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Quick Links. Table of Contents. Polaris industries all terrain vehicle owner's manual pages. Polaris industries all-terrain vehicle owner's manual pages. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvement in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication.

Serial Number Location Publication Numbers. The machine serial number is stamped on the lower left side of the frame tube. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins No.

Polaris measures chain length in number of pitches. CI: Cubic inches. Lubricant and Maintenance Product Numbers 2. Page Periodic Maintenance Chart Change oil immediately and monitor level.

If oil level begins to rise, discontinue use and determine cause. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. Page 22 2 years or hours. Use a medium flat blade screwdriver and insert Clutch Lever Freeplay blade into the pocket of the cover starting on the 1. Measure clutch lever freeplay between the perch 1 position. Start engine and warm it up thoroughly.

NOTE: Pilot screw is covered by a welsh plug. Plug 2. Adjust idle speed by turning the idle adjustment removal will be required to perform these procedures. See Idle Speed Adjustment. Never drain the float bowl when the 4. Loosen lock nut on in-line cable adjuster Ill. Reverse the procedures to install the fuel valve. A cylinder leakdown test is the best indication of engine condition. Start engine and inspect for leaks. Turn the fuel valve to OFF. Spark Plug Torque: 2. Remove the front cab.

Move the fuel valve hose clamp 1 forward and gently remove the hose from the fuel valve fitting Spark Plug Gap on the gas tank.

Doing so will damage Use Polaris corrosion resistant Dielectric Grease PN the case and shorten the life of the battery. Refer on battery bolts. Do not dilute with water. Connect the battery cables. Remove the 4 screws retaining the radiator screen for access to the radiator fins when cleaning. Reinstall crankcase breather filter, pre--filter and air filter into air box.

Page Crankcase Breather Filter Nm. NOTE: The long bolt must be placed in the forward hole. Remove the dipstick and fill the oil tank with 2. Place gear selector in neutral and set parking brake. Place machine on a smooth level surface. Set handlebars in a straight ahead position and To check for play in the tie rod end, secure handlebars in this position. Serious burns could result from contact with ex- If toe alignment is incorrect, measure the distance haust components.

Page Brake System Inspection Inspect brakes in accordance with the maintenance schedule and before each ride. Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. The Setting If there is space between outside Master Link edge of the mas- ter link and plate, Do not back the plate press plate out slightly.

Inspect chain for excessive wear, missing o--rings, etc. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. Tighten the eccentric locking bolts to 45 ft. The compression damping is machine when turned fully to the left or right.

To adjust, turn the clicker 3. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into Operating your ATV with worn tires, improperly taper on wheel.

Nm Valve Cover 6. If the piston has an Water Pump Mechanical Seal Puller identification mark, follow the directions for piston placement below. Page Cooling System Specifications 2. The radiator cap relief pressure is 13 psi. Thoroughly clean the ATV engine and chassis. Clean work area. To correct a situation like the one shown in the illustration, squeeze the crankshaft at points A.

NOTE:Oil pump priming procedures must be delivery pipe supplies oil to the top of the cylinder head performed whenever the oil hose connection and the transmission main shaft. To retract the plunger, rotate the special tool 3. Remove the 8 bolts securing the cam tower clockwise while holding the tensioner stationary. You may also hold the special tool stationary and 4. To free the cam assembly, lift one cam assembly rotate the tensioner assembly counter--clockwise and slightly rotate it while removing the chain from if desired.

Check release cam A for smooth operation 5. Measure ID of camshaft journal bore. The spring B should hold the cam against the stop. Camshaft Journal I. NOTE: Keep all parts in order with respect to their location in the cylinder head. Remove the valve buckets A.

NOTE: To prevent loss of tension, do not compress the valve springs more than necessary. Remove the valve seals. NOTE: Replace seals whenever the cylinder head is disassembled. Check end of valve stem for flaring, pitting, wear or damage A.

NOTE: Assemble the valves one at a time to maintain proper order. Install new valve seals on valve guides. Place retainer on springs and install valve spring compressor. Compress springs only enough to allow split keeper installation and prevent loss of spring tension. Install split keepers with the gap even on both sides. Repeat procedure for remaining valves. Measure valve clearance at TDC Compression stroke using thickness gauge with original adjusting pad installed.

Reference the measurement and the 3 digits marked on the existing adjusting pad on the matrix below 3. NOTE: Follow engine disassembly procedures to 5. Remove dowel pins from crankcase. The oil control ring is a three piece design consisting 5. Record measurements. If cylinder is tapered or of a top and bottom steel rail and center expander out of round beyond specification, the cylinder section.

Remove the top rail first followed by the must be replaced. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if 1.

Measure piston pin bore. Place each piston ring inside cylinder using piston flywheel, stator, cam chain and sprockets can be to push ring squarely into place.

NOTE: Crankcase and transmission components cannot be serviced in the frame.


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Throughout these instructions, important information is brought to your attention by the following symbols:. NOTE provides key information to clarify instructions. Polaris acknowledges the following products mentioned in this manual:. Model Identification. Serial Number Location. Publication Numbers.


Polaris Predator 500 Manuals

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