 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 8. Using a 3/32” Hex Key, loosen the bearing cap set screw. Use pin spanner tool to unscrew the bearing 1. Read through all of these instructions first to cap, and slide the bearing cap up to the bottom--out familiarize yourself with the rebuild procedure.
  • Page 132 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 18. Align the slot of the Foxt IFP Depth Tool (PN 2871351) with the end of the IFP (Internal 15. Gently tap the reservoir end cap with a rubber Floating Piston). Insert the IFP tool into the mallet to expose the wire retaining ring.
  • Page 133 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 25. Insert a 5/32” Hex Key into the screw head of the damp plate. Remove damp plate by twisting 21. Remove the IFP o--ring using a scribe or dental clockwise. (Fig. 10) Place the damp plate pick.
  • Page 134 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 30. Push on the protruding adjuster drum stem to remove it from CD housing. (Fig. 12) 35. Lubricate and carefully install the damp plate sealing o--ring inside the CD housing. Make sure o--ring is properly seated.
  • Page 135 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 37. Fill the two holes that are on either side of the adjuster--drum stub with assembly grease. Insert one new spring into each hole. Place one new clicker ball in the center of each spring. Orient the #1 position of knob with the position indicator of the CD housing.
  • Page 136 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 44. Slide only the tip of Phillips Head Screwdriver into hole at end of shaft. Hold the piston assembly under the top--out plate and lift upwards. Slide the piston assembly onto the shaft of the screwdriver. Remove the screwdriver from shock shaft while supporting the piston assembly.
  • Page 137 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 50. Once the eyelet has been given sufficient time to cool, use an adjustable wrench to remove it from the shaft. Clean the thread--locking compound from eyelet and shaft threads, and set it aside. 53.
  • Page 138 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 59. Install new dust seal into bearing cap. Seal should be installed with lip protruding from the flat side of 57. Using a small pair of needle nose pliers, grab the the bearing cap. Check to make sure seal is lip of the U--cup seal in the bearing assembly.
  • Page 139 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 62. Clamp shaft eyelet securely in vise, and place seal bullet tool on end of shaft. 63. Slide bottom--out bumper onto shaft. NOTE: The tapered side of the bottom--out bumper should be facing away from the shaft eyelet.
  • Page 140 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE 68. Lubricate the flat end of the metering rod with a small amount of assembly lube. Insert metering rod, flat end first, into the shaft. (Fig. 35) Push needle down into the shaft with a blunt object, until you feel the metering rod push past the o--ring seal.
  • Page 141 BODY / STEERING / SUSPENSION REAR SHOCK SERVICE If you pull the shaft out too far you will hear a 73. Set compression adjuster to the #3 position. sucking noise, meaning air was pulled in. If this Firmly grip the reservoir hose at the CD housing. happens, you will have to start the bleeding With your other hand pull back forcefully on the process over.
  • Page 142 BODY / STEERING / SUSPENSION 78. Push the IFP further into the reservoir. As you do 80. Securely clamp Fox Nitrogen Safety Needle in the this, the shaft and bearing assembly should rise vise. Be sure to point the air valve away from your until the bearing assembly engages with the wire face and body.
  • Page 143 BODY / STEERING / SUSPENSION SHOCK STANDARD well--ventilated area to allow the solvents to evaporate. VALVING 85. Clamp the body cap of shock securely in vice, with shaft end up. Use pin spanner tool to secure the CHART bearing cap to bearing. Using a 3/32” hex key, tighten the setscrew to lock the bearing cap into Compression Top Out Plate...
  • Page 144 BODY / STEERING / SUSPENSION REAR SHOCK EXPLODED VIEW 5.43...
  • Page 145 BODY / STEERING / SUSPENSION REAR SHOCK EXPLODED VIEW, CONT’D Ref. Qty Description Ref. Qty Description 1 Shock, Remote Reservoir, Rear 2 Ball 1 Valve 1 Bolt 1 Plate, Damp 1 Knob, Damping 5 Valve 1 Pin, Dowel 1 Screw 1 Ring, Preload 1 Screw 1 Ring, Preload...
  • Page 146 BRAKES CHAPTER 6 BRAKES Specifications/Torques ....Special Tools ..... . Brake System Service Notes .

  • Page 147: Special Tools

    BRAKES SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Thickness .298 / 7.6mm .180 / 4.6mm Brake Disc Thickness .150-.165 / 3.810-4.166mm .140 / 3.556mm Brake Disc Thickness Variance Between .002 / .051mm Measurements Brake Disc Runout .010 / .50mm Rear Brake Caliper Item Standard...

  • Page 148: Brake System Service Notes

    BRAKES BRAKE SYSTEM SERVICE Test for brake drag after any brake system service and investigate cause if brake NOTES drag is evident. Make sure caliper moves freely on guide Disc brake systems light weight, pins. maintenance, and perform well in the conditions ATVs Inspect caliper piston seals for foreign routinely encounter.

  • Page 149: Hydraulic Brake System Operation

    When servicing Polaris ATV brake systems use only Polaris DOT 3 High Temperature Brake Fluid (PN 2870990). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.

  • Page 150: Fluid Replacement/Bleeding Procedure

    5. Add brake fluid to the upper level mark on reservoir. BRAKE BLEEDING - FLUID Polaris DOT 3 Brake Fluid CHANGE (PN 2870990) NOTE: This procedure should be used to change fluid or bleed brakes during regular maintenance.
  • Page 151 BRAKES lever. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. 9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir. CAUTION: Maintain at least 1/2 (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master...

  • Page 152: Master Cylinder Removal

    BRAKES MASTER CYLINDER Front Brake Lines REMOVAL 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to Brake Lines disassemble brake components. 2. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt (A); remove bolt and sealing washers.

  • Page 153: Master Cylinder Installation

    1. Install master cylinder on handlebars. Torque mounting bolts to 25 in. lbs. (3 Nm). Torque the top bolt first. 15 ft.lbs. (21 Nm) Polaris DOT 3 Brake Fluid (PN 2870990) 25 in. lbs. (3 Nm) 4. Follow bleeding procedure on Pages 9.5-9.6.
  • Page 154 BRAKES 3. Remove the caliper bolts (B) and caliper from the 6. Remove the loose caliper slide bolts. The brake mount bracket. pad (D) will slide out of the caliper assembly when the caliper slide bolt is removed. 4. With pads installed, push caliper piston into caliper bore slowly using a C-clamp or locking pliers.

  • Page 155: Front Pad Assembly

    BRAKES FRONT PAD ASSEMBLY 1. Install pads with friction material facing each other. Install the slide bolts through the brake pads and tighten the slide bolts hand tight. Be sure pads and disc are free of dirt or grease. 33 ft.lbs. (45 Nm) 4.

  • Page 156: Front Disc Inspection

    BRAKES FRONT DISC INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1 micrometer. Replace disc if worn beyond service limit. Brake Disc Runout Service Limit .010 (.50 mm) FRONT BRAKE DISC...

  • Page 157: Front Caliper Removal

    BRAKES FRONT CALIPER REMOVAL 33 ft.lbs. CAUTION: (45 Nm) Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or 15 ft.lbs. falls. (21 Nm) 1. Remove brake pads. See Page 6.8.--6.9. 3.
  • Page 158 BRAKES REAR BRAKE PAD REMOVAL 1. Loosen the caliper slide bolt with an Allen wrench before you remove the brake caliper. 4. Remove the c--clips (C) on the ends of the caliper slide bolt. 2. Remove caliper mounting bolts and lift caliper off of disc.

  • Page 159: Rear Brake Pad

    BRAKES 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Front Brake Pad Thickness .298 / 7.6 mm Service Limit .180 / 4.6 mm Measure Thickness Brake Caliper Mounting Bolts Torque: 18 ft. lbs. (25 Nm) REAR BRAKE PAD 3.

  • Page 160: Front/Rear Caliper Disassembly

    BRAKES FRONT / REAR CALIPER to stop machine. Repeat this procedure 10 times, allowing brakes to cool sufficiently after each DISASSEMBLY run. REAR CALIPER REMOVAL 1. Clean caliper area before removal. 2. Using a flare nut wrench, remove the brake lines (A).
  • Page 161 BRAKES 3. Remove the outside dust boot (E). 6. Clean the caliper body, piston, and retaining 4. Remove the piston and dust seal (F). bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. FRONT / REAR CALIPER INSPECTION 1.

  • Page 162: Front/Rear Caliper Assembly

    BRAKES 2. Inspect piston for nicks, scratches, wear or damage. Replace if damaged or worn. Inspect Piston 3. Coat piston and inside of caliper body with clean DOT 3 Brake Fluid (PN 2870990). Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, 3.

  • Page 163: Rear Brake Disc Inspection

    BRAKES REAR BRAKE DISC TROUBLESHOOTING INSPECTION Brakes Squeal Dirty/contaminated friction pads 1. Visually inspect disc for scoring, scratches, or Improper alignment gouges. Replace the disc if any deep scratches Worn disc are evident. Worn disc splines Glazed brake pads Rear Brake Poor Brake Performance Disc Air in system...
  • Page 164 M. Bleeder Screws N. Circlips 33 ft.lbs. (45 Nm) 18 ft.lbs. (25 Nm) 27 in.lbs. (3 Nm) NOTE: BRAKE COMPONENTS ARE NOT SOLD SEPARATELY, APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT REFER TO YOUR PARTS BOOK FOR PARTS BREAK DOWN. 6.19...

  • Page 165: Front Brake System

    BRAKES FRONT BRAKE SYSTEM - - CALIPER/MASTER CYLINDER A. Master Cylinder B. Brake Line C. Pressure Switch D. Junction Box E. Wheel Hub F. Line Retainer G. Banjo Bolt & Washers H. Caliper I. Caliper Mount Bolt 15 ft. lbs. 21 Nm 18 ft.

  • Page 166: Rear Brake System

    BRAKES REAR BRAKE SYSTEM - - CALIPER/MASTER CYLINDER A. Reservoir I. Foot Brake B. Caliper Mount J. Switch C. Rear Caliper K. Mount Bracket D. Brake Disc L. Brake Pedal Return Spring E. Brake Line M. Foot Brake Torsion Spring F.
  • Page 167 BRAKES NOTES 6.22...
  • Page 168 ELECTRICAL CHAPTER 7 ELECTRICAL Special Tools/Service Notes ....Timing Check Procedure ..... 7.2-7.3 Electrical Switch Testing .

  • Page 169: Timing Check Procedure

    ELECTRICAL SPECIAL TOOLS TIMING CHECK PROCEDURE PART NUMBER TOOL 1. The ignition timing check hole is in the starter DESCRIPTION recoil/magneto housing. Remove the check plug. PV- -43568 Fluket77 Digital The ignition timing marks are stamped on the outer Multimeter diameter of the flywheel.

  • Page 170: Fan Motor Current Draw

    ELECTRICAL The fan switch may not function or operation may be NEUTRAL POSITION INDICATOR delayed if coolant level is low or if air is trapped in the SWITCH TEST cooling system. Be sure cooling system is full and purged of air. Refer to Maintenance Chapter 2 for 1.
  • Page 171 ELECTRICAL 6. Turn ignition key and engine stop switch to “RUN” Test the ETC switch at the harness connector. NOTE: position. Read the current draw on ammeter with Adjust throttle cable freeplay (ETC switch) and make fan running. sure throttle mechanism is functioning properly before testing the switch.

  • Page 172: Ignition System Troubleshooting

    ELECTRICAL IGNITION SYSTEM Test output from the CDI and pulse (trigger) coil and compare to the table. The following measurements TROUBLESHOOTING are obtained when cranking the engine with the electric starter, spark plug installed. The starter No Spark, Weak or Intermittent Spark system must be in good condition and the battery fully charged.

  • Page 173: Alternator Output Test

    ELECTRICAL 5. Increase engine RPM while observing ammeter and tachometer. Current Draw Inspection 6. Note RPM at which the battery starts to charge Key Off (ammeter indication is positive). 7. With lights and other electrical load off, the “break even” point should occur at approximately 1500 RPM or lower.

  • Page 174: Flywheel Identification

    ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the casting marks in location A. Refer to “I.D.” location in chart below. 2003 Engine Application Type Stamp Comment I.D. Stamp ES50PL External IJ09 DC/CDI K1805 Trigger PREDATOR DC / CDI IGNITION The Predator has incorporated into it’s design a DC/ Operation Overview:...
  • Page 175 ELECTRICAL COMPONENTS OF ES50PL ALTERNATOR DC/CDI IGNITION Note: DC/CDI components are not compatible with any other type of ignition Refer To Wiring Diagrams For Specified Stator Coil Resistance Primary Coil Coil Lead Meter Ignition Kill Wire 12 Volt DC (Black) Supply Wire (Red) Ignition Coil...

  • Page 176: Ignition System Testing

    ELECTRICAL IGNITION SYSTEM TESTING Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting.

  • Page 177: Charging System Testing Flow Chart

    ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- Page 7.12). It should be 12.5 volts or more. vice.
  • Page 178 NEVER attempt to add electrolyte or water to a BATTERY TERMINALS/BOLTS Maintenance- -Free battery. Doing so will damage the case and shorten the life of the battery. Refer Use Polaris corrosion resistant Dielectric Grease (PN to the Battery Maintenance Video (PN 9917987) 2871329) on battery bolts. proper...

  • Page 179: Battery Testing

    ELECTRICAL BATTERY TESTING 15 seconds. During cranking the observed voltage should not drop below 9.5 volts. If the beginning voltage is 12.6 volts or higher and the cranking voltage drops Whenever a service complaint is related to either the below 9.5 volts during the test, replace the battery and starting or charging systems, the battery should be re--test.

  • Page 180: Headlight Housing Replacement

    ELECTRICAL HEADLIGHT HOUSING WARNING REPLACEMENT To avoid the possibility of explosion or sparks, connect positive (red) cable first and negative (black) CAUTION: Do not service while headlight is hot. cable last. Serious burns may result. Protect lamp during install. 5. After connecting the battery cables, attach the hold down strap.

  • Page 181: Headlamp Switch

    ELECTRICAL HEADLIGHT LAMP HEADLAMP SWITCH REPLACEMENT Probe the headlamp plug wires (Brown and Yellow) at back of connector. Turn headlights on. Test for 1. Remove the wire harness connector from the battery voltage across the connections. back of the headlight. Low Beam -- Brown and Green 2.

  • Page 182: Starter System Troubleshooting

    ELECTRICAL CLUTCH SWITCH TEST 2. Disconnect the wires of the lamp to be removed. Remove indicator lamp from the panel by depressing the lamp holding tangs with a pliers 1. Disconnect the switch by pulling apart the switch while pushing the assembly out of the pod. bullet connector.
  • Page 183 ELECTRICAL STARTER MOTOR Faulty key switch Faulty kill switch DISASSEMBLY Faulty starter solenoid or starter motor. Use only electrical contact cleaner to clean starter Engine problem - seized or binding motor parts. Some solvents may leave a residue or (Can engine be rotated easily ?) damage internal parts and insulation.
  • Page 184 ELECTRICAL 3. Remove brush terminal end of housing while Brush Length holding other two sections together. 5/16 (.8 cm) Brush Length Service Limit: 5/16 (.8 cm) 4. Remove brush plate and brushes. Measure length of brushes and replace if worn past the service limit.

  • Page 185: Armature Testing

    ELECTRICAL ARMATURE TESTING STARTER REASSEMBLY 1. Remove armature from starter casing. Note 1. Place armature in field magnet casing. order of shims on drive end for reassembly. 2. Place shims on drive end of armature shaft with 2. Inspect surface of commutator. Replace if phenolic washer outermost on shaft.
  • Page 186 ELECTRICAL STARTER ONE- -WAY CLUTCH INSPECTION Flywheel One--way Clutch Drive gear 1. Inspect the drive gear teeth, bearings and thrust surfaces for excessive wear or damage. 2. Inspect the one way drive clutch rollers and springs for excessive wear or damage. 3.

  • Page 187: Starter System Testing Flow Chart

    ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.
  • Page 188 No Neutral Light Neutral Start Lost if failed...
  • Page 189 Brake System Service Notes, 6.3 Brake System, Front, 6.20 A--Arm Replacement, 5.11 Brake System, Rear, 6.21 Air Filter Service, 2.17 Brakelight Lamp Replacement, 7.14 Alternator Output Test, 7.6 Breather Filter Maintenance, 2.18 Battery Charging, 2.14, 7.12 Cam Chain Tensioner Inspection, 3.13 Battery Maintenance, 2.13, 7.11 Cam Chain Tensioner Removal, 3.13 Battery Service, 2.14, 7.11, 7.12...
  • Page 190 Controls Inspection, 2.26 Engine Accessible Components, 3.7 Engine Adjusting Pad Matrix, 3.20 Coolant Level Inspection , 2.16 Engine Assembly, 3.30, 3.34, 3.37, 3.39 Coolant Strength, 2.15 Engine Bottom End Disassembly, 3.22, 3.23, Coolant Temp. Sensor Test, 7.3 3.24, 3.25, 3.30, 3.32, 3.33, 3.34 Cooling System Hoses, 2.16 Engine Break in Period, 3.8 Cooling System Overview , 2.15...
  • Page 191 Oil Pressure Test, 3.9 Oil Pump Priming, 3.10 Gear Position Switch Test, 7.3 Pilot Screw Adjustment, 2.10 Handlebars, 2.26 Piston Identification, 3.5 Headlamp Removal, 7.14 Piston Installation, 3.37 Headlamp Service, 7.13 Piston Removal, 3.22 Headlamp Switch Testing, 7.14 Piston Ring Installation, 3.36 Headlight Adjustment, 7.13 Piston Ring Installed Gap, 3.25 Piston to Cylinder Clearance, 3.23...
  • Page 192 Starter Motor Brush Inspection/Replacement, Troubleshooting, Cooling System, 3.46 7.17 Troubleshooting, Engine, 3.45 Starter System Test, 7.20 Troubleshooting, Fuel System/Carb, 4.12 Steering Assembly, Exploded View, 5.4 Troubleshooting, Ignition System, 7.5 Ball Joint, Remove / Install, 5.8 Troubleshooting, Spark Plug, 3.46 Steering Knuckle, Remove / Install, 5.8 Troubleshooting, Starter System, 7.15 Steering Maintenance, 2.19 Steering Post Assembly, 5.18...
  • Page 193 PN 9918062 PN 9918062 Printed in the USA Printed in the USA...

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