Polaris 2007 Predator 500 Скачать руководство пользователя

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152

ADJUSTMENTS

Clutch Lever Freeplay

1. Measure clutch lever freeplay between

the perch and the lever (A). This

distance should be 1/8

″

- 3/16

″

(3-4.7 mm).

2. If adjustment is required, slide the

clutch perch pivot boot down the

clutch cable to access the clutch

adjustment screw (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. Replace the clutch perch pivot boot over the screw and lock ring.

Содержание 2007 Predator 500

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Страница 3: ...wn to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card...

Страница 4: ...1...

Страница 5: ...and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication a...

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

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

Страница 19: ...is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential fo...

Страница 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...

Страница 21: ...hasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on en...

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

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

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

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

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

Страница 27: ...situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA They should then re...

Страница 28: ...skill and experience recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a beginner or inexperienced driver operates this ATV HOW TO AVOID THE HAZARD Only operators...

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

Страница 30: ...reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of...

Страница 31: ...nd driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury...

Страница 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...

Страница 33: ...et increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the...

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

Страница 35: ...NG POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other s...

Страница 36: ...tain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe ope...

Страница 37: ...or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footpeg it could come into contact with t...

Страница 38: ...the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use ext...

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

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

Страница 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...

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

Страница 43: ...t to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 80 Use extra caution when turning on any hill Avoid crossin...

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

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

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

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

Страница 48: ...ling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Pol...

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

Страница 50: ...e vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result...

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

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

Страница 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...

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

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

Страница 56: ...the throttle lever the engine will stop and power to the rear wheels will cease WARNING Modifications to the ETC could result in failure to perform as designed which could result in severe injury or...

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

Страница 58: ...st brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level whic...

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

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

Страница 61: ...vent rolling S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position S Never depend on the parking brake alone...

Страница 62: ...torage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 5 to 8 mile 8 to 13 km range on reserve gas Always refill the gas tank as s...

Страница 63: ...valve has an internal fuel filter Do not attempt to clean the fuel filter See your Polaris dealer for service if you suspect the fuel filter is plugged Choke The choke assists in starting a cold engin...

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

Страница 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...

Страница 66: ...ator from shifting into reverse unintentionally 1 Place the transmission in first gear See page 61 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into r...

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

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

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

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

Страница 71: ...de Checklist Item Remarks See Page Brake system lever travel Ensure proper operation 55 139 Brake fluid Ensure proper level 56 Foot brake Ensure proper operation 54 Clutch lever Check for proper opera...

Страница 72: ...proper operation 52 153 Indicator lights switches Ensure operation 49 Engine stop switch Ensure proper operation 49 Air filter pre filter Inspect clean 109 Headlamp Check operation apply Polaris diel...

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

Страница 74: ...e NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is n...

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

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

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

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

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

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

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

Страница 82: ...wnhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Shift to the lowest gear possible while maintaining a safe speed 5 Apply the foot brake slightly to aid in slowing WARNING Excess...

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

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

Страница 85: ...rking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the...

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

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

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

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

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

Страница 91: ...to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of o...

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

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

Страница 94: ...185 Severe Use Definition S Frequent immersion in mud water or sand S Racing or race style high RPM use S Prolonged low speed heavy load operation S Extended idle S Short trip cold weather operation I...

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

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

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

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

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

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

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

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

Страница 103: ...de the ultimate in lubrication performance and protection and prolonged clutch life See page 173 for the part numbers of Polaris products PS 4 oil possesses unsurpassed film strength over the widest p...

Страница 104: ...ne and let it idle for one minute 3 Stop the engine and remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely NOTE The dipstick must be screwed completely in to keep t...

Страница 105: ...oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine d...

Страница 106: ...t oil and filter overnight Always replace the oil and filter within a few hours of draining the oil Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page...

Страница 107: ...es until warm then stop the engine 4 Place a drain pan beneath the oil tank and remove the drain plug CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin 5 Allow the o...

Страница 108: ...Nm 10 Place shop towels beneath the oil filter 11 Remove the three cover bolts and remove the cover 12 Pull out the oil filter NOTE A spring located behind the filter may pop out as the filter is remo...

Страница 109: ...r with the open end facing outward 17 Install the cover and torque the bolts to 72 78 in lbs 8 9 Nm NOTE The long bolt must be placed in the forward hole 18 Remove the dipstick Fill the oil tank with...

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

Страница 111: ...mp or pinch off the vent line 1 approximately 2I 5 cm from the oil tank 2 Run the engine for 5 10 seconds at idle Stop the engine and remove the vent line clamp If the line is bled properly you should...

Страница 112: ...clamp 1 on the carburetor 3 Pull the duct 2 off the carburetor 4 Release the eight airbox cover clips 3 and remove the cover 4 5 Remove the air filter 5 Inspect and replace if necessary 6 Remove the p...

Страница 113: ...secure the clips 9 Reinstall the intake duct to the carburetor and secure the clamp 10 Check the hoses for cracks deterioration abrasion or leaks Replace as needed CAUTION Operation of your vehicle wi...

Страница 114: ...d that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixtur...

Страница 115: ...ant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con...

Страница 116: ...d only if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry inspect the level in the radiator and add coolant if necessary 1 Remove the press...

Страница 117: ...t spot that will shorten the life of the lamp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the head...

Страница 118: ...he bulb housing and turn it counterclockwise 1 to remove the bulb On the right headlamp turn the bulb housing clockwise 2 to remove the bulb 3 Apply dielectric grease to the socket and install the new...

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

Страница 120: ...eadlamp 7 Adjust for approximately 1 16 clearance between the bracket and the edge of the headlight Tighten the mounting screws IMPORTANT Be sure the bracket is 90 degrees to the pivot pin so the lamp...

Страница 121: ...t and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam shoul...

Страница 122: ...s 1 securing the side panel 3 Remove the side panel Rear Cab Removal 1 Unlatch and remove the seat 2 Remove the four bolts 2 on the rear fenders of the cab and the two bolts 3 washers and grommets 4 o...

Страница 123: ...and and right hand cab mounts 2 Remove the wire harness connector from the headlights 3 Loosen the screw 2 located inside the cab under the front cover 4 Gently pull the cab forward to remove the cab...

Страница 124: ...rranty Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the...

Страница 125: ...TE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is bla...

Страница 126: ...nd front cab see pages 119 120 2 Turn the fuel valve to OFF WARNING A hot ember on the ATV could cause fuel to ignite Allow all components to cool sufficiently before accessing the spark plug Always e...

Страница 127: ...e vent hose 2 from the instrument panel taking note of the hose routing for reinstallation 5 Remove the tank mounting bolt 3 at the rear of the gas tank 6 Move the tank rearward and upward over the en...

Страница 128: ...re to remove the boot Doing so may cause a wire disconnection inside the boot 8 Using the spark plug wrench and handle rotate counterclockwise to remove the spark plug 9 Reverse all steps to install t...

Страница 129: ...gine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Wear eye protection and gloves Never run the engine in an enclosed area Exh...

Страница 130: ...end of the muffler 2 Use a non synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect t...

Страница 131: ...perform the temporary drying out procedure outlined below which will allow short term operation only to drive the ATV to a trailer or towing vehicle Do not perform the following procedures if you don...

Страница 132: ...t one minute or until water vapor is no longer ejecting from the spark plug hole 7 Check the oil level on the dipstick If the level is higher than the pre ride inspection level water has entered the o...

Страница 133: ...water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly WARNING Improperly connecting or disconnecting battery cables can resul...

Страница 134: ...les are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result i...

Страница 135: ...laris Battery Tendert battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point When using an automati...

Страница 136: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 month...

Страница 137: ...will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the ATV decal and in the owner s manual Always use original...

Страница 138: ...to 1 8 3 mm or less See illustration Wheel Removal 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by pl...

Страница 139: ...to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in gear and lock the parking brake 2 Place the wheel on the wheel hub with t...

Страница 140: ...RICATION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Specification Front 3 8 30 35 ft lbs 41 47 Nm Rear 3...

Страница 141: ...6 The front brakes are hydraulic disc brakes They re activated by squeezing the brake lever toward the handlebar The rear brake is a hydraulic disc brake activated by the foot brake pedal Both brakes...

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

Страница 143: ...check the toe alignment of the vehicle The Predator is designed for a neutral toe setting 1 Set the handlebars in a straight ahead position Use tie straps to secure the handlebars to the rear grab ba...

Страница 144: ...on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 The difference between these...

Страница 145: ...rear drive chain too loose or too tight Severe damage to the transmission and drive components can result Chain tension must be inspected with the swing arm in the position shown in the illustration s...

Страница 146: ...vice 1 Collapse the suspension with an adjustable buckle type trailer tie down strap A Fasten the strap around the axle and rear bumper tube 2 Tighten the strap until a straight line B can be drawn fr...

Страница 147: ...ocking bolts 2 Insert a pin punch into the eccentric axle housing 3 Roll the vehicle ahead or back to adjust chain slack to the proper dimension 4 Tighten the eccentric locking bolts to 35 ft lbs 47 5...

Страница 148: ...eering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster...

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

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

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

Страница 152: ...Spring Preload 1 Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend 2 Loosen the jam nut 1 and back it away from the adjusting ring 3 Turn the adjustin...

Страница 153: ...ing seat and the lower shock mount 2 Use a screwdriver make the adjustment Turn the clicker counter clockwise to decrease the rebound damping A Turn the clicker clockwise to increase rebound damping B...

Страница 154: ...of the shock reservoir under the right rear fender Use a screwdriver to make adjustments To increase compression damping turn the clicker clockwise A To decrease compression damping turn the clicker...

Страница 155: ...w B and lock ring C 3 Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever travel Tighten the lock ring 4 Squeeze the lev...

Страница 156: ...s who perform this procedure must follow the adjustment procedures exactly Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 and loosen th...

Страница 157: ...injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the instrument panel and locate the handlebar bolts 1 2 Loosen the four bolts and adjust the ha...

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

Страница 159: ...tion and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this...

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

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

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

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

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

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

Страница 166: ...ff 2 Unlatch and remove the seat 3 Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor 4 Start the engine and spray Polaris fogging oil or a comparable product into the...

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

Страница 168: ...the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting unit securel...

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

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

Страница 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...

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

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

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

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

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

Страница 177: ...r Output 200 w 3000 RPM Wheelbase 50 5 in 128 cm Compression Ratio 10 8 1 Ground Clearance 4 5 in 11 cm Starting System Electric Dry Weight 415 lbs 188 kg Carburetor BSR 42mm Minimum Turning Radius 58...

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

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

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

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

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

Страница 183: ...have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warran ty or service bu...

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

Страница 185: ...ed outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Ve...

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

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

Страница 188: ...185 MAINTENANCE LOG Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs...

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

Страница 190: ...e 112 Cooling System 111 112 Crankcase Emission Control System 89 D Driving Across Hills 78 Driving Downhill 79 Driving in Reverse 86 87 Driving on Slippery Surfaces 76 Driving Over Obstacles 83 Drivi...

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

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