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PREDATOR 2003
Polaris PREDATOR 2003 User Manual
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GENERAL
INFORM
A
T
ION
1.5
MODEL:
2003
PR
EDA
T
OR
500
..........
MODE
L
NUM
BER:
A03GJ50AA
.
ENGINE
MODEL:
ES50PLX
..
Ca
tagory
Dimen
sio
n
Length
71.5
in./
182
cm
Width
47.5
in./
121
cm
Height
45
in.
/1
14
cm
Seat
Height
32
in.
/81.28
cm
Wheel
Base
51
in.
/130
cm
Ground
Clearance
4
.
5i
n
.
/
1
1c
m
Dry
Wei
ght
415
lbs.
/188
kg
Fuel
Capacity
3.25
gal./
12.3
lt
r
Oil
Capacity
2.2
5
q
ts./2.1
ltr
Coolant
Capacity
2.2
5
q
ts./2.1
ltr
Dune
Pac
kage
Shown
Enfocus
Software
-
Customer
Support
9
11
Table of Contents
Chapter 1 General Information 1
6
Table of Contents
6
Model Identification
7
Serial Number Location
7
General
7
Publication Numbers
8
Replacement Keys
8
Standard Torque Specifications
8
Predator Models
9
Maintenance
11
Conversion Table
13
Glossary of Terms
14
Maintenance Chapter 2 Maintenance
16
Default Chapter
17
Periodic Maintenance Chart
17
Pre-Ride Inspection
19
Special Tools
21
Clutch Freeplay Adjustment
24
Throttle Inspection
24
Idle Speed Adjustment
25
Throttle Cable
25
Fuel System
26
Fuel Lines
26
Vent Lines
26
Fuel Valve
26
Compression Test
27
Carburetor Draining
27
Engine Mounts
27
Battery Maintenance
28
Spark Plug Inspection
28
Ignition Timing
28
Liquid Cooling System
30
Cooling System Hoses
31
Radiator Coolant Level Inspection
31
Cooling System Pressure Test
32
Radiator Screen Removal
32
Crankcase Breather Filter
33
Wheel Alignment
34
Chapter 3
35
Body/Suspension
35
Chapter 4
35
Brakes
36
Brake Pad Inspection
37
Brake System Inspection
37
Wheel Removal/Installation
41
Torque Table
41
Tire Inspection
42
Chapter 3 Engine
44
Torque Specifications
45
ES50PL Service Data
46
Engine Fastener Torque Patterns
48
Piston Identification / Compression Test
48
Special Tools
48
Cooling System Specifications
49
Engine Removal
50
Electrical
50
Engine Installation Notes
51
ES50PL Engine Lubrication
52
Oil Pump Priming
53
Camshaft
54
Engine Disassembly
56
ES50PL Lubrication/Oil Flow
54
Cylinder Head
59
Valve Inspection
60
Cylinder Head Assembly
61
Piston Removal
64
Cylinder Inspection
65
Crankcase Separation
72
Crankcase Inspection
72
Transmission
73
Crankshaft Runout Inspection
75
Crankcase
76
Crankcase Reassembly
78
Piston Ring Installation
78
Camshaft Timing
81
Cam Timing
82
Troubleshooting
87
Spark Plug Fouling Checklist
88
Fuel System/Carburetion Chapter 4 Fuel System/Carburetion
90
Fuel Flow Diagram
92
Carburetor Jetting
93
Mikuni Jet Part Numbers
93
Jetting Guidelines
93
CV Carburetor System Function (4 Cycle)
94
Assembly, CV Carburetor
96
Float System
96
Main System
96
Carburetor Cleaning
97
Carburetor Inspection
98
Carburetor Assembly
98
Needle & Seat Leakage Test
99
Fuel Level
100
Fuel Pump Service
100
Troubleshooting
101
Chapter 5 Body and Steering
102
Body Assembly Exploded View
104
Steering Assembly, Exploded View
105
Front Hub Removal
106
Front Hub Assembly/Installation
107
Front Hub Installation
108
Ball Joint Removal/Installation
109
Steering Knuckle Removal/Installation
109
Front Hub Exploded View
111
A-Arm Replacement
112
Concentric Swing Arm Removal
113
Rear Axle Removal/Disassembly
114
Rear Axle Installation
116
Rear Swing Arm / Axle Exploded View
118
Steering Post Assembly/Decal Replacement
119
Brakes Chapter 6 Brakes
146
Special Tools
147
Brake Noise Troubleshooting
148
Brake System Service Notes
148
Hydraulic Brake System Operation
149
Fluid Replacement/Bleeding Procedure
150
Master Cylinder Removal
152
Master Cylinder Installation
153
Front Pad Assembly
155
Front Disc Inspection
156
Front Caliper Removal
157
Rear Brake Pad
159
Front/Rear Caliper Disassembly
160
Front/Rear Caliper Assembly
162
Rear Brake Disc Inspection
163
Troubleshooting
163
Front Brake System
165
Rear Brake System
166
Electrical Chapter 7 Electrical
168
Timing Check Procedure
169
Fan Motor Current Draw
170
Ignition System Troubleshooting
172
Alternator Output Test
173
Flywheel Identification
174
Ignition System
174
Ignition System Testing
176
Charging System Testing Flow Chart
177
Battery Testing
179
Load Test
179
Headlight Housing Replacement
180
Headlight Adjustment
180
Headlamp Switch
181
Brake Light Switches
181
Starter System Troubleshooting
182
Armature Testing
185
Starter System Testing Flow Chart
187
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Polaris PREDATOR 2003 Specifications
General
Brand
Polaris
Model
PREDATOR 2003
Category
Offroad Vehicle
Language
English
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