Polaris PREDATOR 2003 Manuals

Manuals and User Guides for Polaris PREDATOR 2003. We have 1 Polaris PREDATOR 2003 manual available for free PDF download: Service Manual

Polaris PREDATOR 2003 Service Manual

Polaris PREDATOR 2003 Service Manual (193 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 105.44 MB

Table of Contents

Chapter 1 General Information 1

6
- Table of Contents
  6
- Model Identification
  7
- Serial Number Location
  7
  - General
    7
- Publication Numbers
  8
- Replacement Keys
  8
- Standard Torque Specifications
  8
- Predator Models
  9
- Maintenance
  11
- Conversion Table
  13
- Glossary of Terms
  14
Maintenance Chapter 2 Maintenance

16
- Periodic Maintenance Chart
  17
- Pre-Ride Inspection
  19
- Special Tools
  21
- Clutch Freeplay Adjustment
  24
- Throttle Inspection
  24
  - Idle Speed Adjustment
    25
  - Throttle Cable
    25
- Fuel System
  26
  - Fuel Lines
    26
  - Vent Lines
    26
  - Fuel Valve
    26
- Compression Test
  27
  - Carburetor Draining
    27
  - Engine Mounts
    27
- Battery Maintenance
  28
  - Spark Plug Inspection
    28
  - Ignition Timing
    28
  - Liquid Cooling System
    30
  - Cooling System Hoses
    31
  - Radiator Coolant Level Inspection
    31
  - Cooling System Pressure Test
    32
- Radiator Screen Removal
  32
- Crankcase Breather Filter
  33
  - Wheel Alignment
    34
- Chapter 3
  
  35
  - Body/Suspension
    35
- Chapter 4
  
  35
  - Brakes
    36
    
    Brake Pad Inspection
    37
    
    Brake System Inspection
    37
  - Wheel Removal/Installation
    41
    
    Torque Table
    41
  - Tire Inspection
    42
Chapter 3 Engine

44
- Torque Specifications
  45
- ES50PL Service Data
  46
- Engine Fastener Torque Patterns
  48
- Piston Identification / Compression Test
  48
- Special Tools
  48
- Cooling System Specifications
  49
- Engine Removal
  50
  - Electrical
    50
- Engine Installation Notes
  51
- ES50PL Engine Lubrication
  52
  - Oil Pump Priming
    53
- Camshaft
  54
  - Engine Disassembly
    56
- ES50PL Lubrication/Oil Flow
  54
- Cylinder Head
  59
  - Valve Inspection
    60
  - Cylinder Head Assembly
    61
  - Piston Removal
    64
  - Cylinder Inspection
    65
  - Crankcase Separation
    72
  - Crankcase Inspection
    72
- Transmission
  73
- Crankshaft Runout Inspection
  75
- Crankcase
  76
  - Crankcase Reassembly
    78
  - Piston Ring Installation
    78
  - Camshaft Timing
    81
- Cam Timing
  82
- Troubleshooting
  87
- Spark Plug Fouling Checklist
  88
Fuel System/Carburetion Chapter 4 Fuel System/Carburetion

90
- Fuel Flow Diagram
  92
- Carburetor Jetting
  93
  - Mikuni Jet Part Numbers
    93
  - Jetting Guidelines
    93
- CV Carburetor System Function (4 Cycle)
  94
- Assembly, CV Carburetor
  96
  - Float System
    96
  - Main System
    96
  - Carburetor Cleaning
    97
  - Carburetor Inspection
    98
  - Carburetor Assembly
    98
- Needle & Seat Leakage Test
  99
- Fuel Level
  100
- Fuel Pump Service
  100
- Troubleshooting
  101
Chapter 5 Body and Steering

102
- Body Assembly Exploded View
  104
- Steering Assembly, Exploded View
  105
- Front Hub Removal
  106
- Front Hub Assembly/Installation
  107
  - Front Hub Installation
    108
- Ball Joint Removal/Installation
  109
- Steering Knuckle Removal/Installation
  109
- Front Hub Exploded View
  111
- A-Arm Replacement
  112
- Concentric Swing Arm Removal
  113
- Rear Axle Removal/Disassembly
  114
  - Rear Axle Installation
    116
- Rear Swing Arm / Axle Exploded View
  118
- Steering Post Assembly/Decal Replacement
  119
Brakes Chapter 6 Brakes

146
- Special Tools
  147
- Brake Noise Troubleshooting
  148
- Brake System Service Notes
  148
- Hydraulic Brake System Operation
  149
- Fluid Replacement/Bleeding Procedure
  150
- Master Cylinder Removal
  152
- Master Cylinder Installation
  153
- Front Pad Assembly
  155
- Front Disc Inspection
  156
  - Front Caliper Removal
    157
  - Rear Brake Pad
    159
- Front/Rear Caliper Disassembly
  160
- Front/Rear Caliper Assembly
  162
- Rear Brake Disc Inspection
  163
- Troubleshooting
  163
- Front Brake System
  165
- Rear Brake System
  166
Electrical Chapter 7 Electrical

168
- Timing Check Procedure
  169
  - Fan Motor Current Draw
    170
- Ignition System Troubleshooting
  172
  - Alternator Output Test
    173
- Flywheel Identification
  174
- Ignition System
  174
- Ignition System Testing
  176
- Charging System Testing Flow Chart
  177
  - Battery Testing
    179
  - Load Test
    179
  - Headlight Housing Replacement
    180
  - Headlight Adjustment
    180
  - Headlamp Switch
    181
  - Brake Light Switches
    181
- Starter System Troubleshooting
  182
  - Armature Testing
    185
- Starter System Testing Flow Chart
  187

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