Polaris Predator 500 Owner'S Manual For Maintenance And Safety Download Page 149

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146

ADJUSTMENTS

Chain Tension

1. Loosen the two eccentric locking 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 Nm).

Step 1

Proper Splicelink Clip Opening Position

Step 2

Summary of Contents for Predator 500

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Page 3: ...wn to cause cancer birth de fects 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 or if it has been removed please call 1 800 342 3764 for assistance ...

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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 liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2005...

Page 6: ...come to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational Vehicles S Snowmobiles S All terrain vehicles ATVs S Personal watercraft S RANGER utility vehicles S Victory motorcycles ...

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 Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the...

Page 8: ...ICATION 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 173 SPECIFICATIONS 174 WARRANTY 176 INDEX 183 ...

Page 9: ...tion 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 keys are lost the ignition switch must be replaced 2 1 31XX 3 ...

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: ...arefully 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 contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal A B C ...

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 performance vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience 7172560 E1997 2000 IF OWNER S MANUAL IS MISSING CON...

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

Page 14: ...S VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS 7170983 CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting 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 MACHIN...

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 standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 1 2 3 4 5 ...

Page 16: ...be 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 the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the bes...

Page 17: ...during 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 ATV Operator Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age This category S Sport ATV is a high performance vehicle intended for off road us...

Page 18: ...plain 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 operating the ATV If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off roa...

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 for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death ...

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 alert you to important information or instructions ...

Page 21: ...ke 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 nearest you S Never allow anyone under 16 years of age to operate this ATV S Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certi...

Page 22: ...e 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 before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual S Always keep both hands on the handleba...

Page 23: ...efore 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 Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed S Always follow proper procedures for going downhill and for braking o...

Page 24: ...steady 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 pointed straight uphill Turn the ATV around and remount following the procedure described in this manual S Always check for obstacles before operating in a new area Never attempt to operate over large...

Page 25: ...y 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 avoid turning at sharp angles S Always use the size and type of tires specified for your ATV and always maintain proper tire pressure S Never modify an ATV through improper installation or use of ac...

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 equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories may change the handling characteris...

Page 27: ...different 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 regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call ...

Page 28: ...e 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 with advanced skills and substantial experience should operate this ATV ...

Page 29: ...tion 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 be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV Only operators with advanced skills and substantial experience should operate thi...

Page 30: ...y 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 the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers ...

Page 31: ...and 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 HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops ...

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 In many states it s illegal to operate ATVs on public streets roads and highways ...

Page 33: ...met 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 event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pan...

Page 34: ...operating 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 the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE ...

Page 35: ...TIAL 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 or other stunts Avoid exhibition driving ...

Page 36: ...ntain 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 operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual ...

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 the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation ...

Page 38: ...g 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 extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions ...

Page 39: ...xcessively 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 slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain ...

Page 40: ...ribed 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 CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 25_ Practice on sm...

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 weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle o...

Page 42: ...ures 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 descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the...

Page 43: ...pt 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 crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weigh...

Page 44: ...gradually 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 rolling backwards Apply the front brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill...

Page 45: ...les 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 WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and...

Page 46: ...V 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 maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving wate...

Page 47: ...s 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 Overloading the ATV or carrying towing cargo WHAT CAN HAPPEN Overloading or carrying towing cargo can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE H...

Page 48: ...dling 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 Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more informati...

Page 49: ...gh 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 person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly ...

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 operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exposure to the hot components could result in a fire Always keep combusti...

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 RUN position NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine quickly slide the stop switch either ...

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: ...is 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 ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain...

Page 55: ...arise 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 before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 toward the handlebar The throttle le...

Page 56: ...ver 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 safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Clutch Lever The clutch lever 1 is located on the left hand handlebar Squeeze the clutch lever towar...

Page 57: ...ck 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 the foot brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the foot brake Do not aggressively apply the foot brake when goin...

Page 58: ...rakes 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 fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could caus...

Page 59: ...d 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 brakes to apply automatically which could result in serious injury or death Always maintain the fluid level between the MIN and MAX marks After opening a bottle of brake fluid always discard any unus...

Page 60: ...g 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 Push the park brake lock 2 forward to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position 1 2 ...

Page 61: ...revent 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 if the ATV is parked on a hill Always block the wheels to prevent rolling S Place the transmission in first gear or neutral before locking the park brake ...

Page 62: ...storage 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 soon as possible after using the main supply Always return the valve to the ON position after refueling 1 RES OFF ON FUEL OFF OFF RES RES FUEL FUEL ON ON ...

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 the engine starting procedure on page 70 for correct choke and throttle settings during starting The choke is fully on when the choke knob 1 is pulled completely out The choke is off when the knob i...

Page 64: ...released 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 one full stroke See page 62 NOTE To shift into reverse see page 63 WARNING Shifting without releasing the throttle and disengaging the clutch could cause loss of control or vehicle overturn Always r...

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 lever 7 As engine speed RPM increases in first gear simultaneously release the throttle disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke Repeat this proc...

Page 66: ...nts 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 NOTE The lock will automatically re engage when the transmission is shifted out of reverse gear 1 ...

Page 67: ...o 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 to lose traction or stop rotating which could lead to loss of control accident and injury It could also cause engine or drive train damage Make sure the engine RPM has sufficiently decreased before s...

Page 68: ...a 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 and change clothing S Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time S Turn the fuel valve ...

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 during the first three hours of operation may damage close fitted engine and transmission parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use ...

Page 70: ...ore 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 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 68 7 During the break in period change both the oil and the filter after one hour...

Page 71: ...ide 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 operation and correct adjustment 154 Suspension front and rear Inspect lubricate if necessary 97 Steering Ensure free operation Tires Inspect condition and pressure 136 137 Wheels fasteners Inspect ensure...

Page 72: ...e 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 dielectric grease to the socket when the lamp is replaced 116 Brake light tail lamp Check operation Riding gear Wear helmet goggles protective clothing 12 A arm ball joints Check freeplay If the tire mov...

Page 73: ...rbon 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 damage Allow the engine to warm up for several minutes before operating 1 Place the transmission in neutral lock the parking brake and disengage the clutch Make sure the fuel valve is on ...

Page 74: ...se 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 needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 3 Move the engine stop switch to RUN 4 Turn the ignitio...

Page 75: ...r 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 damage 6 If the engine does not start wait five seconds after releasing the start button then activate the starter for another five seconds Repeat until the engine starts 7 If the engine slows or stops...

Page 76: ...be 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 immediately after the engine starts If the engine does not start review the engine troubleshooting information beginning on page 166 If all conditions are favorable and the engine still does not start se...

Page 77: ...it 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 thumb while slowly releasing the clutch lever to begin driving 6 Drive slowly Practice maneuvering and using the throttle clutch and brakes on level surfaces ...

Page 78: ...g 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 The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp angles or at excessive ...

Page 79: ...oiding 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 operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery...

Page 80: ...t 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 operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Use extreme caution when operating on hills and follow all procedures outlin...

Page 81: ...e 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 the hill while keeping your feet on the footpegs 3 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheels downhill if possible or di...

Page 82: ...ownhill 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 Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill ...

Page 83: ...ner 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 weight uphill 2 Pull in the clutch lever and apply the front and rear brakes 3 When completely stopped shut off the engine Leaving the transmission in gear release the clutch lever and lock the par...

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 the clutch lever shift into neutral and restart the engine 9 Release the park brake and slowly release the clutch lever allowing the ATV to proceed slowly Stay in first gear using the brakes for addit...

Page 85: ...arking 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 downhill side See illustration 5 Shut off the fuel supply ...

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 obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 87: ...hs 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 pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 90 The engine oil and all grease f...

Page 88: ...e 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 avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to ta...

Page 89: ...Driving 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 throttle suddenly while backing ...

Page 90: ...ehicle movement Use extra caution Drive slowly Avoid backing on inclines Avoid turning at sharp angles NOTE This Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at full throttle Use just enough throttle to maintain a desired speed CAUTION Excessive throttle operation while in the spee...

Page 91: ...nce 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 Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphe...

Page 92: ...t fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label 1 is located on the recoil cover 1 ...

Page 93: ...ndition 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 and handle S Open end wrench 1 2 in and 10 mm S TorxR T25 screwdriver S L wrench T 27 S Tire pressure gauge S Flat blade screwdriver S Spanner wrench ...

Page 94: ...ion 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 Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If ...

Page 95: ...ath Have an authorized Polaris dealer perform these services Maintenance Chart Key Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service California J Have an authorized Polaris dealer perform these services F Use Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special ...

Page 96: ... Pre Ride Inspect Wheels lug nuts Pre Ride Inspect tighten Frame fasteners Pre Ride Inspect tighten E Air filter and Pre cleaner Pre Ride Inspect clean Coolant Pre Ride Inspect level add as needed Fuel Pre Ride Fill to proper levels Engine transmission oil Pre Ride Fill to proper level with Polaris PS 4 oil Throttle Pre Ride Check operation Clutch Pre Ride Check operation and adjustment Lights Pre...

Page 97: ...re 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 Check freeplay daily have dealer replace if wheel moves excessively Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California J Have an authorized ...

Page 98: ...60 Inspect periodically E Oil Change 10 H 6 M 100 160 Perform break in service after first hour of operation E Oil Filter 10 H 6 M 100 160 Replace with oil change Battery 20 H Monthly 200 320 Check terminals clean E Engine breather filter 20 H Monthly 200 320 Inspect clean as needed F Swing arm pivot 25 H 3 M 250 400 Disassemble components clean and grease F General lubrication 50 H 3 M 500 800 Lu...

Page 99: ...ct 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 needed E Engine breather hose and filter in airbox 50 H 6 M 500 800 Inspect Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California J Have an authorize...

Page 100: ...es 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 ...

Page 101: ...ressure 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 replace lines every two years J E Ignition Timing 12 M Inspect adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California J Have an a...

Page 102: ...luid 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 E Idle speed As required Adjust J Toe adjustment As required Periodic inspection adjust when parts are replaced Headlight aim As required Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emiss...

Page 103: ...ANCE 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 hrs 100 hrs ...

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

Page 105: ...ide 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 possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation ...

Page 106: ...ine 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 the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range 2 between the full and add marks Do not overfill 6 Reinstall the dips...

Page 107: ...e 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 damage and must be drained Water accumulation increases as outside temperature decreases ...

Page 108: ...ut 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 90 Always change the oil filter whenever changing oil Perform a break in oil change after one hour of operation or after the first tank of fuel whichever comes first Change the oil more frequently on...

Page 109: ...tes 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 oil to drain completely 6 Replace the sealing washer and reinstall the plug Torque to 14 ft lbs 19 Nm NOTE The sealing surfaces on drain plugs oil tank and crankcase should be clean and free of burrs ...

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 removed The spring must be reinstalled with the new filter 13 Using a clean dry cloth clean the filter sealing surfaces 14 Replace the o ring in the cover 15 Lubricate the gasket on the new filter with a...

Page 111: ...ith 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 the recommended oil 19 Place the transmission in neutral and set the parking brake Step 14 Step 16 Step 17 ...

Page 112: ...he 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 dipstick 22 Dispose of the used filter oil and shop towels properly ...

Page 113: ...amp 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 hear a rush of air indicating that the line is properly primed and ready for operation If you do not hear air the line has not bled and you ll need to repeat the priming procedure 2I 1 ...

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 pre filter 6 and breather filter 7 Wash both in soapy water then rinse let dry and reinstall 1 2 3 4 5 6 7 ...

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 without a breather filter can cause engine damage Always reinstall the breather filter after removing for service ...

Page 116: ...nd 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 mixture of high quality aluminum compatible anti freeze coolant and distilled water See page 173 for the part numbers of Polaris products NOTE Polaris Premium 60 40 is already premixed and ready to use Do ...

Page 117: ...ing 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 cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe c...

Page 118: ...ed 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 pressure cap 2 Using a funnel slowly add coolant as necessary through the radiator filler neck 3 Replace the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to func...

Page 119: ...ot 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 headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently ...

Page 120: ...the 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 bulb Rotate firmly NOTE The bulb must be positioned so the harness installs into the lamp at outer side 4 Reinstall the connector to the back of the headlight 1 2 ...

Page 121: ...e 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 install it on the new lamp 4 Remove the large pivot bracket 2 and remove the headlamp 1 2 ...

Page 122: ...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 t...

Page 123: ...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 should be aimed 2 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Loosen the pivot screw 1 and adjust the beam to the desired position 6 Tighten the screw an...

Page 124: ...ws 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 on the top of the cab 3 Remove the two screws 5 from the rear cab supports 4 Remove the cab 2 3 2 4 5 5 1 ...

Page 125: ...hand 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 and disengage it from the stand offs on the fuel tank 5 Reverse all steps to reinstall the front cab 2 1 ...

Page 126: ...arranty 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 vehicle has been driven at higher speeds Immediately check the spark plug for correct color WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spar...

Page 127: ...OTE 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 black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil ...

Page 128: ...and 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 exercise extreme caution when handling fuel systems and gasoline Always heed the fuel warnings on page 65 ...

Page 129: ...he 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 engine Slowly remove the tank and be careful not to catch any hoses wires or other components Place the tank on a stable surface or work bench Be sure to protect the valve from contamination or damage ...

Page 130: ...ire 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 the spark plug and reassemble the body Torque the spark plug to 14 ft lbs 19 Nm Be sure to reroute the vent hose 1 through the instrument panel Torque the tank mounting bolt to 9 ft lbs 12 Nm 1 ...

Page 131: ...ngine 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 Exhaust contains poisonous carbon monoxide gas Failure to heed these warnings could result in serious injury or death ...

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 the screen for wear and damage Replace if necessary 4 Remove and inspect the gasket Replace if worn or damaged 5 Reinstall the gasket and arrestor 6 Torque screws to 50 in lbs 5 6 Nm 1 2 3 ...

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 t feel completely capable or if you suspect that water has entered the fuel tank likely if the water was deep or if the ATV overturned Tow or trailer the ATV to your dealer for immediate service 1 Tu...

Page 134: ...ut 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 oil tank Do not start the engine Tow the ATV and see your dealer If the oil level is unchanged from the pre ride inspection level replace the spark plug start the engine and move the ATV promptly to a...

Page 135: ...p 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 result in an explosion and cause serious injury or death When removing a battery always disconnect the negative black cable first When reinstalling the battery always connect the negative cable last Batte...

Page 136: ...bles 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 in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed and stored out of the sun in a coo...

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 automatic charger such as the Polaris Battery Tendert refer to the manufacturer s instructions for recharging When using a constant current charger use the guidelines on the following page for recharg...

Page 138: ...tandard 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 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At ...

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 equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less ...

Page 140: ...n 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 placing a suitable stand under the frame 4 Remove the wheel nuts and remove the wheel 1 8I 3 cm ...

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 the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the nuts to sp...

Page 142: ...D 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 8 27 ft lbs 36 5 Nm ...

Page 143: ...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 are self adjusting but the following checks are recommended to keep the brake systems in good operating condition Check more often if brakes are used heavily under normal operation WARNING Overfilling the master cylinder will result in brake fai...

Page 144: ...or 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 brake disc spline and pad wear surface for excessive wear NOTE Pads should be changed when worn to 3 64 1 cm 3 64 1 cm ...

Page 145: ...o 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 bar so they can t move NOTE The steering arm can be used as an indicator of whether the handlebars are straight The arm should always point straight back from the steering post 2 Place stands 1 in fron...

Page 146: ...tires 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 two measurements should be between 0 and 1 16 toe out NOTE If you discover improper alignment see your Polaris dealer for service 1 2 3 ...

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 so that the axle swing arm pivot and drive sprocket are aligned horizontally B B C A ...

Page 148: ...rvice 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 from the axle to the transmission output shaft intersecting the swing arm pivot This establishes the tightest chain position 3 At this point C the chain should have 1 4 3 8 6 9 cm deflection Use the pr...

Page 149: ...locking 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 Nm Step 1 Proper Splicelink Clip Opening Position Step 2 ...

Page 150: ...teering 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 The camber and caster are non adjustable ...

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 closed Firmest 2 clicks from closed 2 clicks from closed Front Shock Troy Lee Setting Compression Softest 20 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed ...

Page 152: ...pression 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 ATV which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments ...

Page 153: ...e 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 Tighten the jam nut against the adjusting ring NOTE See Suspension Settings on page 148 A B 1 2 ...

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 adjusting ring 2 to the left A to increase preload Turn the ring to the right B to decrease preload See Suspension Settings on page 148 4 Tighten the jam nut firmly against the adjuster ring A B 1 2 ...

Page 155: ...ring 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 NOTE The rebound damping is factory set at 16 clicks from fully closed See Suspension Settings on page 148 A B ...

Page 156: ...p of the shock reservoir under the left rear fender Use a screwdriver to make adjustments To increase compression damping turn the clicker clockwise A To decrease compression damping turn the clicker counter clockwise B The factory setting is at 10 clicks from fully closed See Suspension Settings on page 148 ...

Page 157: ...crew 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 lever fully and release Slightly squeeze the lever again until a slight resistance is felt Measure the freeplay again If necessary repeat the adjustment procedure until proper freeplay is attained 5 R...

Page 158: ...persons 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 the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the l...

Page 159: ...ous 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 handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 3 Torque the front two bolts to 10 12 ft lb...

Page 160: ...Warm 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 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 1 ...

Page 161: ...ation 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 power cannot be regained changes to the carburetor and drive system can be made to allow more efficient operation NOTE Contact your dealer for altitude adjustments Your dealer has the training and s...

Page 162: ...nsmission 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 parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety decals are damaged contact your a Polaris dealer for free replacement Grease all zerk fitti...

Page 163: ...h 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 surfaces Use caution when using these products near plastic surfaces ...

Page 164: ...pairs 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 container for the recommended amount Fill the fuel tank with fuel Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off a...

Page 165: ...r 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 levels and change as outlined in the Maintenance Schedule beginning on page 90 Battery Refer to pages 133 134 for battery storage and battery charging procedures ...

Page 166: ...off 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 carburetor following the instructions on the fogging oil container 5 Turn the engine off reassemble the intake duct to the carburetor secure the clamp and reinstall the seat ...

Page 167: ...ason 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 with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enoug...

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 securely as shown in the illustration using suitable straps or rope 5 Always place the transmission in first gear and lock the parking brake ...

Page 169: ...ns 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 connections Check all connections and tighten Loose solenoid connections Check all connections and tighten ...

Page 170: ...e 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 plug s verify stop switch is on Overuse of choke Inspect clean and or replace spark plugs Low battery voltage Recharge battery to 12 8 VDC Mechanical failure See your Polaris dealer Throttle ETC swi...

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 or replace plugs Old poor or non recommended fuel Replace with new fuel Incorrectly installed spark plug wire See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical fail...

Page 172: ...ecs 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 plugged fuel tank vent line Inspect and replace Old poor or non recommended fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle control ETC malfunction S...

Page 173: ...non 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 Inspect clean and or replace spark plugs Fuel is very high octane Replace with recommended lower octane fuel Incorrect jetting See your Polaris dealer Plugged dirty or wet air filter Clean pre filte...

Page 174: ...ke 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 heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 8 VDC or replace Old poor or non recommended fuel...

Page 175: ...mechanical 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 lodged in screen Remove and clean the screen Plugged radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling ef...

Page 176: ...ts 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 cartridge 2870652 Fuel Stabilizer 16 oz 2871460 Starter Drive Grease 2 oz 2870990 DOT3 Brake Fluid 12 oz 2871329 Dielectric Grease Nyogelt 2872893 Engine Degreaser 12 oz 2872073 Chain Lube 6 25 oz aerosol ...

Page 177: ...tor 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 in 170 cm Ignition System CDI Engine Oil Capacity 2 5 qts 2 37 l Ignition Timing 30 3 3500 RPM Coolant Capacity 2 25 qts 2 1 l Spark Plug Gap NGK DCPR8E 0 9 mm 035 in Engine ES50PLX Lubrication Syste...

Page 178: ...ydraulic 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 35w Gear Ratio 4th 1 1 Std 1 2 Troy Lee Taillights LED Gear Ratio 5th 0 9 Brakelight 26 9w Jetting Chart Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 180...

Page 179: ...on 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 PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form wi...

Page 180: ...efectsin parts com ponents 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 are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET...

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 WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied war ranty lasts so the above limitation may not apply to you if inconsistent with controlling state law ...

Page 182: ...erform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance 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 are void because of state or federal law all other warranty terms will...

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 bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s au...

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 the servicing dealer will be autho rized to perform the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the desti...

Page 185: ...red 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 Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions ca...

Page 186: ...le 114 Cooling System 113 114 Crankcase Emission Control System 88 D Driving Across Hills 78 Driving Downhill 79 Driving in Reverse 86 87 Driving on Slippery Surfaces 76 Driving Over Obstacles 83 Driving Procedures 74 Driving Safely 74 87 Driving Through Water 84 85 Driving Uphill 77 E Electrical Switches 48 49 Electronic Throttle Control 53 EMISSION CONTROL SYSTEMS 88 89 Engine Cooling System 115...

Page 187: ...h 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 88 Spark Arrestor Clean Out 128 129 Spark Plugs 123 127 SPECIFICATIONS 174 175 Spring Preload 149 151 Starting a Cold Engine 70 72 S Starting a Warm Engine 73 Steering Assembly 147 Storage Recommendations 1...

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

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Summary of Contents for Predator 500

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