Polaris PREDATOR 2003 Bedienungsanleitung

2003 PREDATOR SERVICE MANUAL

PN 9918062

2003 PREDATOR 500 SERVICE MANUAL PN 9918062

PN 9918062PN 9918062

Printed in the USAPrinted in the USA

230486_cov_01c.qxd 11/19/02 11:35 AM Page 1

2003 PREDATOR

SERVICE MANUAL

Foreword

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. All references to left and right side of the vehicle

are from the operator’s perspective when seated in a normal riding position.

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. Technicians should read the text and be familiar

with service procedures before starting the work. Certain procedures require the use of special tools. Use

only the proper tools as specified.

This manual includes procedures for maintenance operations, component identification and unit repair, along

with service specifications for the 2003 Polaris Predator ATV. Comments or suggestions about this manual

may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.

2003 Polaris Predator ATV Service Manual (PN 9918062)

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. Depictions and/or procedures in this publication are

intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions

and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS

Throughout these instructions, important information is brought to your attention by the following symbols:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

DANGER

Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person

inspecting or servicing the ATV.

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or

person inspecting or servicing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property

damage.

NOTE:

A NOTE provides key information to clarify instructions.

Trademarks

Polaris acknowledges the following products mentioned in this manual:

Loctite, Registered Trademark of the Loctite Corporation

FOX, Registered Trademark of Fox Shox

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity Vac, Registered Trademark of Neward Enterprises, Inc.

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CHAPTER INDEX

CHAPTER 1 GENERAL

CHAPTER 2 MAINTENANCE

CHAPTER 3 ENGINE/TRANSMISSION

CHAPTER 4 FUEL SYSTEM

CHAPTER 5 BODY/SUSPENSION

CHAPTER 6 BRAKES

CHAPTER 7 ELECTRICAL

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GENERAL INFORMATION

1.1

CHAPTER 1

GENERAL INFORMATION

Model Identification 1.2.......................

Serial Number Location 1.2...................

Publication Numbers 1.3.....................

Replacement Keys 1.3.......................

Standard Torque Specifications 1.3............

Predator Models 1.4.........................

Specifications 1.5-1.6............................

Tap Drill Charts 1.7..........................

Decimal Equivalent Chart 1.7.................

Unit of Measure Conversion Table 1.8..........

Glossary of Terms 1.9........................

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GENERAL INFORMATION

1.2

MODEL IDENTIFICATION

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

Year Designation Basic Chassis

Designation Engine Designation

A03GJ50AA

Emissions &

Model Option

ENGINE DESIGNATION NUMBER

ES50PLE01 Single, Water Cooled, Electric Start, Manual 5--Speed, DOHC 4 Stroke................

VIN IDENTIFICATION

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17

4XA GA 50A* 3P0 00 000

Vehicle Descriptor Vehicle Identifier

Powertrain

Engine

Emissions Model

Year

Plant No.*

Individual Serial No.

Body Style

Check Digit*

World Mfg. ID

* This could be either

a number or a letter

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

Whenever corresponding with Polaris about a

particular issue, the machine model number and

serial number are important for vehicle

identification. The machine serial number is

stamped on the lower left side of the frame

tube.(B)

ENGINE SERIAL NUMBER LOCATION

This information can be found on the clutch housing

on the left side of engine.(A)

RH View

BLH View

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31XX

Key Series

Number

GENERAL INFORMATION

1.3

PUBLICATION NUMBERS

Year Model Model No. Owner’s

Manual PN

Parts

Manual PN

Parts

Micro Fiche PN

2003

9917574 9917576 9917577

NOTE: When ordering service parts be sure to use the correct parts manual.

REPLACEMENT KEYS

Replacement keys can be made from the original key. To identify which series the key is, take the first two digits

on the original key and refer to the chart to the right for the proper part number. Should both keys become lost,

replacement of the ignition switch assembly is necessary.

Series # Part Number

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF

FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,

suspension, and engine sections.

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)

#10 - 24 27 (3.1) 43 (5.0) 60 (6.9).............. ................ ..............

#10 - 32 31 (3.6) 49 (5.6) 68 (7.8).............. ................ ..............

Torque ft. lbs. (Nm)*

1/4 - 20 5 (7) 8 (11) 12 (16).............. .................. ................

1/4 - 28 6 (8) 10 (14) 14 (19).............. .................. ..............

5/16 - 18 11 (15) 17 (23) 25 (35).............. ................ ..............

5/16 - 24 12 (16) 19 (26) 29 (40).............. ................ ..............

3/8 - 16 20 (27) 30 (40) 45 (62).............. ................ ..............

3/8 - 24 23 (32) 35 (48) 50 (69).............. ................ ..............

7/16 - 14 30 (40) 50 (69) 70 (97).............. ................ ..............

7/16 - 20 35 (48) 55 (76) 80 (110).............. ................ ..............

1/2 - 13 50 (69) 75 (104) 110 (152).............. ................ .............

1/2 - 20 55 (76) 90 (124) 120 (166).............. ................ .............

Metric / Torque 6 x 1.0. 72-78 In. lbs. 8 x 1.25 14-18 ft. lbs 10 x 1.25 26-30 ft. lbs.

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GENERAL INFORMATION

1.4

PREDATOR MODELS

PREDATOR 500

TROY LEE LIMITED EDITION

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GENERAL INFORMATION

1.5

MODEL: 2003 PREDATOR 500..........

MODEL NUMBER: A03GJ50AA.

ENGINE MODEL: ES50PLX..

Catagory Dimension

Length 71.5 in./182 cm

Width 47.5 in./121 cm

Height 45 in./114 cm

Seat Height 32 in./81.28 cm

Wheel Base 51 in./130 cm

Ground Clearance 4.5in./11cm

Dry Weight 415 lbs./188 kg

Fuel Capacity 3.25 gal./12.3 ltr

Oil Capacity 2.25 qts./2.1 ltr

Coolant Capacity 2.25 qts./2.1 ltr

Dune Package Shown

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