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Polaris 2006 Predator 500, Owner'S Manual For Maintenance And Safety

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Polaris 2006 Predator 500 Owner'S Manual For Maintenance And Safety Download Page 100

97

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours

Calendar

Miles (Km)

"
F

A-Arm (A)

50 H

3 M

500 (800)

Inspect; tighten fasteners; grease (also af-

ter washing ATV or driving in water)

"
F

Rear axle/

Rear eccentric (B)

25 H

3 M

250 (400)

Inspect; grease (also after washing ATV or

driving in water)

"
F

Upper steering post

(C)

50 H

6 M

500 (800)

Inspect; tighten fasteners; grease after

washing ATV or driving in water

A

A

C

B

Summary of Contents for 2006 Predator 500

Page 1: ......

Page 2: ......

Page 3: ...wn to cause cancer birth defects 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...

Page 4: ...1...

Page 5: ...minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liab...

Page 6: ...a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products S Snowmobiles S All terrain vehicles ATVs S RANGER uti...

Page 7: ...Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service...

Page 8: ...CATION NUMBERS 6 SAFETY 8 FEATURES AND CONTROLS 48 OPERATION 65 EMISSION CONTROL SYSTEMS 88 MAINTENANCE AND LUBRICATION 90 ADJUSTMENTS 140 CLEANING AND STORAGE 159 TROUBLESHOOTING 166 POLARIS PRODUCTS...

Page 9: ...ion numbers and key number in the spaces provided 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...

Page 10: ...7 VEHICLE IDENTIFICATION NUMBERS Vehicle Model Number Frame VIN 1 left side Engine Serial Number 2 right side Key Number 3...

Page 11: ...refully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off con...

Page 12: ...parking on grades leave ATV in gear WARNING 7170906 Location A Location C WARNING This ATV may exceed the performance of other ATVs you may have ridden in the past This category S Sport ATV is a high...

Page 13: ...10 SAFETY Safety Decals and Locations E D F Location F H G I 7172566 WARNING Location E...

Page 14: ...VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS 7170983 CE V HICULE EST UN V HICULE TOUT TERRAIN QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS IMPROPER TIR...

Page 15: ...1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets or exceeds your state s safety standa...

Page 16: ...e of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over...

Page 17: ...uring routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris AT...

Page 18: ...lain safe operating procedures which you should review on a regular basis If your model is recommended for use by experienced operators only you also received a safety video Be sure to view it before...

Page 19: ...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 fo...

Page 20: ...caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will...

Page 21: ...e 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 near...

Page 22: ...at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other stunts S Always inspect your ATV befor...

Page 23: ...fore attempting larger hills S Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose surfaces Shif...

Page 24: ...teady speed when climbing a hill If you stall or roll back wards follow the special procedure for braking described in this manual Always dis mount on the uphill side or to either side if the ATV is p...

Page 25: ...them lightly several times to allow friction to dry out the pads S Always check for obstacles or people behind the ATV before operating in reverse When it s safe to proceed in reverse move slowly and...

Page 26: ...purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equi...

Page 27: ...ifferent situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should re...

Page 28: ...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...

Page 29: ...ion operates this ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could...

Page 30: ...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 The purpose of...

Page 31: ...nd 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: ...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: ...et 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...

Page 34: ...perating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating th...

Page 35: ...IAL 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 o...

Page 36: ...tain 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 ope...

Page 37: ...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 t...

Page 38: ...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 ext...

Page 39: ...cessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slip...

Page 40: ...ibed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT C...

Page 41: ...the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your...

Page 42: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 79 Always check the terrain carefully before descend...

Page 43: ...t 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 See page 80 Use extra caution when turning on any hill Avoid crossin...

Page 44: ...radually When fully stopped apply rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rollin...

Page 45: ...es such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WH...

Page 46: ...through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 85 travel slowly balance your weight carefully avoid sudden movements and mai...

Page 47: ...use the size and type of tires specified for the ATV in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Overlo...

Page 48: ...ling which could lead to an accident 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 Pol...

Page 49: ...h the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or per...

Page 50: ...limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who oper...

Page 51: ...48 FEATURES AND CONTROLS Engine Electrical Switches 1 2 3...

Page 52: ...quick means of engine shutdown in case of an emergency The engine will not start or run when the switch is in the OFF position 3 Main Key Switch To start the engine the main key switch must be in the...

Page 53: ...50 FEATURES AND CONTROLS Lights 1 Headlight HI LO Switch 2 High Temp Indicator Lamp 3 Neutral Indicator Lamp 4 Reverse Indicator Lamp 1 2 3 4...

Page 54: ...s in the ON position and the engine stop switch is in the RUN position WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your...

Page 55: ...rise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return be...

Page 56: ...er the engine will stop and power to the rear wheels will cease WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safe...

Page 57: ...k the brake fluid level frequently for the foot brake system The reservoir is located behind the right side panel Maintain the fluid level between the MIN and MAX marks WARNING Aggressively applying t...

Page 58: ...akes Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fl...

Page 59: ...only Do not overfill See page 173 for the part numbers of Polaris products WARNING Overfilling the master cylinder will result in brake failure Without room to expand the excess fluid will cause the...

Page 60: ...brake is disengaged before operating Setting the Parking Brake 1 Place the transmission in first gear or neutral 2 Squeeze and release the brake lever 1 two or three times then squeeze and hold 3 Pus...

Page 61: ...event 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 S Never depend on the parking brake alon...

Page 62: ...torage 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 Always refill the gas tank as s...

Page 63: ...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...

Page 64: ...eleased To upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift place your foot on the gear shift pedal and depress the pedal...

Page 65: ...lever to disengage the clutch 4 Depress the gear shift pedal one full stroke to shift into first gear 5 Release the brake lever 6 Gradually squeeze the throttle lever while slowly releasing the clutch...

Page 66: ...ts the operator from shifting into reverse unintentionally 1 Place the transmission in first gear See page 61 2 Rotate the lock out switch forward to unlock the transmission 3 Shift into reverse gear...

Page 67: ...a lower gear NOTE Be sure the engine RPM has sufficiently decreased before shifting to a lower gear WARNING Improper use of the brakes or shifting when the engine RPM is too high can cause the tires...

Page 68: ...where refueling is performed or where gasoline is stored S Do not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and wa te...

Page 69: ...hours of cautious operation No single action on your part is as important as following the procedures for a proper break in Perform the following procedures carefully CAUTION Excessive heat build up d...

Page 70: ...re operating 4 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 5 Vary the throttle positions Do not operate at sustained idle 6 P...

Page 71: ...de Checklist Item Remarks See Page Brake system lever travel Ensure proper operation 55 141 Brake fluid Ensure proper level 56 Foot brake Ensure proper operation 54 Clutch lever Check for proper opera...

Page 72: ...proper operation 52 155 Indicator lights switches Ensure operation 49 Engine stop switch Ensure proper operation 49 Air filter pre filter Inspect clean 111 Headlamp Check operation apply Polaris diel...

Page 73: ...bon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine...

Page 74: ...e 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 n...

Page 75: ...a maximum of five seconds Release the start button immediately when the engine starts NOTE Do not press the throttle lever while starting the engine NOTE Excessive engagement may result in starter da...

Page 76: ...e necessary If you believe the engine is over choked when warm push the choke lever completely in and depress the throttle lever fully while cranking to aid in starting Release the throttle lever imme...

Page 77: ...t to warm up then shift the transmission into gear See page 62 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thu...

Page 78: ...your upper body to the inside of the turn while supporting your weight on the outer footpeg This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly...

Page 79: ...iding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise care when operat...

Page 80: ...a steady rate of speed and throttle opening 5 Be alert and prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when o...

Page 81: ...Follow proper procedures as outlined in the owner s manual If you enter into a situation where sidehilling is unavoidable 1 Slow down 2 Lean into the hill transferring your upper body weight toward t...

Page 82: ...wnhill 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 Apply the foot brake slightly to aid in slowing WARNING Excess...

Page 83: ...er s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Keep your bod...

Page 84: ...pointing across the hill or slightly downward 7 With the front brakes still applied release the clutch lever and lock the park brake Remount from the uphill side keeping body weight uphill 8 Pull in...

Page 85: ...rking 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...

Page 86: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obs...

Page 87: ...s and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pre...

Page 88: ...starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully av...

Page 89: ...riving in Reverse Follow these precautions when operating in reverse 1 Avoid backing downhill 2 Back slowly 3 Apply the brakes lightly for stopping 4 Avoid turning at sharp angles 5 Never open the thr...

Page 90: ...r people behind the vehicle Drive slowly Avoid backing on inclines Avoid turning at sharp angles NOTE This Polaris ATV is equipped with a reverse speed limiter Do not operate at full throttle Use just...

Page 91: ...to be 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 Operation of o...

Page 92: ...stem The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris spe...

Page 93: ...dition Inspection adjustment and lubrication of important components are explained in the following pages A tool kit is provided in the storage compartment under the seat Tool Kit S Spark plug socket...

Page 94: ...100 Severe Use Definition S Frequent immersion in mud water or sand S Racing or race style high RPM use S Prolonged low speed heavy load operation S Extended idle S Short trip cold weather operation I...

Page 95: ...form these services Maintenance Chart Key Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the...

Page 96: ...Inspect Wheels lug nuts Pre Ride Inspect tighten Frame fasteners Pre Ride Inspect tighten E Air filter and Pre cleaner Pre Ride Inspect clean replace as needed Coolant Pre Ride Inspect level add as ne...

Page 97: ...tubes Pre Ride Drain deposits when visible Headlamp Pre Ride Check daily apply Polaris dielectric grease to connector when replaced Tail lamp brake lamp Pre Ride Check daily A arm ball joint Pre Ride...

Page 98: ...160 Inspect periodically Oil Change 10 H 6 M 100 160 Perform break in service after first hour of operation Oil Filter 10 H 6 M 100 160 Replace with oil change Battery 20 H Monthly 200 320 Check termi...

Page 99: ...00 Inspect adjust replace if necessary E Choke enricher cable 50 H 6 M 500 800 Inspect adjust lubricate replace if neces sary Drive chain s 50 H 6 M 500 800 Inspect daily adjust and lubricate if neede...

Page 100: ...s Km F A Arm A 50 H 3 M 500 800 Inspect tighten fasteners grease also af ter washing ATV or driving in water F Rear axle Rear eccentric B 25 H 3 M 250 400 Inspect grease also after washing ATV or driv...

Page 101: ...0 1600 Pressure test system annually E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed J E Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve pump and carburetor r...

Page 102: ...J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out J Front wheel bearings 300 H 36 M 3000 4800 Inspect replace as needed Idle speed As required Adj...

Page 103: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50...

Page 104: ...101 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Page 105: ...de the ultimate in lubrication performance and protection and prolonged clutch life See page 173 for the part numbers of Polaris products PS 4 oil possesses unsurpassed film strength over the widest p...

Page 106: ...ne and let it idle for one minute 3 Stop the engine and remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely NOTE The dipstick must be screwed completely in to keep t...

Page 107: ...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 d...

Page 108: ...t oil and filter overnight Always replace the oil and filter within a few hours of draining the oil Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page...

Page 109: ...es until warm then stop the engine 4 Place a drain pan beneath the oil tank and remove the drain plug CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin 5 Allow the o...

Page 110: ...Nm 10 Place shop towels beneath the oil filter 11 Remove the three cover bolts and remove the cover 12 Pull out the oil filter NOTE A spring located behind the filter may pop out as the filter is remo...

Page 111: ...th the open end facing outward 17 Install the cover and torque the bolts to 72 78 in lbs 8 9 Nm NOTE The long bolt must be placed in the forward hole 18 Remove the dipstick and fill the oil tank with...

Page 112: ...e oil pump using the procedure on page 110 Then stop the engine and inspect for leaks 21 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dip...

Page 113: ...mp or pinch off the vent line 1 approximately 2I 5 cm from the oil tank 2 Run the engine for 5 10 seconds at idle Stop the engine and remove the vent line clamp If the line is bled properly you should...

Page 114: ...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 Remove the air filter 5 Inspect and replace if necessary 6 Remove the p...

Page 115: ...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 CAUTION Operation of your vehicle wi...

Page 116: ...d that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixtur...

Page 117: ...ng temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting co...

Page 118: ...d only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry inspect the level in the radiator and add coolant if necessary 1 Remove the press...

Page 119: ...t spot that will shorten the life of the lamp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the head...

Page 120: ...he 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 3 Apply dielectric grease to the socket and install the new...

Page 121: ...harness connector from the headlights 2 Remove the front cab see page 122 Position the cab upside down on a soft protective surface to prevent scratching 3 Remove the small adjuster bracket 1 and ins...

Page 122: ...eadlamp 7 Adjust for approximately 1 16 clearance between the bracket and the edge of the headlight Tighten the mounting screws IMPORTANT Be sure the bracket is 90 degrees to the pivot pin so the lamp...

Page 123: ...and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should...

Page 124: ...s 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 o...

Page 125: ...and 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 Gently pull the cab forward to remove the cab...

Page 126: ...rranty 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...

Page 127: ...TE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is bla...

Page 128: ...nd front cab see pages 121 122 2 Turn the fuel valve to OFF WARNING A hot ember on the ATV could cause fuel to ignite Allow all components to cool sufficiently before accessing the spark plug Always e...

Page 129: ...e vent hose 2 from the instrument panel taking note of the hose routing for reinstallation 5 Remove the tank mounting bolt 3 at the rear of the gas tank 6 Move the tank rearward and upward over the en...

Page 130: ...re to remove the boot Doing so may cause a wire disconnection inside the boot 8 Using the spark plug wrench and handle rotate counterclockwise to remove the spark plug 9 Reverse all steps to install t...

Page 131: ...gine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Wear eye protection and gloves Never run the engine in an enclosed area Exh...

Page 132: ...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 If necessary blow debris from the screen with compressed air 3 Inspect t...

Page 133: ...perform the temporary drying out procedure outlined below which will allow short term operation only to drive the ATV to a trailer or towing vehicle Do not perform the following procedures if you don...

Page 134: ...t one minute or until water vapor is no longer ejecting from the spark plug hole 7 Check the oil level on the dipstick If the level is higher than the pre ride inspection level water has entered the o...

Page 135: ...water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly WARNING Improperly connecting or disconnecting battery cables can resul...

Page 136: ...les are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result i...

Page 137: ...Battery Tendert battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point see page 173 When using an a...

Page 138: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 month...

Page 139: ...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 Always use original...

Page 140: ...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 Elevate the side of the vehicle by pl...

Page 141: ...to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in gear and lock the parking brake 2 Place the wheel on the wheel hub with t...

Page 142: ...LUBRICATION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Specification Front 3 8 27 ft lbs 36 5 Nm Rear 3...

Page 143: ...hey re activated by squeezing the brake lever toward the handlebar The rear brake is a hydraulic disc brake activated by the foot brake pedal Both brakes are self adjusting but the following checks ar...

Page 144: ...r fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc 6 Inspect the rear b...

Page 145: ...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 to the rear grab ba...

Page 146: ...ires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The difference between th...

Page 147: ...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 s...

Page 148: ...vice 1 Collapse the suspension with an adjustable buckle type trailer tie down strap A Fasten the strap around the axle and rear bumper tube 2 Tighten the strap until a straight line B can be drawn fr...

Page 149: ...ocking 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...

Page 150: ...eering 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...

Page 151: ...the fully closed position Rear Shock Standard and Troy Lee Setting Compression Damping Rebound Damping Softest 20 clicks from closed 24 clicks from closed Factory 10 clicks from closed 16 clicks from...

Page 152: ...ression damping on page 153 Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight WARNING Uneven adjustment may cause poor handling of the...

Page 153: ...ATV off the ground to allow the suspension to fully extend 2 Loosen the jam nut 1 3 Turn the adjusting ring 2 to the left to increase preload A Turn the ring to the right to decrease preload B 4 Tigh...

Page 154: ...Spring Preload 1 Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend 2 Loosen the jam nut 1 and back it away from the adjusting ring 3 Turn the adjustin...

Page 155: ...ing seat and the lower shock mount 2 Use a screwdriver make the adjustment Turn the clicker counter clockwise to decrease the rebound damping A Turn the clicker clockwise to increase rebound damping B...

Page 156: ...of the shock reservoir under the right rear fender Use a screwdriver to make adjustments To increase compression damping turn the clicker clockwise A To decrease compression damping turn the clicker...

Page 157: ...rew B and lock ring C 3 Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever travel Tighten the lock ring 4 Squeeze the l...

Page 158: ...ersons who perform this procedure must follow the adjustment procedures exactly Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 and loos...

Page 159: ...us injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the instrument panel and locate the handlebar bolts 1 2 Loosen the four bolts and adjust the...

Page 160: ...arm up the engine by running the vehicle for five minutes or until operating temperature is reached 2 Apply the park brake and place the transmission in neutral 3 Adjust the carburetor idle screw 1 ei...

Page 161: ...tion 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 Although this...

Page 162: ...smission seals body panels brakes and decals Clean your ATV with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower part...

Page 163: ...any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic sur...

Page 164: ...airs and then clean the ATV thoroughly as outlined on page 159 Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank following the instructions on the...

Page 165: ...replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter inside the airbox Fluid Levels Inspect all fluid...

Page 166: ...ff 2 Unlatch and remove the seat 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...

Page 167: ...son Grease Engine Anti Freeze Test engine coolant strength and add or change coolant if necessary Replace coolant every two years Storage Area Covers Set the tire pressure and safely support the ATV w...

Page 168: ...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 4 Always tie the frame of the ATV to the transporting unit securel...

Page 169: ...s using the following charts Engine Doesn t Turn Over Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12 8 VDC Loose battery connection...

Page 170: ...is turned off Turn the fuel valve on Old poor or non recommended fuel Drain and replace with new fuel Fouled or defective spark plug Inspect plug s replace if necessary No spark to spark plug Inspect...

Page 171: ...to specs or replace plugs Engine Backfires Possible Cause Solution Weak fouled or defective spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs...

Page 172: ...cs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC or replace Kinked or plugg...

Page 173: ...on recommended fuel Replace with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke...

Page 174: ...e Inspect clean and or replace spark plugs Fouled or defective spark plug Inspect clean and or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or...

Page 175: ...echanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris l...

Page 176: ...s 2871312 Grease Gun Kit Premium All Season 3 oz Additives Miscellaneous 2871322 Premium All Season Grease 3 oz cartridge 2871326 Carbon Clean Plus 12 oz 2871423 Premium All Season Grease 14 oz cartri...

Page 177: ...or Output 200 w 3000 RPM Wheelbase 51 in 130 cm Compression Ratio 10 8 1 Ground Clearance 4 5 in 11 cm Starting System Electric Dry Weight 415 lbs 188 kg Carburetor BSR 42mm Minimum Turning Radius 67...

Page 178: ...draulic Disc Gear Ratio 1st 2 4 Rear Brake Hydraulic Disc Gear Ratio 2nd 1 6 Std 1 9 Troy Lee Parking Brake Hydraulic lock front wheel Gear Ratio 3rd 1 3 Std 1 5 Troy Lee Headlights 2 Dual Beam 35w 35...

Page 179: ...istration 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 PUR CHASER MUST COMPLET...

Page 180: ...osion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that...

Page 181: ...OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Som...

Page 182: ...istance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms...

Page 183: ...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 bu...

Page 184: ...ve hicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification th...

Page 185: ...ed 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 Ve...

Page 186: ...ranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes fir...

Page 187: ...TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied war ranty lasts so the above...

Page 188: ...very Bottle 114 Cooling System 113 114 Crankcase Emission Control System 89 D Driving Across Hills 78 Driving Downhill 79 Driving in Reverse 86 87 Driving on Slippery Surfaces 76 Driving Over Obstacle...

Page 189: ...t Switch 63 S Safe Riding Gear 12 13 Safety 8 47 Safety Decals and Locations 8 11 Safety Training 15 Setting the Parking Brake 57 Shift Pedal 61 Shifting Gears 62 Side Panel Removal 121 Spark Arrestor...

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