Polaris PREDATOR 2003 Page 165 Service Manual Download

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BRAKES

6.20

FRONT BRAKE SYSTEM -- CALIPER/MASTER CYLINDER

18 ft. lbs.

24.8 Nm

A. Master Cylinder
B. Brake Line
C. Pressure Switch
D. Junction Box
E. Wheel Hub
F. Line Retainer
G. Banjo Bolt & Washers
H. Caliper

I. Caliper Mount Bolt

15 ft. lbs.

21 Nm

15 ft. lbs.

21 Nm

Enfocus Software - Customer Support

Summary of Contents for PREDATOR 2003

Page 1: ...2003 PREDATOR SERVICE MANUAL 2003 PREDATOR SERVICE MANUAL PN 9918062 PN 9918062...

Page 2: ...rations component identification and unit repair along with service specifications for the 2003 Polaris Predator ATV Comments or suggestions about this manual may be directed to Service Publications D...

Page 3: ...to follow WARNING instructions could result in severe injury or death to the operator bystander or person inspecting or servicing the ATV CAUTION A CAUTION indicates special precautions that must be...

Page 4: ...CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE TRANSMISSION CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY SUSPENSION CHAPTER 6 BRAKES CHAPTER 7 ELECTRICAL...

Page 5: ......

Page 6: ...cation 1 2 Serial Number Location 1 2 Publication Numbers 1 3 Replacement Keys 1 3 Standard Torque Specifications 1 3 Predator Models 1 4 Specifications 1 5 1 6 Tap Drill Charts 1 7 Decimal Equivalent...

Page 7: ...15 16 17 4 X A G A 5 0 A 3 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No Individual Serial No Body Style Check Digit World Mfg ID This could be e...

Page 8: ...278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general gu...

Page 9: ...GENERAL INFORMATION 1 4 PREDATOR MODELS PREDATOR 500 PREDATOR 500 TROY LEE LIMITED EDITION...

Page 10: ...ry Dimension Length 71 5 in 182 cm Width 47 5 in 121 cm Height 45 in 114 cm Seat Height 32 in 81 28 cm Wheel Base 51 in 130 cm Ground Clearance 4 5 in 11 cm Dry Weight 415 lbs 188 kg Fuel Capacity 3 2...

Page 11: ...0 9 mm Battery Model Amp Hr Maintenance Free Yuasa YTX9 9 Amp Hr Circuit Breakers Fan 10 amp Harness 20 amp Starting Electric Standard Instrument Cluster N A Drivetrain Transmission Type Manual 5 spee...

Page 12: ...13 32 13 32 0 0995 0 0937 0 1285 0 125 0 166 0 161 0 196 0 234 0 277 0 265 0 3125 0 3125 0 3437 0 339 0 375 0 406 0 406 3 32 3 32 1 8 1 8 11 64 5 32 13 64 15 64 9 32 17 64 5 16 5 16 11 32 11 32 3 8 1...

Page 13: ...c centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt...

Page 14: ...a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm 2 Kilograms per square centimeter kg m Kilogram...

Page 15: ...GENERAL INFORMATION 1 10 NOTES...

Page 16: ...stem 2 11 2 12 Compression Test 2 12 Spark Plug Maintenance 2 13 Battery Maintenance 2 13 2 14 Electrical 2 14 2 15 Coolant System Maintenance 2 15 2 16 Radiator Screen Removal 2 17 Air Filter Service...

Page 17: ...al Whichever comes first Remarks Hours Calendar Miles Km E Engine Oil Level Change 10 hrs 100 160 Check level pre ride Break In service at 1 hour E Oil Filter 10 hrs 100 160 Replace with oil change E...

Page 18: ...ion 50 hrs 3 months 500 800 Lubricate All Fittings Pivots Cables Etc Drive Chain Pre ride Pre ride Pre ride Clean and Inspect Adjust Lubricate H Steering Pre ride Pre ride Pre ride Inspect Daily Lubri...

Page 19: ...nusual looseness in any area G Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners G Engine coolant check for proper level at the recovery bottle RECOMMENDED PRE RIDE...

Page 20: ...871326 Premium Carbon Clean 12 oz 2870652 Fuel Stabilizer 16 oz 2870585 Loctitet Primer N Aerosol 25 g 2870990 DOT3 Brake Fluid 2871956 Loctitet Thread Sealant 565 50 ml 2871949 Loctitet Threadlock 24...

Page 21: ...nstaller 3 PA 46077 MAG End Crankshaft Installer 3 2871283 Crankshaft Water Pump Seal Install Kit 3 5131135 Water Pump Install Kit 3 PA 46502 Valve Spring Compressor 3 2870975 Mity Vact Pressure Test...

Page 22: ...2 years or 200 hours 3 Drive Chain Polaris Chain Lube Apply to chain link plates and rollers As required More often under severe use such as operation in mud water sand or under severe loads Every 10...

Page 23: ...grease after washing ATV Every 3 months 8 Upper Steering Post Bushing Polaris All Season Grease Locate fittings and grease also grease after washing ATV Semi annually More often under severe use such...

Page 24: ...m full right to full left If idle speed increases at any point in the turning range inspect throttle cable routing and condition Adjust cable tension as needed until lock to lock turning can be accomp...

Page 25: ...w clockwise using the pilot screw wrench until engine begins to miss 6 Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM Continue turning counterclockwise until idle...

Page 26: ...thing immediately wash it off with soap and water and change clothing G Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness...

Page 27: ...ST NOTE This engine has built in decompression components Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 85 90 psi 400 RPM during...

Page 28: ...park plug type and gap Adjust gap if necessary by bending the side electrode carefully 11 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark...

Page 29: ...ablespoon baking soda Rinse well with clean water and dry thoroughly Test battery for condition and charge accordingly 5 Reinstall battery attaching positive red cable first and then the negative blac...

Page 30: ...ottle Asenginecoolanttemperaturedecreasesthe contracting cooled coolantisdrawnbackupfromthe tank past the pressure cap and into the radiator G Some coolant level drop on new machines is normal as the...

Page 31: ...with Polaris Premium 60 40 Anti Freeze Coolant PN 2871323 or a mixture of antifreeze and distilled water as required for freeze protection in your area 3 Reinstall cap NOTE If overheating is evident...

Page 32: ...t must be replaced Cleaning 5 Remove the pre filter F and the crankcase breather filter G Clean with hot soapy water Allow to dry thoroughly 6 Inspect pre filter for tears or damage 7 Inspect the inta...

Page 33: ...aling surfaces on drain plugs oil tank and crankcase should be clean and free of burrs nicks or scratches 7 Place a drain pan beneath the crankcase and remove the drain plug 8 Allow the oil to drain c...

Page 34: ...n this chapter Polaris recommends steering component repair and adjustment be performed by an authorized PolarisMSD certi fied technician when replacing worn or dam aged steering parts Use only genuin...

Page 35: ...is measurement B Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 0 to 1 16s 0 to 0625 cm toe...

Page 36: ...e illustration 2 G After alignment is complete torque jam nuts to 12 14 ft lbs 16 19 Nm EXHAUST PIPE WARNING G Do not perform clean out immediately after the engine has been run as the ex haust system...

Page 37: ...eck surface condition of the disc G Inspect thickness of brake pad friction material BRAKE PAD INSPECTION Pads should be changed when the friction material is worn to 3 64s 1 cm or about the thickness...

Page 38: ...ot exceed 11 875 inches 30 cm Exceeding this length may cause the spring to unseat from the shock body FRONT Setting Spring Length Softest 11 875 inches Factory 11 5 inches Firmest 11 125 inches A B C...

Page 39: ...ster Link Do not press plate in too far Ill 2 DRIVE CHAIN ADJUSTMENT CONCENTRIC SWINGARM CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage t...

Page 40: ...P BOLTS PRE MATURE BEARING FAILURE MAY RESULT SHOCK REBOUND AND COMPRESSION DAMPING ADJUSTMENT Rebound Damping 1 Locate the rebound damping clicker drum between the lower spring seat and the lower sho...

Page 41: ...s 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts WHEELS Inspect all wheels for runout or damage Check wheel nuts and ensure they are tight Do not over tighten...

Page 42: ...ing Tire Tread Depth Always replace tires when tread depth is worn to 1 8s 3 mm or less Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires wi...

Page 43: ...MAINTENANCE 2 28 NOTES...

Page 44: ...cation Oil Flow 3 10 ES50PLEngine Oil Flow Diagram 3 11 ES50PL Engine Exploded Views 3 12 ES50PL Engine Top End Service 3 13 3 23 Camshaft 3 14 3 15 Cylinder Head 3 15 3 20 ES50PL Engine Bottom End Se...

Page 45: ...ket and Sprocket Cover 6mm 6 6 8 1 9 11 Nm Flywheel Apply engine oil to threads 14mm 111 125 150 170 Nm Neutral Indicator Switch 5mm 2 2 3 7 3 5 Nm Oil Delivery Pipe 12mm 11 1 15 5 15 21 Nm Oil Drain...

Page 46: ...990 22 000 mm Camshaft Oil clearance Mag 0014 0029s 037 075 mm PTO 0001 0009s 005 024 mm Limit 004s 10 mm Cylinder Head Surface warpage limit 0020s 05 mm y Standard height 4 975s 126 4 mm Valve Seat C...

Page 47: ...Piston pin must be a push by hand fit at 68q F 20q C Piston Ring to ring groove clearance Top Std 0012 0028s 030 070 mm g g g p ring Limit 0059s 15 mm Second Std 0012 0028s 030 070 mm ring Limit 0059...

Page 48: ...ave an identification mark the direction for placement of the piston does not matter Note the directional and identification marks when viewing the pistons from the top Identifying marks such as F or...

Page 49: ...rcially available 2 The radiator cap relief pressure is 13 psi for all models Replace if cap releases at less than 13 psi Pressure test here with cap in place Coolant Flow Diagram Sensor From Thermost...

Page 50: ...own In most instances the carburetor will not have to be disconnected from the throttle cable choke cable and fuel line for engine removal Insert a shop towel into the carburetor flange to prevent dir...

Page 51: ...reservoir tank and add coolant if necessary NOTE Should the reservoir tank become empty it will be necessary to refill at the radiator and repeat the bleeding procedure Engine Break In Period The brea...

Page 52: ...n above it will be necessary to spread the crankshaft at position A as shown in the illustration at right When rebuilding and straightening a crankshaft runout must be as close to zero as possible A H...

Page 53: ...side oil passage lubricating the crank bearings crankpin piston cylinder and connecting rod bearings A delivery pipe supplies oil to the top of the cylinder head and the transmission main shaft Oil is...

Page 54: ...ide Cylinder Piston ConnectingRod Small End Crankcase Oil Strainer Oil Pump Scavenging Crankcase Oil Gallery Crankcase Mag Side Oil Gallery Oil Hose Cam Support Oil Gallery Cam Lobe Valve Lifter Cam S...

Page 55: ...ENGINE 3 12 ES50PL ENGINE EXPLODED VIEWS Crankcase Transmission Cylinder Cylinder Head Crankshaft and Piston Valve Train A...

Page 56: ...tly on tensioner body with a soft face hammer and remove tensioner CAUTION The assembly is under spring tension Maintain inward pressure while removing 7 For installation retract the plunger using the...

Page 57: ...e the valve cover 2 Remove the tensioner assembly 3 Remove the 8 bolts securing the cam tower assembly and remove the cover 4 To free the cam assembly lift one cam assembly and slightly rotate it whil...

Page 58: ...hness Camshaft Journal O D Mag End 9821 9828I 24 946 24 963 mm 5 Measure ID of camshaft journal bore Camshaft Journal I D Mag End 9842 9851I 25 00 25 021 mm NOTE Replace camshaft as an assembly if dam...

Page 59: ...cylinder head surface If warpage exceeds the service limit replace the cylinder head Cylinder Head Warpage Limit 002s 05 mm CYLINDER HEAD DISASSEMBLY WARNING Wear eye protection during cylinder head d...

Page 60: ...reassembly in the same guide 7 Measure free length of the inner and outer springs with a Vernier caliper Check springs for squareness Compare to specifications Replace inner and outer springs as a se...

Page 61: ...em in several places Valve Stem Diameter Intake 2343 2348I 5 950 5 965 mm Exhaust 2341 2346I 5 945 5 960 mm CYLINDER HEAD ASSEMBLY CAUTION Wear eye protection during assembly NOTE Assemble the valves...

Page 62: ...installed tap lightly with soft faced hammer on the end of the valves to seat the keepers 9 Install the shims and buckets for each valve in the order they were removed 10 Check valve clearance with e...

Page 63: ...replace existing pad 4 Measure and confirm that valve clearance is within the standard values 5 If valve clearance is not within standard reverify step 1 and repeat procedures again Example Intake Va...

Page 64: ...t Block PN 2870390 5 Remove dowel pins from crankcase PISTON REMOVAL 1 Remove circlip Note piston directional aid that is pointing toward the right stator side of engine Directional aid 2 Remove pisto...

Page 65: ...a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2s down from top in the middle and 1 2s up from bottom 5 Record...

Page 66: ...Piston Pin O D 9053 9065I 22 994 23 mm 3 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove c...

Page 67: ...re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with oil immediately to...

Page 68: ...e flywheel CAUTION Thread the puller onto the flywheel fully or flywheel threads may be damaged 3 Removing the flywheel exposes the starter drive main gear and one way clutch which is mounted on the f...

Page 69: ...ng the clutch cover NOTE Oil filter cover has been previously removed 2 Remove the gasket Clean the gasket surfaces prior to reassembly 3 Inspect or replace the crankshaft oil seal anytime the clutch...

Page 70: ...the clutch basket retaining nut to 66 81 Ft Lbs 90 110 Nm Stake the nut at the flat on the transmission shaft Install the clutch plates in order of removal Reinsert the plunger into the shaft Reinsta...

Page 71: ...ndard Body Feed Scavenge 006 008I 15 21mm Rotor Tip Feed Scavenge Less than 006I Less than 15 mm Rotor Side Feed 0007 003I 02 08mm Scavenge 002 006I 05 16mm 6 Installation Reverse the procedures Use a...

Page 72: ...attern 2 Separate crankcase by tapping with a soft faced hammer in reinforced areas 3 Watch the gap along the crankcase mating surface making sure to separate the crankcase evenly It may also be neces...

Page 73: ...e halves Replace if any roughness or wear is felt See page 3 33 for crankcase bearing inspection removal 4 To reassemble reverse the procedures using the following photos for reference Transmission Re...

Page 74: ...Heating of screws is required for removal Use caution and wear the proper safety equipment while performing this procedure A PTO side shown for clarity 3 Support the stator side crankcase in a stand t...

Page 75: ...nkshaft rebuilding manual and parts manual for rebuild information 1 Inspect the crankshaft connecting rod bearing journal for scoring and abnormal wear 2 Use a feeler gauge to measure the connecting...

Page 76: ...to expand the bearing cavity Place the bearings in a freezer This shrinks the bearing outer diameter slightly Wear the appropriate safety equipment during the heating and installation process 1 Instal...

Page 77: ...ined remove the water pump cover impeller and the sealing washer Ill 1 Ill 1 Impeller Sealing Washer Mechanical Seal 2 Slide the main puller body over the outer portion of the mechanical seal as shown...

Page 78: ...h the stator side casehalve settled in a suitable fixture that allows the casehalve to lay flat This allows easier installation without parts falling out of position Make sure the oil galley tube is o...

Page 79: ...nt loss of radial tension Severe engine damage may result if circlips are re used or deformed during installation 4 Apply clean engine oil to the piston rings ring lands piston pin bore piston pin and...

Page 80: ...nder Remove all traces of old gasket material Refer to disassembly photos 1 Install the cam chain tensioner guides Be sure bottom end of guide is located properly in crankcase 2 Install the two dowels...

Page 81: ...y aligning the bottom cam timing mark with the brass colored bottom chain link Keep tension on the chain so as to not lose chain alignment at the crankshaft sprocket during cam installation Align spro...

Page 82: ...top rotation and reverify cam timing NOTE Rotating the engine during verification will cause the timing alignment marks to rotate out of phase and will take as many as 20 revolutions to come back into...

Page 83: ...ENGINE 3 40 INTAKE TIMING MARK EXHAUST TIMING MARK TIMING PLATE COLD HEAD COVER FITTING SURFACE AT CYLINDER HEAD...

Page 84: ...r correct cross hatch NOTE Do not allow cylinder to heat up during honing G After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be...

Page 85: ...il to guides VALVE SEAT RECONDITIONING Follow the manufacturers instructions provided with the Valve Seat Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Ke...

Page 86: ...om cutters to narrow the seat G If the seat is too narrow widen using the 45q cutter and re check contact point on the valve face and seat width after each cut Valve Seat Width Intake Std 028I 7 mm Li...

Page 87: ...eck compression G PVT not operating properly G Restricted exhaust muffler G Carburetor vacuum slide sticking diaphragm damaged G Dirty carburetor Piston Failure Scoring G Lack of lubrication G Dirt en...

Page 88: ...tem G Improperly assembled air intake system G Restricted engine breather system G Oil contaminated with fuel G Restricted oil tank vent COOLING SYSTEM TROUBLESHOOTING Overheating G Low coolant level...

Page 89: ...ENGINE 3 46 NOTES...

Page 90: ...ting 4 4 Main Jet Pilot Jet Part Numbers 4 4 CV Carburetor System Function 4 Cycle 4 5 CV Carburetor Vent System 4 Cycle 4 5 CV Carburetor Operation 4 5 4 7 Disassembly Notes CV Carburetor 4 7 4 8 Cle...

Page 91: ...Guide Cable 32 Jet Main 150 33 Ring 49 E Ring 34 Holder Jet 50 Cap 35 Jet Needle 51 Asm Plunger 36 O Ring 52 Spring 37 Valve Needle 53 Holder Guide 38 Screw 54 Screw 39 Screw 55 Cover 40 Plug 56 Spri...

Page 92: ...TANK ASSEMBLY Impulse Line Fuel Valve Fuel Tank Fuel Line Fuel Pump Tank Cap Vent Line Fuel Tank Fuel Valve Engine Fuel Pump Carburetor Fuel Tank Vent Carburetor Vent Fuel Screens L L Located on upper...

Page 93: ...higher elevations and higher temperatures the air is less dense with reduced oxygen Polaris ATV Carburetors are calibrated for an altitude of 0 6000 ft 0 1800 meters and ambient temperatures between...

Page 94: ...id range and high throttle settings 1 4 to full throttle VENT SYSTEMS CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl The lines must be free of kinks r...

Page 95: ...Mikuni BST carburetor PILOT IDLE AND SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot je...

Page 96: ...SYSTEM As throttle valve 1 is opened engine speed rises and this increases negative pressure in the venturi Consequently the vacuum slide 2 moves upward The fuel in float chamber 3 is metered by main...

Page 97: ...tely Carburetor cleaners can be extremely caustic Extended periods of soaking can loosen the adhesive sealer on the passage drill way plugs Do not soak rubber or plastic components such as the vacuum...

Page 98: ...ndition Worn Deposits Wear areas Seat Needle CARBURETOR ASSEMBLY Inspect the diaphragm A for holes deterioration or damage Make sure the diaphragm is pliable but not swollen The diaphragm should fit p...

Page 99: ...face the carburetor has been tilted back too far and the float tongue is likely compressing the needle valve pin Float Parallel with Float Bowl Mating Surface 13 14 mm Ill 2 Float Too Far Inward Ill 3...

Page 100: ...redator 500 is equipped with a pressure regulated fuel pump 1 3 PSI The pump is located in the front fender cavity of the machine To test the fuel pump 1 Turn fuel off 2 Disconnect impulse line from p...

Page 101: ...ckfire G Air intake restricted inspect intake duct G Air filter dirty plugged G Choke plunger sticking incorrectly adjusted choke G Choke cable binding or improperly routed G Incorrect pilot air fuel...

Page 102: ...nstallation 5 6 5 7 Steering Knuckle Removal Installation 5 8 Ball Joint Removal Installation 5 9 Front Hub Exploded View 5 10 A Arm Replacement 5 11 Concentric Swing Arm Removal 5 12 Rear Axle Remova...

Page 103: ...nch 2870623 Shock Absorber Spring Compression Tool 2871572 Strut Rod Wrench 2871573 LH Strut Spring Compressor 2871574 RH Strut Spring Compressor 7052069 Charging Needle 2200421 Gas Shock Recharging K...

Page 104: ...DED VIEW B F A C G H E J I A Seat B Seat Release Latch C Rear Cab D Side Panel E Front Cover F Front Cab G Heel Pocket H Heel Support I Grab Bar J Fuel Tank Support K Rear Frame L Foot Peg M Rock Guar...

Page 105: ...NDLEBAR B BLOCK CLAMPS C STEERING BUSHINGS D STEERING POST E CENTERLINK F IDLER ASSEMBLY G STEERING MOUNT BLOCK H TIE ROD ASSEMBLY I UPPER A ARM J LOWER A ARM K STEERING KNUCKLE L BALL JOINT I J K L F...

Page 106: ...he two brake caliper bolts and the brake caliper Use mechanic s wire or other suitable material to support the caliper assembly Do not allow caliper assembly to hang by the brake line Brake Caliper 5...

Page 107: ...Inspect spacer for wear or damage Measure the tapered spacer for wear replace as needed 774 r 005 797 r 005 Tapered Spacer FRONT HUB ASSEMBLY 1 Drive or press one new bearing into hub using a bearing...

Page 108: ...lbs 41 Nm Front Spindle Nut 40 ft lbs 54 Nm Front Wheel Torque 5 Install a new cotter pin Tighten nut slightly if necessary to align cotter pin holes 6 Rotate wheel and check for smooth operation Ben...

Page 109: ...BALL JOINT REMOVAL INSTALLATION Ball Joint Removal 1 The A arm must be removed to perform this procedure Refer to A arm Replacement on Page 10 2 Be sure to remove the retaining ring from the top of th...

Page 110: ...nt installation Face the A arm end flat on top of the driver Carefully drive the ball joint into place until the ball joint is properly installed Press Driver Ball Joint Press Driver Ball Joint 6 Afte...

Page 111: ...Cotter 4 2 Washer 5 2 Spacer Outer 6 2 Seal 7 2 Bearing Ball Sealed 8 2 Hub Wheel Front Indy Red 9 8 Stud 10 2 Spacer Tapered 11 2 Bearing Ball 12 2 Seal 13 2 Disc Brake 14 2 Spacer Inner 15 8 Bolt 16...

Page 112: ...osen two bolts on the A arm tube D upper and lower A arms by alternating each about 1 3 of the way until A arm can be removed WARNING The patch lock on the existing bolts were destroyed during removal...

Page 113: ...by the brake line Brake line damage may result 4 Remove rear wheels and or hubs 5 Remove lower shock bolt 6 Remove the foot brake assembly 7 Remove the nylok nut H and washers G fromthe mount bolt B 8...

Page 114: ...2 Remove the brake caliper bolts and remove the brake caliper 3 Remove the master link from the drive chain Remove the drive chain 4 Loosen the hex screw A to loosen the axle nut Turn the axle nut D c...

Page 115: ...remove the axle nut D with a 1 3 4 Wrench PN 2870772 D 8 Remove the retaining ring E and caliper mounting bracket F E F 9 Remove the O ring G from the axle assembly G 10 Remove the four bolts that se...

Page 116: ...sing 3 Install the sprocket C onto the sprocket hub A Torque the four sprockets nuts to 29 35 ft lbs 39 47 Nm 4 Apply grease to the O ring D and install the O ring on the sprocket side of the axle Ins...

Page 117: ...ex pinch bolt to 50 in lbs 6 Nm 10 Reinstall the chain and masterlink To verify proper chain tension refer to Chapter 2 page 2 25 for this procedure Torque the two eccentric clamp bolts to 30 ft lbs 4...

Page 118: ...Lubrication 7 1 Axle Rear 8 4 Nut Nylok 9 1 Sprocket 10 1 Hub Sprocket 11 4 Bolt 12 1 Ring Retaining 13 1 Chain 94P 14 1 Link Connector 15 1 Bushing Caliper 16 1 Bracket Caliper Mount 17 1 Ring Exter...

Page 119: ...r fender cabs are plastic polyethylene material Therefore they must be flame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to re...

Page 120: ...321 3 00 350 3 25 380 3 50 409 3 75 438 4 00 467 4 25 496 4 50 526 4 75 555 5 00 584 Spacer PN 5431355 TYPICAL VALVE STACK ARRANGEMENT Top Out Plate 900 x 008 Back Up Plate 1 10 x 008 7 C BODY STEERI...

Page 121: ...re added to reduce shock travel by 1 5 inches multiply 029 x 6 to calculate the amount to subtract from IFP depth Example 835 174 661 r 025s New IFP Depth Fox Shock Maintenance Changing oil on Foxt Sh...

Page 122: ...water to remove dirt and other debris Dry thoroughly with compressed air Position and clamp body cap of shock in soft jaws aluminumor brass of vise Remove Allen screw from pressure valve 2 With valve...

Page 123: ...Clamp Tool PN 2871071 Shock Body Clamp Tool PN 2871071 NOTE Position body clamp at least 1 1 2s below bearing cap 6 Pull shock rod and piston straight out to avoid seal or valve damage Be prepared to...

Page 124: ...vity 3 Clean seal cavity and inspect bushing for wear or damage and replace bearing cap if necessary 4 Lubricate new seals and O ring with Polaris shock oil and install Be sure the seals are seated co...

Page 125: ...using IFP tool Be prepared to catch piston ring and piston as it comes out Remove Allen screw from center of piston Inspect bleeder screw O ring and IFP sealing O ring for wear or damage Replace O ri...

Page 126: ...IFP 7 Install body cap until O ring is lightly seated 8 Mount shock in vise by top eyelet as shown Support shock and strike body cap end 2 3 times with a soft faced hammer to remove all air trapped in...

Page 127: ...IFP from turning Pour out excess oil It is not necessary to completely clean all oil from the nitrogen chamber a small amount of oil will lubricate the IFP Verify the proper IFP depth to within r 025s...

Page 128: ...amping 20 To check for leaks submerge the shock in water and look for bubbles or oil seepage around the bearing and body caps 21 When reinstalling shocks on the machine torque only to required specifi...

Page 129: ...ng 18 1 Screw O ring 4 1 Body 19 1 Screw 5 1 Back Up Plate 20 4 Air Valve 6 1 Piston 21 1 Bushing 7 1 Guide Spring 22 1 Bottom Out Bumper 8 1 Bearing 23 1 O Ring 9 1 Shaft 24 1 U Cup 10 1 Eyelet Assy...

Page 130: ...s G Every ride Wash and dry the vehicle and suspension G Every 100 hours Visually inspect shock seals G Every 500 hours or Annually Change shock oil and seals 1 Safety Glasses 2 Latex Gloves 3 Lint Fr...

Page 131: ...ing the wire retaining ring Slide the lower spring retainer off 5 Remove the spring and stainless steel spring support washer 6 Back the rebound adjustment knob out until the clicking stops Set the co...

Page 132: ...8 Align the slot of the Foxt IFP Depth Tool PN 2871351 with the end of the IFP Internal Floating Piston Insert the IFP tool into the reservoir and rotate 90 degrees to engage Push the IFP Tool until t...

Page 133: ...s hole in the side of the CD housing to unseat the wire retaining ring that secures the damp plate assembly Use a pointed tool such as a scribe or dental pick to remove the retaining ring Use extreme...

Page 134: ...the o ring When the adjuster drum is seated properly the adjuster drum should be flush with the inside surface of the CD housing Fig 13 Check to make sure the drum rotates freely in the bore and orie...

Page 135: ...ing outer o ring Use extreme caution to avoid scratching the o ring groove Lubricate the new o ring with assembly lube and install it onto the housing 39 Check the bore of reservoir for any visible si...

Page 136: ...e caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft Fig 20 46 Slide the bearing cap and bottom out bumper off of the shaft 47 Using proper shaft cl...

Page 137: ...pick to remove the brass support washer and metering rod o ring from end of shaft Fig 24 Use extreme caution not to scratch o ring gland Clean all thread locking compound from the end of the shaft 53...

Page 138: ...e 59 Install new dust seal into bearing cap Seal should be installed with lip protruding from the flat side of the bearing cap Check to make sure seal is properly seated If a tool is required to aid i...

Page 139: ...f assembly lube Slide the bearing assembly onto shaft with the threaded side facing the bearing cap Fig 31 This should be done in a single smooth motion to avoid damaging the seals If a seal hangs up...

Page 140: ...y If oil level has fallen add more oil until level is at retaining ring groove Insert IFP into reservoir Use a smooth motion and push straight in until o ring seats into the retaining ring groove allo...

Page 141: ...shaft assembly as straight as possible and hit the shaft eyelet a couple of times squarely from above with a rubber mallet Fig 40 This is done to momentarily open the shim stack and allow any trapped...

Page 142: ...n Safety Needle inthe vise Be sure to point the air valve away from your face and body 81 Insert the safety needle squarely into center of the air valve and pressurize the reservoir to 300psi Fig 45 C...

Page 143: ...apter and seat the spring retainer against it 88 Thread the spring preload ring down against the spring and set the preload to the measurement you took when you removed the spring Fig 1 Thread the pre...

Page 144: ...EAR SHOCK EXPLODED VIEW 35 69 27 23 45 57 55 68 52 51 65 56 71 70 43 18 31 30 32 29 22 21 15 16 14 12 11 17 20 33 19 37 40 7 5 6 39 41 8 9 50 49 10 61 28 24 26 25 53 54 46 47 4 1 3 48 44 2 13 38 42 36...

Page 145: ...up 30 1 O Ring 31 1 Bearing 32 1 Bearing Internal 33 1 Piston Damping 34 2 Plate Back Up 35 1 Nut Lock 36 1 Jet 37 1 Reservoir 38 1 O Ring 39 1 O Ring 40 1 Housing Damping 41 1 O Ring 42 1 Hose 43 2 F...

Page 146: ...tallation 6 8 Front Pad Removal Install 6 8 6 9 Front Pad Assembly 6 10 Front Disc Inspection 6 10 6 11 Front Disc Removal Replacement 6 11 Front Caliper Removal Install 6 12 Rear Pad Removal 6 13 6 1...

Page 147: ...mm Master Cylinder I D 750s Master Cylinder I D Aux Rear 500s TORQUE SPECIFICATIONS Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bolts 18 0 25 Rear Caliper Mounting Bolts 15...

Page 148: ...of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise check the backing of each pad for worn spots allowing metal to metal contact See table below Brake...

Page 149: ...r to enter the system and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened...

Page 150: ...ove old fluid from reservoir with a Mity Vact PN 2870975 or similar tool NOTE Do not remove brake lever when reservoir fluid level is low MAX 5 Add brake fluid to the upper level mark on reservoir Pol...

Page 151: ...epeat procedure Steps 5 9 for the remaining caliper s 12 Add brake fluid to the proper level Master Cylinder Fluid Level MAX level inside reservoir Sight glass must look dark if sight glass is clear f...

Page 152: ...ng washers A B CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 Loosen the master cylinder clamp bolts B on the handlebar side of...

Page 153: ...he brake line into the master cylinder Torque the brake switch bolt to 15 ft lbs 21 Nm Brake Line Sealing Washers Torque to 15 ft lbs 21 Nm Master Cylinder Mounting Clamp Bolt Torque 25 in lbs 3 Nm Br...

Page 154: ...ed back into caliper Remove excess fluid from reservoir as required 5 Remove the c clips C from the end of the caliper slide bolts C 6 Remove the loose caliper slide bolts The brake pad D will slide o...

Page 155: ...lbs 45 Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2s 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 5 Be sure fluid l...

Page 156: ...ly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 010s 50 mm FRONT BRAKE DISC REMOVAL REPLACEMENT 18 ft l...

Page 157: ...g bolts to 18 ft lbs 25 Nm 18 ft lbs 25 Nm 2 Install brake line and tighten securely with a line wrench 33 ft lbs 45 Nm 15 ft lbs 21 Nm 3 Torque the caliper slide bolts to 33 ft lbs 45 Nm Torque the b...

Page 158: ...rt caliper so as not to kink or bend brake line 3 With pads installed push caliper piston into caliper bore A slowly using a C clamp B or locking pliers NOTE Brake fluid will be forced through compens...

Page 159: ...bs 25 Nm Brake Caliper Mounting Bolts Torque 18 ft lbs 25 Nm 3 Torque the caliper slide bolts to 33 ft lbs 45 Nm Install the c clips onto the ends of the caliper slide bolts 33 ft lbs 25 m 4 Slowly pu...

Page 160: ...g a flare nut wrench remove the brake lines A Place a container to catch brake fluid draining from brake lines A 3 Remove the caliper mounting bolts and remove the caliper assembly B from the caliper...

Page 161: ...ull the caliper bodies apart if necessary G 6 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body FRONT REAR CALIPER IN...

Page 162: ...the dust boot over the caliper and seat the dust boot into caliper groove Be sure groove is clean and free of residue or brakes may drag A B 3 Coat piston and inside of caliper body with clean DOT 3...

Page 163: ...gnment G Worn disc G Worn disc splines G Glazed brake pads Poor Brake Performance G Air in system G Water in system brake fluid contaminated G Caliper disc misaligned G Caliper dirty or damaged G Brak...

Page 164: ...Ring G Dust Boot H Caliper Body I O Ring J Sleeve K Slide Bolt L Caliper Bolt M Bleeder Screws N Circlips A C D E 33 ft lbs 45 Nm 18 ft lbs 25 Nm 27 in lbs 3 Nm APPLY POLARIS DOT 3 BRAKE FLUID TO COMP...

Page 165: ...ER MASTER CYLINDER 18 ft lbs 24 8 Nm A B A Master Cylinder B Brake Line C Pressure Switch D Junction Box E Wheel Hub F Line Retainer G Banjo Bolt Washers H Caliper I Caliper Mount Bolt C D E F G H 15...

Page 166: ...ear Caliper D Brake Disc E Brake Line F Line Retainer G Banjo Bolt Washers H Master Cylinder C D E F G G H I J K L M N I Foot Brake J Switch K Mount Bracket L Brake Pedal Return Spring M Foot Brake To...

Page 167: ...BRAKES 6 22 NOTES...

Page 168: ...Tests 7 5 7 6 Flywheel Identification 7 7 Ignition System 7 7 ES50PL 200 Watt Alternator Exploded 7 8 Ignition System Testing 7 9 Charging System Testing 7 10 Battery Activation Service 7 11 7 12 Head...

Page 169: ...ned with a Fluket 77 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ G Pay attention to the prefix on the multimet...

Page 170: ...power to the fan motor through to the Orange Black wire The ground path for the fan motor is through the Brown harness wire CAUTION Keep hands away from fan blades during this procedure Serious person...

Page 171: ...C switch is mounted independently of the throttle actuator lever inside the throttle block assembly This is a normally closed switch and is held in the open position contacts are separated as shown be...

Page 172: ...are indicated in DC Volts Readings obtained without a peak reading adaptor will be significantly different Test output from the CDI and pulse trigger coil and compare to the table The following measu...

Page 173: ...al and start the engine With the engine running at idle disconnect the negative cable from the battery post without disturbing the meter leads Observe meter readings 5 Increase engine RPM while observ...

Page 174: ...and maintenance Operation Overview The DC CDI system relies on battery power for ignition function Instead of generating DC voltage via magnetic induction a 12 volt DC current is supplied directly to...

Page 175: ...030s 4 75mm Meter Ignition Coil 3 Ignition Kill Wire Black Coil Lead Refer To Wiring Diagrams For Specified Stator Coil Resistance Starter Solenoid Meter 190 Note DC CDI components are not compatible...

Page 176: ...n Page 7 8 or the wiring schemat ic for meter connections and specifications Compare results to the specifications Is it within specification Inspect connectors wiring and grounds to the component in...

Page 177: ...or connector Is it Check regulator rectifier connections and ground battery connections cir cuit breaker and connecting wires Repair or replace faulty wiring or components If all of the previous tests...

Page 178: ...by the plates Therefore a Maintenance Free battery case is opaque and the sealing caps are not removable since there is no need to check electrolyte level NEVER attempt to add electrolyte or water to...

Page 179: ...n the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds...

Page 180: ...r of the low beam lamp 5 Loosen the pivot screw 1 and adjust the beam to the desired position 6 Tighten the screw and torque to 27 in lbs 3 Nm HEADLIGHT HOUSING REPLACEMENT CAUTION Do not service whil...

Page 181: ...mp and replace it with recommended lamp Apply Dielectric Grease PN 2871329 to the new bulb contacts 3 Reinstall the lens cover removed in step 1 4 Test the taillight brakelight to see it is working HE...

Page 182: ...ive trim buttons Turn pod over 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 while pushing the assembly out o...

Page 183: ...ARTER VOLTAGE DROP TESTING A Voltage Drop Test tests for bad connections When performing the procedure you are testing the amount of voltage drop through the connection A poor or corroded connection w...

Page 184: ...Length 5 16s 8 cm Brush Length Service Limit 5 16s 8 cm 4 Remove brush plate and brushes Measure length of brushes and replace if worn past the service limit Replace springs if they are discolored or...

Page 185: ...replaced STARTER REASSEMBLY 1 Place armature in field magnet casing 2 Place shims on drive end of armature shaft with phenolic washer outermost on shaft Engage tabs of stationary washer in drive end...

Page 186: ...rings for excessive wear or damage 3 Proper function can be determined by rotating the drive gear counterclockwise which will engage the one way clutch rollers and turn the flywheel During engine rota...

Page 187: ...eplace the defective component s or wiring Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire De press st...

Page 188: ...ELECTRICAL 7 21 WIRING DIAGRAM 2003 PREDATOR No Neutral Light Neutral Start Lost if failed...

Page 189: ...8 Brake Pad Removal Rear 6 13 Brake System Inspection 2 22 Brake System Operation 6 4 Brake System Service Notes 6 3 Brake System Front 6 20 Brake System Rear 6 21 Brakelight Lamp Replacement 7 14 Bre...

Page 190: ...Special tools 7 2 Engine Accessible Components 3 7 Engine Adjusting Pad Matrix 3 20 Engine Assembly 3 30 3 34 3 37 3 39 Engine Bottom End Disassembly 3 22 3 23 3 24 3 25 3 30 3 32 3 33 3 34 Engine Br...

Page 191: ...3 5 Piston Installation 3 37 Piston Removal 3 22 Piston Ring Installation 3 36 Piston Ring Installed Gap 3 25 Piston to Cylinder Clearance 3 23 Piston Rod Inspection 3 24 Pre Ride Inspection 2 4 R Rad...

Page 192: ...terns Engine 3 5 Transmission Removal 3 31 Troubleshooting Brakes 6 18 Troubleshooting Cooling System 3 46 Troubleshooting Engine 3 45 Troubleshooting Fuel System Carb 4 12 Troubleshooting Ignition Sy...

Page 193: ...PN 9918062 PN 9918062 Printed in the USA Printed in the USA...

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Polaris PREDATOR 2003, Service Manual

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