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DIY ManualsDIY Manuals >> Service & Repair >> Motorcycle Manuals >> Polaris ATV Repair Manuals >> Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual 2003-2007
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Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual 2003-2007

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  • Item Description
  • Table of Contents
  • Specifications

The DIY 2003-2007 Polaris Predator 500 ATV repair manual by Clymer, covers the following models:

  • Polaris Predator 500, 2003-2007
  • Polaris Predator 500 Troy Lee Designs, 2005-2006

Book Excerpt: 2003-2007 Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual

LUBRICATION, MAINTENANCE AND TUNE-UP

FRONT SUSPENSION: INSPECTION

Inspect the front suspension at the interval shown in Table 1.

  1. Park the ATV on level ground and set the parking brake.
  2. Inspect all components of the steering system. Repair or replace damaged components as described in Chapter Twelve.
  3. Remove the instrument panel from the handlebar (Chapter Ten).
  4. Check that the handlebar holder bolts and nuts (Figure 73) are tight. If necessary, tighten to 14-17 N-m (124-150 in. -lb.).
  5. Remove the front hub cover. Make sure the front hub nut (Figure 74) is tight and that the cotter pin is correctly installed.
  6. Check that all cotter pins are in place on all steering components. If any cotter pins are missing, check the nut for looseness. Tighten the nut and install a new cotter pin as described in Chapter Twelve.

ENGINE LOWER END
This chapter covers the engine lower end components, including the crankshaft, balancer shaft, oil pump and oil tank. Refer to Table 1 and Table 2 at the end of this chapter for specifications.

ENGINE

The engine must be removed from the frame to service the following components:

  1. Crankcase.
  2. Crankshaft and connecting rod.
  3. Balancer shaft.
  4. Main bearings.
  5. Oil pump
REMOVAL

Refer to Figure 1.

  1. Place the vehicle on a level surface and set the parking brake. Block the wheels to keep it from rolling in either direction.
  2. Remove the fuel tank as described in Chapter Nine.
  3. Remove the seat, front fender and rear fender as described in Chapter Fifteen.

TABLE of CONTENTS:
  • General Information
  • Troubleshooting
  • Lubrication, Maintenance and Tune-up
  • Engine
  • Clutch and External Gearshift Linkage
  • Transmission and Internal Shift Mechanism
  • Fuel and Emission Systems
  • Exhaust System
  • Electrical System
  • Wheels, Tires and Drivetrain
  • Front Suspension and Steering
  • Rear Suspension
  • Brakes
  • Body and Frame
  • Color Wiring Diagrams

Subject: 2003, 2004, 2005, 2006, 2007 Polaris Predator 500, Predator 500 Troy Lee Designs service, maintenance, repair. ISBN-10: 1599692619 | ISBN-13: 9781599692616 | Clymer M367

  • Publisher: Clymer Manuals
  • Pages: 334 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 7 x 10 inches
  • ISBN: 978-1-59969-261-6
  • Years: 2003 - 2007
  • Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual 2003-2007
    $26.95