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Polaris Predator Owner's Manual

Polaris 2004 atv owner's manual
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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 5 Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc. Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Table Of Contents Welcome

    WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft...
  • Page 7 WELCOME We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

  • Page 8: Table Of Contents

    CLEANING AND STORAGE TROUBLESHOOTING POLARIS PRODUCTS SPECIFICATIONS ..........

  • Page 9: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced. See your Polaris dealer.
  • Page 10 VEHICLE IDENTIFICATION NUMBERS Frame VIN: Vehicle Model Number: Engine Serial Number: Key Number:...

  • Page 11: Safety

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

  • Page 12: Safety Decals And Locations

    Location A WARNING 7170906 IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 SAFETY WARNING Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.
  • Page 13 SAFETY Safety Decals and Locations 7077920 Location E Location F...
  • Page 14 Safety Decals and Locations Location G WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 4 (27,6) REAR 4 (27,6) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 645 LBS.

  • Page 15: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding.

  • Page 16: Eye Protection

    SAFETY Safe Riding Gear 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8).

  • Page 17: Operator Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 18: Know Your Vehicle

    Be sure to view it before operating the ATV. If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can request this free safety training from any authorized Polaris dealer.
  • Page 19 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
  • Page 20 Operator Safety The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. A caution indicates a situation that may result in damage to the vehicle. A note will alert you to important information or instructions. CAUTION CAUTION NOTE:...
  • Page 21 S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 22 Operator Safety S Never operate an ATV on a public street, road or highway, including a dirt or gravel road. S Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.
  • Page 23 S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident.
  • Page 24 Operator Safety S Always follow proper procedures for crossing the side of a hill. Avoid hills with exces- sively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual.
  • Page 25 S Never modify an ATV through improper installation or use of accessories. S Never exceed the stated load capacity for your ATV. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or call Polaris at 1-800-342-3764.

  • Page 26: Equipment Modifications

    The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.
  • Page 27 HOW TO AVOID THE HAZARD: Beginning and inexperienced operators should complete the certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating techniques described in the owner’s manual.
  • Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN: Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD: Only operators with advanced skills and substantial experience should operate this ATV.
  • Page 29 ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD: No one under the age of 16 should operate a Polaris ATV. Only operators with advanced skills and substantial experience should operate this ATV. WARNING...
  • Page 30 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Carrying a passenger on an ATV. WHAT CAN HAPPEN: Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD: Never carry a passenger.
  • Page 31 SAFETY Operator Safety POTENTIAL HAZARD: Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN: ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.
  • Page 32 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN: The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD: Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 33 SAFETY Operator Safety POTENTIAL HAZARD: Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN: Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.
  • Page 34 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN: Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 35 SAFETY Operator Safety POTENTIAL HAZARD: Operating the ATV at excessive speeds. WHAT CAN HAPPEN: Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD: Always operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.
  • Page 36 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN: Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD: Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
  • Page 37 SAFETY Operator Safety POTENTIAL HAZARD: Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN: Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD: Always inspect your ATV before each use to make sure it’s in safe operating condition.
  • Page 38 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Removing hands from the handlebars or feet from the footpegs during operation. WHAT CAN HAPPEN: Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footpeg, it could come into contact with the rear wheels and lead to accident or injury.
  • Page 39 SAFETY Operator Safety POTENTIAL HAZARD: Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN: Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 40 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN: Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
  • Page 41 SAFETY Operator Safety POTENTIAL HAZARD: Turning improperly. WHAT CAN HAPPEN: Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.
  • Page 42 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating on excessively steep hills. WHAT CAN HAPPEN: The vehicle may overturn. HOW TO AVOID THE HAZARD: Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees 25_.
  • Page 43 SAFETY Operator Safety POTENTIAL HAZARD: Climbing hills improperly. WHAT CAN HAPPEN: Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
  • Page 44 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Traveling downhill improperly. WHAT CAN HAPPEN: Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for traveling down hills as described in the owner’s manual.
  • Page 45 SAFETY Operator Safety POTENTIAL HAZARD: Improperly crossing hills and turning on hills. WHAT CAN HAPPEN: Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 46 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Stalling, rolling or improperly dismounting while climbing a hill. WHAT CAN HAPPEN: The vehicle could overturn. HOW TO AVOID THE HAZARD: Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Apply front brakes gradually.
  • Page 47 SAFETY Operator Safety POTENTIAL HAZARD: Improperly operating over obstacles. WHAT CAN HAPPEN: Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 48 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Skidding or sliding. WHAT CAN HAPPEN: Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD: On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 49 SAFETY Operator Safety POTENTIAL HAZARD: Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN: Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD: Avoid operating the ATV through deep or fast-flowing water.
  • Page 50 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN: Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD: Always use the size and type of tires specified for the ATV in the owner’s manual.
  • Page 51 HOW TO AVOID THE HAZARD: Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
  • Page 52 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Overloading the ATV or carrying/towing cargo. WHAT CAN HAPPEN: Overloading or carrying/towing cargo can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD: Never haul cargo or tow a load with this ATV. Never exceed the stated load capacity for this ATV.
  • Page 53 SAFETY Operator Safety POTENTIAL HAZARD: Operating on frozen bodies of water. WHAT CAN HAPPEN: Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD: Never operate the ATV on a frozen body of water. WARNING...
  • Page 54 Operator Safety Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 55: Features And Controls

    FEATURES AND CONTROLS Engine Electrical Switches...
  • Page 56 Engine Electrical Switches Start Button - The start button engages the starter. Always release the start button as soon as the engine starts. Engine Stop Switch - The purpose of this switch is to provide the operator with a quick means of engine shutdown in case of an emergency.
  • Page 57 FEATURES AND CONTROLS Lights 1. Headlight HI/LO Switch 2. Neutral Indicator Lamp 3. High Temp Indicator Lamp...

  • Page 58: Light Switches

    Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the engine stop switch is in the RUN position.

  • Page 59: Throttle Lever

    FEATURES AND CONTROLS Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

  • Page 60: Clutch Lever

    Electronic Throttle Control This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

  • Page 61: Foot Brake

    FEATURES AND CONTROLS Foot Brake Your Polaris ATV has a foot pedal (1) that activates the rear brakes. It’s located in front of the right-hand footpeg (2) and is operated by the right foot. If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding.

  • Page 62: Brake Lever

    Brake Lever The Predator ATV has a single brake lever for the front brakes. It’s located on the right handlebar. The front brakes are applied by squeezing the brake lever (1) toward the handlebar. The front brakes are hydraulically activated disc type brakes.

  • Page 63: Master Cylinder

    If the fluid level is low add DOT 3 brake fluid only. Do not overfill. See page 175 for the part numbers of Polaris products. Overfilling the master cylinder will result in brake failure. Without room to expand, the excess fluid will cause the brakes to apply automatically, which could result in serious injury or death.

  • Page 64: Parking Brake

    Parking Brake Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in first gear or neutral. 2.
  • Page 65 FEATURES AND CONTROLS Parking Brake Important Safeguards S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position.

  • Page 66: Fuel Valve

    FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located under the fuel tank on the left side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 5 to 8 mile (8 to 13 km) range on reserve gas.

  • Page 67: Fuel Tank

    Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged. Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 74 for correct choke and throttle settings during starting.

  • Page 68: Shift Pedal

    Manual Shift Shift Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released. To upshift to a higher gear, place the toe of your boot under the gear shift pedal and raise the pedal one full stroke.
  • Page 69 FEATURES AND CONTROLS Manual Shift The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. Place the stop switch in the RUN position, then turn the key to ON. If starting while in neutral, the neutral indicator light should be on. If it isn’t, disengage the clutch (squeeze the clutch lever fully) and shift the foot pedal to find neutral.

  • Page 70: Shifting Gears

    Manual Shift Shifting Gears NOTE: Always allow the engine to warm up before shifting gears. 1. When starting from a stopped position with the transmission in neutral, squeeze and hold the brake lever. 2. With the throttle closed (not depressed), squeeze the clutch lever to disengage the clutch.
  • Page 71 FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a lower gear. NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear.

  • Page 72: Operation

    Fuel Safety Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 73: Break-In Period

    Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The break-in period for your new Polaris Predator is defined as the first one hour of operation (followed by an additional two hours of cautious operation), or the time it takes to use the first full tank of gasoline.
  • Page 74 Break-In Period 1. Fill the fuel tank with gasoline. See page 64. 2. Check the oil level on the dipstick. See page 105. Add oil if necessary to maintain the level between the safe and add marks. 3. Allow the engine sufficient time to warm up before operating. 4.
  • Page 75 OPERATION Pre-Ride Inspection If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Use the following checklist to verify that your vehicle is in proper working condition before each use.
  • Page 76 11. Wheels - Check for tightness of wheel nuts and axle nuts. Check that axle nuts are secured by cotter pins. 12. A-arm ball joints - Check freeplay. If the tire moves excessively, see your Polaris dealer for replacement before operating.

  • Page 77: Starting A Cold Engine

    OPERATION Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Place the transmission in neutral, lock the parking brake and disengage the clutch.
  • Page 78 Starting a Cold Engine NOTE: The variable choke is fully on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, as excess fuel washing into the engine oil will increase wear on engine components.

  • Page 79: Starting A Warm Engine

    4. If the engine does not start, review the engine troubleshooting information beginning on page 167. If all conditions are favorable and the engine still does not start, see your Polaris dealer for service.

  • Page 80: Driving Safely

    Driving Safely Driving Procedures 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. See page 67. 3. Check your surroundings and determine your path of travel.

  • Page 81: Making Turns

    OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance than the inside wheel when turning, and the inside tire slips traction slightly.

  • Page 82: Driving On Slippery Surfaces

    Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

  • Page 83: Driving Uphill

    OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footpegs and transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5.

  • Page 84: Driving Across Hills

    Driving Safely Driving Across Hills Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. If you enter into a situation where sidehilling is unavoidable: 1.
  • Page 85 OPERATION Driving Safely Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
  • Page 86 Driving Safely Turning Around on a Hill 5. Staying uphill of the ATV, turn the handlebars full left. Reach across the handlebar and apply the front brakes to unlock the park brake. 6. With the front brakes applied, pull in the clutch lever.

  • Page 87: Driving Downhill

    OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Shift to the lowest gear possible while maintaining a safe speed. 5.

  • Page 88: Parking On An Incline

    Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

  • Page 89: Driving Through Water

    OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs (1). Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2.
  • Page 90 Driving Safely Driving Through Water Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footpeg level, take it to your dealer for service before starting the engine.

  • Page 91: Driving Over Obstacles

    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 92: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 93: Exhaust Emission Control System

    The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set carburetion and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform.

  • Page 94: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and...

  • Page 95: Periodic Maintenance Schedule

    Perform all services more frequently under severe use. Improperly performing the procedures marked with a failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often under severe use, such as in dirty or wet "...
  • Page 96 (see page 60); change every 200 mi. or 24 months Inspect Inspect; tighten Inspect; tighten Inspect; clean Inspect level; add as needed Fill to proper levels Fill to proper level with Polaris PS-4 oil Check operation Check operation and adjustment Check operation Check operation...
  • Page 97 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a and lead to serious injury or death. Have a Polaris dealer perform these services. Item Steering " Air box sediment tubes " Headlamp Tail lamp/brake lamp A-arm ball joint...
  • Page 98 " General lubrication " " More often under severe use, such as dirty or wet conditions Emission Control System Service (California) J Dealer service item F Polaris Premium All Season Grease MAINTENANCE AND LUBRICATION Hours/Miles Frequency Weekly Weekly 10 hrs.
  • Page 99 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a and lead to serious injury or death. Have a Polaris dealer perform these services. Item A-Arm (A) " Rear axle/ " Rear eccentric (B) Swing arm pivot "...
  • Page 100 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Lubrication Points...
  • Page 101 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Improperly performing the procedures marked with a and lead to serious injury or death. Have a Polaris dealer perform these services. Item Carburetor float bowl Throttle Cable/ETC Switch Choke (enricher) cable Drive chain(s) "...
  • Page 102 Ignition Timing Fuel system " More often under severe use, such as dirty or wet conditions Emission Control System Service (California) J Dealer service item F Polaris Premium All Season Grease MAINTENANCE AND LUBRICATION Hours/Miles Frequency 50 hrs. 6 months 100 hrs.
  • Page 103 Idle speed Toe adjustment Headlight aim " More often under severe use, such as dirty or wet conditions Emission Control System Service (California) J Dealer service item F Polaris Premium All Season Grease Hours/Miles Frequency 100 hrs. Annually 100 hrs.
  • Page 104 NOTES...
  • Page 105 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Servicing Interval Date Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Dealer or Person Remarks...
  • Page 106 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...

  • Page 107: Lubrication Recommendations

    Lubrication Recommendations Performance Synthetic 4-Stroke (PS-4) Oil Polaris highly recommends the use of Polaris PS-4 or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. PS-4 has been specifically formulated for use in high performance engines. PS-4 is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection and prolonged clutch life.

  • Page 108: Engine Oil Level

    Engine Oil Level Check the oil level before each use of the vehicle. The dipstick (1) is located on the left side of the ATV. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for one minute. 3.
  • Page 109 MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

  • Page 110: Oil And Filter Change

    Oil and Filter Change If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight. Always replace the oil and filter within a few hours of draining the oil. The suggested break-in oil change should be performed after one hour of operation, or after the first tank of fuel, whichever comes first.
  • Page 111 MAINTENANCE AND LUBRICATION Oil and Filter Change 1. Place the vehicle on a level surface. 2. Clean the area around the oil tank (1) and crankcase (2) drain plugs with clean shop towels. 3. Run the engine for two to three minutes until warm, then stop the engine.
  • Page 112 Oil and Filter Change 7. Place a drain pan beneath the crankcase and remove the drain plug. 8. Allow the oil to drain completely. 9. Replace the sealing washer and reinstall the plug. Torque to 14 ft. lbs. (19 Nm). 10.
  • Page 113 MAINTENANCE AND LUBRICATION Oil and Filter Change 14. Replace the o-ring in the cover. 15. Lubricate the gasket on the new filter with a film of fresh engine oil. 16. Reinstall the spring and install the new filter with the open end facing outward. 17.
  • Page 114 Oil and Filter Change 18. Remove the dipstick and fill the oil tank with 2 quarts (1.9 l) of recommended oil. 19. Place the transmission in neutral and set the parking brake. 20. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

  • Page 115: Air Filter Systems

    MAINTENANCE AND LUBRICATION Air Filter Systems 1. Unlatch and remove the seat. 2. Loosen the intake duct clamp (1) on the carburetor. 3. Pull the duct (2) off the carburetor. 4. Release the eight airbox cover clips (3) and remove the cover (4). 5.
  • Page 116 Air Filter Systems 7. Reinstall the air filter. 8. Reinstall the airbox cover and secure the clips. 9. Reinstall the intake duct to the carburetor and secure the clamp. 10. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. Operation of your vehicle without a breather filter can cause engine damage.

  • Page 117: Engine Cooling System

    See page 175 for the part numbers of Polaris products. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze...

  • Page 118: Coolant Level

    MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine under the front fender. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool). As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the recovery...

  • Page 119: Radiator Coolant Level

    MAINTENANCE AND LUBRICATION Engine Cooling System Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the cap. Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair.
  • Page 120 Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 121: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise (1) to remove the bulb. On the right headlamp, turn the bulb housing clockwise (2) to remove the bulb.
  • Page 122 Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see page 124). Position the cab upside down on a soft protective surface to prevent scratching. 3. Remove the small adjuster bracket (1) and install it on the new lamp.
  • Page 123 MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement 5. Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab. 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. 7.
  • Page 124 Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws (1). Remove the lens cover (2) and gasket and set aside for reassembly. 2. Remove the lamp (3) and replace it with a new lamp. 3.

  • Page 125: Headlight Adjustment

    MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1. Position the ATV on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

  • Page 126: Side Panel Removal

    Side Panel Removal 1. Unlatch and remove the seat. 2. Remove the four screws (1) securing the side panel. 3. Remove the side panel. Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the four bolts (2) on the rear fenders of the cab and the two bolts (3), washers and grommets (4) on the top of the cab.
  • Page 127 MAINTENANCE AND LUBRICATION Front Cab Removal 1. Remove the screws and washers (1) from the front left-hand and right-hand cab mounts. 2. Remove the wire harness connector from the headlights. 3. Loosen the screw (2) located inside the cab under the front cover. 4.

  • Page 128: Spark Plugs

    S Spark plug torque is 14 ft. lbs. (19 Nm). Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
  • Page 129 MAINTENANCE AND LUBRICATION Spark Plugs 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.
  • Page 130 Spark Plugs Spark Plug Removal and Replacement 1. Remove the side panels and front cab (see pages 123-124). 2. Turn the fuel valve to OFF. A hot ember on the ATV could cause fuel to ignite. Allow all components to cool sufficiently before accessing the spark plug.
  • Page 131 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3. Move the fuel valve hose clamp (1) forward and gently remove the hose from the fuel valve fitting on the gas tank. 4. Remove the vent hose (2) from the instrument panel, taking note of the hose routing for reinstallation.
  • Page 132 Spark Plugs Spark Plug Removal and Replacement 7. Using the forked end of the spark plug wrench handle, remove the spark plug boot. IMPORTANT: Do not pull on the wire to remove the boot. Doing so may cause a wire disconnection inside the boot.

  • Page 133: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.
  • Page 134 Spark Arrestor Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if components are warm. 3.

  • Page 135: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level, it’s critical to dry it promptly and properly before starting the engine. Do not start the engine after an ATV has been in water that exceeds the recommended depth.
  • Page 136 Vehicle Immersion Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts. Stand clear of the spark plug while performing the following steps. 5. Intermittently and briefly touch the starter button in half-second intervals to SLOWLY rotate the engine three or four times.

  • Page 137: Battery Removal

    MAINTENANCE AND LUBRICATION Battery The YUASA sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush.

  • Page 138: Battery Installation

    MAINTENANCE AND LUBRICATION Battery Installation 1. Set the battery in the battery holder. 2. Connect and tighten the red (positive) cable first, then connect and tighten the black (negative) cable. 3. Attach the hold-down strap and reinstall the rear cab. 4.
  • Page 139 (see page 175). When using an automatic charger such as the Polaris Battery Tendert, refer to the manufacturer’s instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging.
  • Page 140 Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after charging. State of Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less MAINTENANCE AND LUBRICATION Voltage None, check at 3 mos.
  • Page 141 MAINTENANCE AND LUBRICATION Tires Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the ATV decal and in the owner’s manual.

  • Page 142: Wheel Removal

    Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3.

  • Page 143: Wheel Installation

    3. Install the wheel nuts and finger tighten. 4. Lower the vehicle to the ground. 5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: Any nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer.

  • Page 144: Wheel Nut Torque Specifications

    Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service. Bolt Size Front 3/8″ Rear 3/8″ Specification 25 ft. lbs. (34 Nm) 25 ft. lbs. (34 Nm)

  • Page 145: Adjustments

    ADJUSTMENTS Brakes Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation.
  • Page 146 Brakes 1. Always maintain the brake fluid at an adequate level (see page 60). 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5.

  • Page 147: Toe Alignment

    Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The Predator is designed for a neutral toe setting. 1. Set the handlebars in a straight-ahead position. Use tie straps to secure the handlebars so they can’t move.
  • Page 148 4. Measure the distance from the string to the rim at the front and rear of the front rim (3). The difference between these two measurements should be between 0″ and 1/16″ toe out. NOTE: If you discover improper alignment, see your Polaris dealer for service. ADJUSTMENTS...

  • Page 149: Chain Tension

    ADJUSTMENTS Chain Tension Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Chain tension must be inspected with the swing arm in the position shown in the illustration so that the axle, swing arm pivot and drive sprocket are aligned horizontally (B).
  • Page 150 Chain Tension Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. NOTE: The chain has a press-on master link. A chain tool must be used if it’s necessary to remove the chain for service.
  • Page 151 ADJUSTMENTS Chain Tension 1. Loosen the two eccentric locking bolts. 2. Insert a pin punch into the eccentric axle housing. 3. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. 4. Tighten the eccentric locking bolts to 35 ft. lbs. (47.5 Nm). Step 2 Proper Splicelink Clip Opening Position Step 1...

  • Page 152: Steering Assembly

    Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.

  • Page 153: Front Suspension

    Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments. WARNING...

  • Page 154: Spring Preload

    Front Suspension Spring Preload 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring to the left (A) to increase preload. Turn the ring to the right (B) to decrease preload.

  • Page 155: Rear Suspension

    ADJUSTMENTS Rear Suspension The rear suspension spring preload, shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend.

  • Page 156: Rebound Damping

    Rear Suspension Rebound Damping 1. Locate the rebound damping clicker drum between the lower spring seat and the lower shock mount. 2. Turn the clicker to the left (A) to decrease the rebound damping. Turn it to the right (B) to increase rebound damping.

  • Page 157: Compression Damping

    ADJUSTMENTS Rear Suspension Compression Damping The compression damping clicker drum is located on top of the shock reservoir, under the left rear fender. It has eight possible positions ranging from position 1 (softest) to 8 (firmest). The compression damping is factory set at position 4. To adjust, turn the clicker drum to the desired setting.

  • Page 158: Clutch Lever Freeplay

    Clutch Lever Freeplay 1. Measure clutch lever freeplay between the perch and the lever (A). This distance should be 1/8″ - 3/16″ (3.1 mm - 4.7 mm). 2. If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw (B) and lock ring (C).

  • Page 159: Throttle Cable Freeplay

    Throttle Cable Freeplay Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it’s done correctly. Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly.
  • Page 160 Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the instrument panel and locate the handlebar bolts (1).
  • Page 161 ADJUSTMENTS Carburetor/Idle RPM If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for five minutes, or until operating temperature is reached. 2.
  • Page 162 ADJUSTMENTS Carburetor/Idle RPM If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.

  • Page 163: Cleaning And Storage

    Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning and safety decals are damaged, contact your a Polaris dealer for free replacement. Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 164 Waxing the ATV Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish. Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when using these products near plastic surfaces. CLEANING AND STORAGE CAUTION...

  • Page 165: Stabilize The Fuel

    Make necessary repairs and then clean the ATV thoroughly as outlined on page 160. Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank, following the instructions on the container for the recommended amount. Fill the fuel tank with fuel.

  • Page 166: Fluid Levels

    CLEANING AND STORAGE Storage Recommendations Oil and Filter Warm the engine and change the oil and filter. See page 107. Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube.
  • Page 167 3. Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor. 4. Start the engine and spray Polaris fogging oil or a comparable product into the carburetor, following the instructions on the fogging oil container.
  • Page 168 Set the tire pressure and safely support the ATV with the tires 1-2” off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine Polaris ATV cover. NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to...

  • Page 169: Transporting The Atv

    CLEANING AND STORAGE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly.

  • Page 170: Troubleshooting

    Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Fuseable link Low battery voltage Loose battery connections Loose solenoid connections TROUBLESHOOTING Solution See Polaris dealer for replacement Recharge battery to 12.8 VDC...
  • Page 171 Turn the fuel valve on Drain and replace with new fuel Inspect plug(s), replace if necessary Inspect plug(s), verify stop switch is on Inspect, clean and/or replace spark plugs Recharge battery to 12.8 VDC See your Polaris dealer Adjust throttle freeplay...
  • Page 172 Incorrect ignition timing Mechanical failure TROUBLESHOOTING Solution Replace with recommended fuel See your Polaris dealer Set gap to specs or replace plugs Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel...
  • Page 173 Electronic throttle control (ETC) malfunction Other mechanical failure Solution Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Recharge battery to 12.8 VDC or replace...
  • Page 174 Plugged, dirty or wet air filter Solution Add or change fuel, clean the fuel system Replace with recommended fuel Replace with recommended fuel See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs Replace with recommended lower octane fuel...
  • Page 175 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC or replace...

  • Page 176: Engine Overheating

    Possible Cause Debris lodged in screen Plugged radiator TROUBLESHOOTING Solution Inspect and clean or replace See your Polaris dealer See your Polaris dealer Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Solution Remove and clean the screen.
  • Page 177 NOTES...

  • Page 178: Polaris Products

    2871423 Premium All Season Grease (14 oz. cartridge) 2871460 Starter Drive Grease (2 oz.) 2871329 Dielectric Grease (Nyogelt) 2872073 Chain Lube (6.25 oz. aerosol) 2872348 Chain Lube (16 oz. aerosol) POLARIS PRODUCTS Part # Description Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.)

  • Page 179: Specifications

    2.25 qts./2.1 l Coolant Capacity 2.25 qts./2.1 l Engine ES50PLX Displacement 499 cc Bore x Stroke 99.2 x 64.6 mm Predator 500 Pilot Jet Main Jet Needle Jet O-OM Jet Needle 6CGY07-060-3 Alternator Output 200 w @ 3000 RPM Compression Ratio 10.8:1...

  • Page 180: Jetting Chart

    Altitude AMBIENT TEMPERATURE Meters 0-1800 (Feet) (Feet) (0-6000) 1800-3700 (6000-12000) Predator 500 Tire Size/Pressure - Front Tire Size/Pressure - Rear Front Brake Rear Brake Parking Brake Headlights Taillights Brakelight Below 40° F +40° F and above (+5° C and above) (Below 5°...

  • Page 181: Warranty

    This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV.
  • Page 182 LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does...
  • Page 183 MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR- RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied war-...

  • Page 184: Engine Oil

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 185 LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warran- ty or service bulletin coverage if you have any questions.
  • Page 186 In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 187 Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce- dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.

  • Page 188: Index

    ADJUSTMENTS ... 142-159 Air Filter Systems ... 112-113 Battery ..... . Battery Charging .
  • Page 189 ... . Periodic Maintenance Schedule 91-100 POLARIS PRODUCTS ..Pre-Ride Inspection ...

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