2003 polaris predator 500 service manual free download

Install the inner spacer. Front Wheel Nuts 4 30 ft. Place the upper and lower A--arms into the steering knuckle. Install the castle nuts onto the upper and lower A--arms. Torque the nuts to 25 ft. Removal 7. After the new ball joint is installed into the A--arm, install a NEW retaining ring. Install Use new bolts upon reassembly. Spring B. IFP Shock C.

Upper A--Arm D. Bolt E. A--Arm Shaft F. Bolt G. Chain Slide G. Washer B. Mount Bolt H. Nylok Nut C. Spacer I. Chain Guide D. Seal J.

Sprocket Guard E. Needle Bearing K. Thrust Bushing L. Securely support rear of machine with rear wheels off the floor. Remove rear wheels and hubs. Loosen the hex screw A to loosen the axle nut. 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.

With the axle out, remove the retaining ring I and sprocket hub J from the axle. Install the mounting bracket E and retaining ring F. Be sure to properly align the bracket E and bushing I upon installation. Page 9. Install the brake disc if previously removed. Lubricate the axle housing through the grease Torque the brake disc nuts to ft. Torque the hex pinch bolt to 50 Torque to 50 ft. Align cotter pin hole.

The table on page 5. Parts in boxed area are an example of typical valving. Note the direction and position of all internal parts for 1. Remove spring and bushings from shock eyes. Thoroughly wash shocks in a parts washer or with soap and water to remove dirt and other debris. Remove valve and sealing O-ring from body cap. Pull shock rod and piston straight out to avoid seal or valve damage. 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. Position shock in vise with Body Clamp Tool. Clean body clamp tool before installing. Carefully clean all parts thoroughly with electrical contact cleaner or solvent and dry with compressed air.

Inspect shock body for scratches or wear. Do not over-tighten vise or bearing cap may be damaged. Unscrew body cap and remove. Invert shock and mount bearing cap flats lightly in vise. Place a shop towel over the end of IFP tool to catch any spilled shock oil. Reinstall body cap with a new O-ring and tighten by hand.

Set the nitrogen tank pressure regulator to - As a final check, push the damper rod through a PSI. 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. Qty Description Ref. 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.

Gently tap the reservoir end cap with a rubber Floating Piston. Insert the IFP tool into the mallet to expose the wire retaining ring. Remove damp plate by twisting Remove the IFP o--ring using a scribe or dental clockwise. Push on the protruding adjuster drum stem to remove it from CD housing.

Lubricate and carefully install the damp plate sealing o--ring inside the CD housing. Make sure o--ring is properly seated. 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. 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. 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. Install new dust seal into bearing cap. Seal should be installed with lip protruding from the flat side of 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. Clamp shaft eyelet securely in vise, and place seal bullet tool on end of shaft. Slide bottom--out bumper onto shaft. NOTE: The tapered side of the bottom--out bumper should be facing away from the shaft eyelet.

Lubricate the flat end of the metering rod with a small amount of assembly lube. Insert metering rod, flat end first, into the shaft. Set compression adjuster to the 3 position. If this Firmly grip the reservoir hose at the CD housing.

Push the IFP further into the reservoir. As you do 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. Clamp the body cap of shock securely in vice, with shaft end up. Special Tools Brake System Service Notes. Make sure caliper moves freely on guide Disc brake systems light weight, pins. Add brake fluid to the upper level mark on reservoir. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged.

Add fluid as necessary to maintain level in reservoir. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to Brake Lines disassemble brake components. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt A ; remove bolt and sealing washers.

Page Master Cylinder Installation 1. Install master cylinder on handlebars. Torque mounting bolts to 25 in. Torque the top bolt first. Follow bleeding procedure on Pages 9. Remove the caliper bolts B and caliper from the 6. Remove the loose caliper slide bolts. The brake mount bracket. With pads installed, push caliper piston into caliper bore slowly using a C-clamp or locking pliers. 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. Visually inspect the brake disc for nicks, scratches, or damage. Measure the disc thickness at 8 different points around the pad contact surface using a micrometer. Replace disc if worn beyond service limit. Brake Disc Runout Service Limit. Severe injury may occur if machine tips or 15 ft. Remove brake pads. See Page 6. Loosen the caliper slide bolt with an Allen wrench before you remove the brake caliper.

Remove the c--clips C on the ends of the caliper slide bolt. Remove caliper mounting bolts and lift caliper off of disc. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Front Brake Pad Thickness. Clean caliper area before removal. Using a flare nut wrench, remove the brake lines A. Remove the outside dust boot E. Clean the caliper body, piston, and retaining 4. Remove the piston and dust seal F. NOTE: Be sure to clean seal grooves in caliper body.

Inspect piston for nicks, scratches, wear or damage. Replace if damaged or worn. Inspect Piston 3. Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, 3. Visually inspect disc for scoring, scratches, or Improper alignment gouges. Replace the disc if any deep scratches Worn disc are evident.

Page M. Bleeder Screws N. Circlips 33 ft. Master Cylinder B. Brake Line C. Pressure Switch D. Junction Box E. Wheel Hub F. Line Retainer G. Caliper I. Caliper Mount Bolt 15 ft.

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. Timing Check Procedure Remove the check plug. PV- Fluket77 Digital The ignition timing marks are stamped on the outer Multimeter diameter of the flywheel. Be sure cooling system is full and purged of air. Refer to Maintenance Chapter 2 for 1. NOTE: position. Read the current draw on ammeter with Adjust throttle cable freeplay ETC switch and make fan running.

The starter No Spark, Weak or Intermittent Spark system must be in good condition and the battery fully charged. Increase engine RPM while observing ammeter and tachometer.

Current Draw Inspection 6. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. Using a multitester set on D. It should be Doing so will damage the case and shorten the life of the battery. During cranking the observed voltage should not drop below 9. If the beginning voltage is Serious burns may result. Protect lamp during install. After connecting the battery cables, attach the hold down strap. Turn headlights on. Test for 1. Remove the wire harness connector from the battery voltage across the connections.

Low Beam -- Brown and Green 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.

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? Remove brush terminal end of housing while Brush Length holding other two sections together. Remove brush plate and brushes.

Measure length of brushes and replace if worn past the service limit. Remove armature from starter casing. Note 1. Place armature in field magnet casing. Place shims on drive end of armature shaft with 2.

Inspect surface of commutator. Replace if phenolic washer outermost on shaft. Inspect the drive gear teeth, bearings and thrust surfaces for excessive wear or damage. Inspect the one way drive clutch rollers and springs for excessive wear or damage. 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. Page Brake System Service Notes, 6. Page Controls Inspection, 2. Sensor Test, 7. Page Oil Pressure Test, 3. Registration is fast and you can even login with social network accounts to sync your profiles and content. By Ajmboy. This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.

Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the Polaris Predator ATV.

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