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  Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual 2003-2007
  Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual 2003-2007
 
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Product Code: CL-M367

Features
 
Features
This repair and service manual covers Polaris Predator 500 ATVs, including:
  • Predator 500 2003-2007
  • Predator 500 Troy Lee Designs 2005-2006
Table of Contents

Quick Reference Data

Chapter One: General Information
Manual organization | Warnings,cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

Chapter Two: Troubleshooting
Water damage | Starting the engine | Engine does not start | Poor engine performance | Electronic throttle control | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Electrical testing | Front suspension and steering | Brake system

Chapter Three: Lubrication, Maintenance and Tune-Up
Pre-ride inspection | Air box drain plugs | Air filter | Engine oil and filter | Oil pressure test | Spark plug | Spark arrester cleaning | Fuel tank vent hose | Fuel hose inspection | Carburetor | Choke adjustment | Ignition timing | Valve clearance | Compression test | Control cables | Cooling system | Battery | Tires and wheels | Drive chain | Brake system | Front suspension | Rear suspension inspection | Suspension lubrication | Skid plate inspection | Fastener inspection | Lights and horn inspection | Specifications

Chapter Four: Engine Top End Engine service
Cylinder head cover | Camshaft | Camshaft chain tensioner | Camshaft chain, timing sprocket and chain guides | Cylinder head | Valve lifters and shims | Valves and valve components | Cylinder block | Piston and piston rings | Break-in procedure | Specifications

Chapter Five: Engine Lower End Engine
Crankcase | Water pump mechanical seal and bearing replacement | Crankshaft | Balancer shaft inspection | Primary drive gear | Oil pump | One-way check valve | Oil tank, oil pipes and hoses | Break-in procedure | Specifications

Chapter Six: Shift and External Clutch Mechanism
Drive belt cover | Outer bearing housing | Drive belt inspection and replacement | Primary and secondary sheaves | Right crankcase cover | Clutch | Specifications

Chapter Seven: Transmission and Gearshift Mechanisms (2003-2004 Models)
Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection

Chapter Eight: Transmission and Internal Gearshift Mechanism (2005-on Models)
Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection | Reverse gear arm shifter

Chapter Nine: Fuel System and Exhaust
Carburetor operation | Carburetor | Pilot screw | Carburetor tests and adjustments | Throttle cable replacement | Choke cable replacement | Fuel tank | Fuel shutoff valve | Air box | Fuel pump | Exhaust system | Specifications

Chapter Ten: Electrical System
Electrical component replacement | Electrical connectors | Battery negative cable | Charging system | Voltage regulator-rectifier | Capacitor discharge ignition (CDI) | Alternator cover and stator coil | Alternator rotor and starter gears | Ignition coil | Starter | Starter solenoid | Lighting system | Switches | Cooling system fan switch and sensor | Circuit breaker | Specifications

Chapter Eleven: Cooling System
Cooling system | Coolant reservoir | Radiator | Cooling fan | Water pump | Thermostat | Cooling fan switch | Engine coolant temperature sensor | Specifications

Chapter Twelve: Front Suspension and Steering
Front wheel | Front hub | Shock absorber | Tie rods | Front spindle | Control arms | Center link and idle arms (2003-2006 models) | Handlebar | Steering shaft | Tires and wheels | Specifications

Chapter Thirteen: Rear Suspension
Rear wheel | Rear hub | Rear axle | Rear axle eccentric | Drive chain | Sprockets | Shock absorber | Swing arm | Specifications

Chapter Fourteen: Brakes
Brake service | Front brake pad replacement | Front caliper (2003-2006 models) | Front caliper (2007 models) | Front master cylinder | Rear brake page replacement | Rear caliper (2003-2006 models) | Rear caliper (2007 models) | Rear master cylinder | Brake hose replacement | Rear brake pedal | Brake disc | Brake bleeding | Specifications

Chapter Fifteen: Body
Seat | Side panels | Front fender | Rear fender | Heel pocket and mounting bracket

Color Wiring Diagrams

Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

PRODUCT DETAILS:
  • Publisher: Clymer Manuals - 2008
  • Author: Ed Scott
  • Binding: Paperback - 7 x 10 inches
  • Pages: 334 - Hundreds of b&w photos and illustrations
  • ISBN: 9781599692616

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