ATV Polaris Predator 500 Workshop Repair Troubleshooting Manual (2003)
The following workshop, repair and troubleshooting manual apply for Polaris Predator 500 ATV 2003 model years. This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.

The workshop and repair manual is divided into following sections:

Chapter 1, General, provides detail information about Model Identification, Serial Number Location, Publication Numbers, Replacement Keys, Standard Torque Specifications, Predator Models, Specifications, Tap Drill Charts, Decimal Equivalent Chart, Unit of Measure Conversion Table and Glossary of Terms.

Chapter 2, Maintenance, this chapter outline detail information about Periodic Maintenance Chart, Pre-Ride Inspection, Lubrication and Maintenance Product Numbers, Special Tools, Lubrication Charts, Clutch Freeplay Adjustment, Throttle Inspection, Fuel System, Compression Test, Spark Plug and Battery Maintenance, Electrical Troubleshooting, Coolant System Maintenance, Radiator Screen Removal, Air Filter Service, etc.

Chapter 3, Engine/Transmission, explains about Torque Specifications, Service Data, Engine Removal, Cooling System Pressure Test, Cooling System Specifications, Flow Diagram, Cam Timing Diagram, etc.

Chapter 4, Fuel System, contains Exploded View of Mikuni BSR 42 Carburetor, Fuel Tank Asm. Exploded View, Fuel Flow Diagram, Special Tool & Jetting Guidelines, Carburetor Jetting, Main Jet / Pilot Jet Part Numbers, Float Adjustment, CV Carburetor, etc.

Chapter 5, Body/Suspension, contains Body Assembly and Exploded V view, Steering Assembly, Front Hub Removal, Front Hub Assembly/Installation, Steering Knuckle Removal/Installation, Ball Joint Removal/Installation, Concentric Swing Arm Removal, etc.

Chapter 6, Brakes, provides detail information about Brake System Service Notes, Brake Noise Troubleshooting, Master Cylinder Removal/Installation, Fluid Replacement/Bleeding Procedure, etc.

Chapter 7, Electrical System, about Timing Check Procedure, Electrical Switch Testing, Fan Motor Current Draw Test, Electronic Throttle Circuit System Operation, Ignition System Troubleshooting, CDI Output Tests/Stator Output Tests, etc.
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