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

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Item # M367  ISBN: 9781599692616




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This repair and service manual covers Polaris Predator 500 ATVs, including:

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

Table of Contents

Quick Reference Data

Chapter One: General Information
Manual organization | Warnings,cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

Chapter Two: Troubleshooting
Water damage | Starting the engine | Engine does not start | Poor engine performance | Electronic throttle control | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Electrical testing | Front suspension and steering | Brake system

Chapter Three: Lubrication, Maintenance and Tune-Up
Pre-ride inspection | Air box drain plugs | Air filter | Engine oil and filter | Oil pressure test | Spark plug | Spark arrester cleaning | Fuel tank vent hose | Fuel hose inspection | Carburetor | Choke adjustment | Ignition timing | Valve clearance | Compression test | Control cables | Cooling system | Battery | Tires and wheels | Drive chain | Brake system | Front suspension | Rear suspension inspection | Suspension lubrication | Skid plate inspection | Fastener inspection | Lights and horn inspection | Specifications

Chapter Four: Engine Top End Engine service
Cylinder head cover | Camshaft | Camshaft chain tensioner | Camshaft chain, timing sprocket and chain guides | Cylinder head | Valve lifters and shims | Valves and valve components | Cylinder block | Piston and piston rings | Break-in procedure | Specifications

Chapter Five: Engine Lower End Engine
Crankcase | Water pump mechanical seal and bearing replacement | Crankshaft | Balancer shaft inspection | Primary drive gear | Oil pump | One-way check valve | Oil tank, oil pipes and hoses | Break-in procedure | Specifications

Chapter Six: Shift and External Clutch Mechanism
Drive belt cover | Outer bearing housing | Drive belt inspection and replacement | Primary and secondary sheaves | Right crankcase cover | Clutch | Specifications

Chapter Seven: Transmission and Gearshift Mechanisms (2003-2004 Models)
Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection

Chapter Eight: Transmission and Internal Gearshift Mechanism (2005-on Models)
Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection | Reverse gear arm shifter

Chapter Nine: Fuel System and Exhaust
Carburetor operation | Carburetor | Pilot screw | Carburetor tests and adjustments | Throttle cable replacement | Choke cable replacement | Fuel tank | Fuel shutoff valve | Air box | Fuel pump | Exhaust system | Specifications

Chapter Ten: Electrical System
Electrical component replacement | Electrical connectors | Battery negative cable | Charging system | Voltage regulator-rectifier | Capacitor discharge ignition (CDI) | Alternator cover and stator coil | Alternator rotor and starter gears | Ignition coil | Starter | Starter solenoid | Lighting system | Switches | Cooling system fan switch and sensor | Circuit breaker | Specifications

Chapter Eleven: Cooling System
Cooling system | Coolant reservoir | Radiator | Cooling fan | Water pump | Thermostat | Cooling fan switch | Engine coolant temperature sensor | Specifications

Chapter Twelve: Front Suspension and Steering
Front wheel | Front hub | Shock absorber | Tie rods | Front spindle | Control arms | Center link and idle arms (2003-2006 models) | Handlebar | Steering shaft | Tires and wheels | Specifications

Chapter Thirteen: Rear Suspension
Rear wheel | Rear hub | Rear axle | Rear axle eccentric | Drive chain | Sprockets | Shock absorber | Swing arm | Specifications

Chapter Fourteen: Brakes
Brake service | Front brake pad replacement | Front caliper (2003-2006 models) | Front caliper (2007 models) | Front master cylinder | Rear brake page replacement | Rear caliper (2003-2006 models) | Rear caliper (2007 models) | Rear master cylinder | Brake hose replacement | Rear brake pedal | Brake disc | Brake bleeding | Specifications

Chapter Fifteen: Body
Seat | Side panels | Front fender | Rear fender | Heel pocket and mounting bracket

Color Wiring Diagrams

Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

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