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Polaris 2007 Predator 500, Owner'S Manual

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Polaris 2007 Predator 500 Owner'S Manual Download Page 120

117

MAINTENANCE AND LUBRICATION

Lights

Headlight Assembly Replacement

5. Install the new headlamp by inserting the outboard pivot pin in the hole of the

mounting tab on the cab.

6. Install the adjuster bracket onto the inboard pivot pin of the headlamp.
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 can move freely.

8. Install the adjusting screw, leaving it loose so the headlight can be adjusted.
9. Reinstall the front cab and connect the wire harness to the headlamp.
10. Adjust the lamps as needed, then tighten the adjuster screw. See page 118.

Summary of Contents for 2007 Predator 500

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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: ...and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication a...

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: ...SAFETY 8 FEATURES AND CONTROLS 48 OPERATION 65 EMISSION CONTROL SYSTEMS 88 MAINTENANCE AND LUBRICATION 90 ADJUSTMENTS 138 CLEANING AND STORAGE 157 TROUBLESHOOTING 166 POLARIS PRODUCTS 173 SPECIFICATIO...

Page 9: ...ut all aspects of your vehicle including safe operating procedures Vehicle Identification Numbers Record your ATV s identification numbers and key number in the spaces provided Remove the spare key an...

Page 10: ...7 KNOW YOUR VEHICLE Vehicle Identification Numbers Vehicle Model Number Frame VIN 1 left side Engine Serial Number 2 right side Key Number 3...

Page 11: ...efully 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 cont...

Page 12: ...o fast for your skills or the condi tions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALW...

Page 13: ...vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience Discretionary Warning 4 WARNING S Never operate this vehicle on...

Page 14: ...in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 4 27 6 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 645 LBS 293 kg Reduce speed and allow gr...

Page 15: ...helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the...

Page 16: ...nal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean 3 Gloves Off road style gloves with knuckle pads are the best for comfort and p...

Page 17: ...utine 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 ATV Operat...

Page 18: ...rials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Expr...

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: ...hasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on en...

Page 22: ...ate at excessive speeds Trav el at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt jumps or other stunts S Always inspect your ATV before eac...

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

Page 24: ...duce the chance of skidding or sliding out of con trol S Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hil...

Page 25: ...imes to allow friction to dry out the pads S Always check for obstacles or people be hind the ATV before operating in re verse When it s safe to proceed in reverse move slowly and avoid turning at sha...

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: ...situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA They should then 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: ...NG POTENTIAL HAZARD Attempting 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 jumps or other s...

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: ...e vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result...

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

Page 52: ...the switch is in the OFF position 3 Main Key Switch To start the engine the main key switch must be in the RUN position NOTE Both the main switch and the emergency engine stop switch will shut off al...

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: ...the throttle lever the engine will stop and power to the rear wheels will cease WARNING Modifications to the ETC could result in failure to perform as designed which could result in severe injury or...

Page 57: ...e brake fluid level frequently for the foot brake system The reservoir is located behind the right side panel Maintain the fluid level between the minimum and maximum marks WARNING Aggressively applyi...

Page 58: ...st 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 fluid level whic...

Page 59: ...DOT 4 brake fluid only Do not overfill See page 173 for the part numbers of Polaris products WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious in...

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

Page 61: ...vent 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 alone...

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: ...valve has 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 engin...

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: ...ator from shifting into reverse unintentionally 1 Place the transmission in first gear See page 61 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into r...

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 ter...

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 55 139 Brake fluid Ensure proper level 56 Foot brake Ensure proper operation 54 Clutch lever Check for proper opera...

Page 72: ...proper operation 52 153 Indicator lights switches Ensure operation 49 Engine stop switch Ensure proper operation 49 Air filter pre filter Inspect clean 109 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: ...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 body...

Page 84: ...ointing across the hill or slightly downward 7 With the front brakes still applied release the clutch lever and lock the parking 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: ...185 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: ...es Km F A Arm A 50 H 3 M 500 800 Inspect tighten fasteners grease also after 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: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...r with 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 Fill the oil tank with...

Page 110: ...e the oil pump using the procedure on page 108 Then stop the engine and inspect for leaks 21 Check the oil level on the dipstick Add oil as necessary to bring the level to the upper mark on the dipsti...

Page 111: ...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 112: ...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 113: ...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 114: ...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 115: ...ant operating 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 con...

Page 116: ...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 117: ...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 118: ...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 119: ...harness connector from the headlights 2 Remove the front cab see page 120 Position the cab upside down on a soft protective surface to prevent scratching 3 Remove the small adjuster bracket 1 and ins...

Page 120: ...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 121: ...t 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 shoul...

Page 122: ...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 123: ...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 124: ...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 125: ...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 126: ...nd front cab see pages 119 120 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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...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 135: ...laris 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 When using an automati...

Page 136: ...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 137: ...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 138: ...to 1 8 3 mm 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 139: ...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 140: ...RICATION 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 30 35 ft lbs 41 47 Nm Rear 3...

Page 141: ...6 The front brakes are hydraulic disc brakes They 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...

Page 142: ...ks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to3 64 1 mm 5 Check the security a...

Page 143: ...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 144: ...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 these...

Page 145: ...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 146: ...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 147: ...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 148: ...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 149: ...sed position Rear Shock Standard and Limited Edition Setting Compression Damping Rebound Damping Softest 20 clicks from closed 24 clicks from closed Factory 10 clicks from closed 16 clicks from closed...

Page 150: ...sion damping on page 151 Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight See page 148 WARNING Uneven adjustment may cause poor handl...

Page 151: ...rt the front of the ATV off the ground to allow the suspension to fully extend 2 Turn the adjuster 1 to the left A to increase preload for a stiffer ride Turn the adjuster to the right B to decrease p...

Page 152: ...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 153: ...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 154: ...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 155: ...w 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 lev...

Page 156: ...s 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 loosen th...

Page 157: ...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 ha...

Page 158: ...Warm up the engine by running the vehicle for five minutes or until operating temperature is reached 2 Lock the parking brake Place the transmission in neutral 3 Adjust the carburetor idle screw 1 eit...

Page 159: ...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 160: ...also extend the life of various components CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products incl...

Page 161: ...wer parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips S Avoid the use of harsh cleaners which can scratch the finish S Do not use a power...

Page 162: ...s Avoid directing the water stream at the following items S Wheel bearings S Transmission seals S Brakes S Cab and body panels S Labels and decals NOTE If warning and safety labels are damaged contact...

Page 163: ...the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips S Avoid the use of automotive products some of which can scratch the finish of your ve hicle S Always use cl...

Page 164: ...vehicle as recommended See page 157 Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank following the instructions on the container for the recommend...

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: ...r Output 200 w 3000 RPM Wheelbase 50 5 in 128 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 58...

Page 178: ...inal 14 38 Front Brake Hydraulic Disc Gear Ratio 1st 2 4 Rear Brake Hydraulic Disc Gear Ratio 2nd 1 6 Parking Brake Hydraulic lock front wheel Gear Ratio 3rd 1 3 Headlights 2 Dual Beam 35w 35w Gear Ra...

Page 179: ...laris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will re...

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: ...185 MAINTENANCE LOG Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs...

Page 189: ...186 MAINTENANCE LOG Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Page 190: ...e 112 Cooling System 111 112 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 Obstacles 83 Drivi...

Page 191: ...1 Rebound Damping 150 Reverse Lock Out Switch 63 S Safe Riding Gear 12 13 Safety Decals and Locations 8 11 Safety Training 15 Shift Pedal 61 Shifting Gears 62 Side Panel Removal 119 Spark Arrestor Cle...

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