Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual 2003-2007

The DIY 2003-2007 Polaris Predator 500 ATV repair manual by Clymer, covers the following models:

• Polaris Predator 500, 2003-2007
• Polaris Predator 500 Troy Lee Designs, 2005-2006

Book Excerpt: 2003-2007 Polaris Predator 500, Predator 500 Troy Lee Designs Repair Manual LUBRICATION, MAINTENANCE AND TUNE-UP

FRONT SUSPENSION: INSPECTION Inspect the front suspension at the interval shown in Table 1.

1. Park the ATV on level ground and set the parking brake.
2. Inspect all components of the steering system. Repair or replace damaged components as described in Chapter Twelve.
3. Remove the instrument panel from the handlebar (Chapter Ten).
4. Check that the handlebar holder bolts and nuts (Figure 73) are tight. If necessary, tighten to 14-17 N-m (124-150 in. -lb.).
5. Remove the front hub cover. Make sure the front hub nut (Figure 74) is tight and that the cotter pin is correctly installed.
6. Check that all cotter pins are in place on all steering components. If any cotter pins are missing, check the nut for looseness. Tighten the nut and install a new cotter pin as described in Chapter Twelve.

ENGINE LOWER END

This chapter covers the engine lower end components, including the crankshaft, balancer shaft, oil pump and oil tank. Refer to Table 1 and Table 2 at the end of this chapter for specifications. ENGINE The engine must be removed from the frame to service the following components:

1. Crankcase.
2. Crankshaft and connecting rod.
3. Balancer shaft.
4. Main bearings.
5. Oil pump

REMOVAL Refer to Figure 1.

1. Place the vehicle on a level surface and set the parking brake. Block the wheels to keep it from rolling in either direction.
2. Remove the fuel tank as described in Chapter Nine.
3. Remove the seat, front fender and rear fender as described in Chapter Fifteen.

Subject: 2003, 2004, 2005, 2006, 2007 Polaris Predator 500, Predator 500 Troy Lee Designs service, maintenance, repair. ISBN-10: 1599692619 | ISBN-13: 9781599692616 | Clymer M367