Polaris 500 manual

2003 PRED A T OR SER VICE MANU AL 2003 PRED A T OR SER VICE MANU AL PN 9918062 PN 9918062 2003 PREDA TOR 500 SERVICE MANU AL PN 9918062 2003 PREDA TOR 500 SERVICE MANU AL PN 9918062 PN 9918062 PN 9918062 Printed in the USA Printed in the USA 230486_cov_01c.qxd 11/19/02 11:35 AM Page 1[...]

2003 PREDA T OR SERVICE MANUAL Foreword This m anual is designed primarily for us e by certif ied Polaris Mast er Serv ice Dealer technicians in a properly equipped shop and should be kept av ailable for ref erence. All ref erences t o lef t and right side of the vehic le are f rom the oper ator ’s perspec tive when s eated in a normal r iding po[...]

UNDERST ANDING SAFE TY LABELS AND INSTRUCTI ONS Thr oughout thes e instruc tions, import ant inf ormation is brought t o your at tent ion by the f ollowing symbols : The Saf ety Aler t Symbol means A TT ENT ION! BECO ME ALERT! YO UR SA FET Y IS INVO L VED! DANGER Failur e to follow DA NGER inst ruct ions will result in sev ere injury or deat h to t[...]

CHAPTER I NDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE/TRANSMISSION CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 BRAKES CHAPTER 7 ELECTRICAL Enfocus Software - Customer Support[...]

Enfocus Software - Customer Support[...]

1 GENERAL INFORM A T ION 1.1 CHAPTER 1 GENERAL INFORMA TION Model Identificati on 1.2 ....................... Serial N umber Location 1.2 ................... Publi cation Numbers 1.3 ..................... Replacement Keys 1.3 ....................... Standard T orque Specific ations 1.3 ............ Predator Models 1.4 ......................... Spec[...]

GENERAL INFORM A T ION 1.2 MODE L IDE NTIF ICA TION The m achine model number m ust be us ed with any corr espondence regarding warr anty or serv ice. Machine Model Number I dentif ication Y ear Desi gnation Basic Chassi s Designat ion Engine Desi gnation A0 3G J5 0 A A Emissi ons & Model Op ti o n ENG INE DESIGN A TION NUMBER ES50PLE 01 Single[...]

31XX Key Ser ies Number GENERAL INFORM A T ION 1.3 PUB LICA TION NUMBE RS Y ear Model Model No. Owner’ s Manual PN Part s Manual PN Part s Micr o Fiche PN 2 0 0 3 P R E D A T O R A 0 3 G J 5 0 C A 9 9 1 7 5 7 4 9 9 1 7 5 7 6 9 9 1 7 5 7 7 2003 P R E D A T O R A 0 3 G J 5 0 C A 9917574 9917576 9917577 NOTE: When ordering ser vice part s be sure t [...]

GENERAL INFORM A T ION 1.4 PRED A TO R MODELS PRED A TO R 500 PRED A TO R 500 TRO Y LEE LIMITED ED ITION Enfocus Software - Customer Support[...]

GENERAL INFORM A T ION 1.5 MODEL: 2003 PR EDA TOR 500 .......... MODE L NUMBER: A03GJ50AA . ENGINE MODEL: ES50PLX .. Ca tagory Dimensi on Length 71. 5 in./ 182 cm Width 47.5 i n./121 cm Height 45 i n./1 14 cm Seat Height 32 in. /81.28 cm Wheel Base 51 in. /130 cm Ground Cl earance 4 . 5i n . / 1 1c m Dry W eight 415 lbs. /188 kg Fuel Capacit y 3.25[...]

GENERAL INFORM A T ION 1.6 MODEL: 2003 PR EDA TOR 500 .......... MODE L NUMBER: A03GJ50AA . ENGINE MODEL: ES50PLE01 .. Engine Platform Fu ji DOHC 4 stroke Engine Model Number ES50PLE 01 Engine Dis placement 499cc Number of C ylinders 1 Bore & Strok e (mm) 99.2 x 64. 6 mm Com pressio n Rati o 10.8: 1 Co mpr essio n Pre ssure 130 psi Engine Idle [...]

GENERAL INFORM A T ION 1.7 SAE T AP DRIL L SIZES Thread Size/Drill Size T hrea d Si ze/Dr ill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/1[...]

GENERAL INFORM A T ION 1.8 CO NVER SION T ABL E Uni t of Measu re Multiplie d by C onver ts to ft. lb s. x1 2 =i n .l b s . in. lbs. x .0833 = ft. lb s. ft. lb s. x1 . 3 5 6 =N m in. lbs. x .01 15 =k g - m Nm x .7376 = ft. lb s. kg-m x7 . 2 3 3 = ft. lb s. kg-m x 86.796 =i n .l b s . kg-m x9 . 8 0 7 =N m in. x2 5 . 4 =m m mm x .03937 =i n . in. x2 [...]

GENERAL INFORM A T ION 1.9 GLOSSAR Y OF TERMS ABDC: After bottom dead center . ACV : Al ternating current volt age. Altern ator: Electri cal generator producing v oltage alternating current. A T DC: A fter top dead center . BBDC: Before bottom dead center . BDC: Bottom dead center . BTDC: Before top dead center . CC: Cubic centi meters. Center Dist[...]

GENERAL INFORM A T ION 1.10 NOTES Enfocus Software - Customer Support[...]

2 MAINTENANCE 2.1 CHAPTER 2 MAINTENANCE Periodi c M aintenance Chart 2.2-2.3 ............... Pre-Ride Inspection 2.4 ...................... Lubricant and Maintenance P roduct Numbers 2.5 Special T ools 2.6 ............................ Lubrication C harts 2.7-2.8 ........................ Clutch Freeplay Adj ustment 2.9 ............... Throttle Inspe[...]

MAINTENANCE 2.2 PE RIODI C MAINT ENANCE CHART Inspec tion, adjus tment and lubricat ion interv als of impor tant c omponent s are list ed in the f ollowing chart. Maint enance interv als are based upon aver age riding conditions and vehic le speed. The following sy mbols de note potentia l item s to be awa re of during maint en an ce: H = CAUTI ON:[...]

MAINTENANCE 2.3 PE RIODI C MAINT ENANCE CHART CONT ’D ELECT RICAL Item Maintenance Interval (Which ever comes fir st) Rema rks E Spark Plug 100 hrs 12 months 1000 (1600) Inspec t - R eplace if nec ess ary " Wiring 100 hrs 12 months 1000 (1600) Inspec t for abras ion, routing, s ecur ity . Apply Dielec tric greas e to c onnector s that are su[...]

MAINTENANCE 2.4 PRE -RIDE / DAI L Y INSPECTIO N Perf orm t he following pre-r ide inspection daily , and when servicing t he v ehicle at each scheduled maintenance. G T ir es - check condit ion and pressures G Fuel and oil t anks - f ill both tank s to t heir proper lev el; Do not ov erfill oi l tank G All brakes - c heck operation and adjust ment [...]

MAINTENANCE 2.5 POL ARIS L UBRICANTS ,M AINTE NANCE AND SERVICE PRODUCTS Part No. Descri ption Engine Lubr icant 2874414 Engine Oi l (Quar t) PS 4 S ynthet ic (4- - Cycle) 2874415 Engine Oi l (Gal lon) PS 4 Synt hetic ( 4 - - Cycle) Grease / Special ized Lubri cants 2871322 Premi um All Season Grease (3 oz. cart ri dge) 2871423 Premi um All Season [...]

MAINTENANCE 2.6 SPECIA L T OOLS P ART NUMBER T OOL DESCRIPTION CHAPTER TOOL USED IN 8712100 or 8712500 T achometer 2, 7 2200634 V al ve Seat Recondit ioning Ki t 3 PU - - 45257 V alve Spr ing Compr essor 3 P A- - 46075 Flywheel Pul ler 3 P A- - 46087 Crankcase Separ ator 3 2870390 Pist on Support Bl ock 3 2872105 W ater Pump Mechanical Seal Pul ler[...]

MAINTENANCE 2.7 LUBRI CA TION 1. Engine Oil and Fil ter ¡ 2. Brake Flui d © (Ri ght hand and Foot Brake Master Cyl inder) 3. Rear Dri ve Chain Ill. # Item Lube Rec. Method Frequency* 1. Engine Oil / T ransm ission Polar is PS - - 4 Synthet ic Check dipst ick and add to proper l evel. Perf orm break- in oil /fi lter change at one hour; change oil [...]

MAINTENANCE 2.8 LUBRI CA TION, CON T . 5. Upper Contr ol Arm 6. Lower Contr ol Arm 8. Upper Steer ing Post Bushing 7. Rear Axle Eccentr ic Ill. # Item Lube Rec. Method Fr equency* 5. Upper Contr ol Arms Polar is All Season Grease ¢ Locate f itt ings and grease (als o grease aft er was hing A TV) Every 3 mont hs ¡ 6. Lower Contr ol Arms Polar is A[...]

MAINTENANCE 2.9 CLUTCH ADJUS TME NT Clu tch Lever Fr eeplay 1. Measur e clutch lev er freeplay between t he perch and the lever (A) . This dis tance should be 1/ 8 s - 3/16 s (3.1 mm - 4.7 mm). C B A 2. If adjust ment is required, s lide the clutc h perch pivot boot down the clutch cable to acc ess the clutc h adjustm ent scr ew (B) and lock ring ([...]

MAINTENANCE 2.10 CARBURETOR PI LOT S CREW ADJUST MENT Pilot Scr ew FRON T (Engine) Ill. 2 NOTE: Pilot scr ew is covered by a wels h plug. P lug remov al will be requir ed t o perfor m t hese procedur es. 1. Star t engine and warm it up to operating tem perature ( about 10 minut es). 2. T ur n pilot scr ew in (clockwis e) until light ly seated. T ur[...]

MAINTENANCE 2.1 1 NOTE: Be sure the engine is at operat ing tem perature. See I dle Speed Adjust ment. 4. Loosen lock nut on in-line cable adjus ter ( Ill. 1) . 5. T ur n adjuster unt il 1/16 s to 1/8 s freeplay is achieved at thumb lever. (Ill. 2). Af ter making adjustm ents, quickly act uate t he t humb lever sever al times and r everify fr eepla[...]

MAINTENANCE 2.12 5. Revers e the procedur es to inst all the f uel valve. 6. Star t engine and inspec t for leak s. CARBURETOR DRAINI NG The carburetor f loat bowl s hould be drained periodically to rem ove moist ure or sedim ent f rom the bowl, or bef ore ext ended periods of s torage. NOTE: The bowl drain scr ew is loc ated on the bottom left sid[...]

MAINTENANCE 2.13 SP ARK PLU G INSPECTION Spark Plug R emoval and Rep lacement 1. T ur n the fuel v alve to O FF . 2. Remove t he front cab. 3. Move t he fuel valv e hose clamp (1) f orward and gently remove t he hos e from the f uel valv e fitt ing on the gas t ank. 1 2 3 4. Remove t he vent hos e (2) fr om the instr ument panel, t aking note of t [...]

MAINTENANCE 2.14 New Batteri es: Batteries mu st be ful ly charg ed bef ore us e or batte ry life will be reduc ed by 10-30% o f ful l p oten tial . Charge batter y for 3 - - 5 hours at a c urre nt equiva lent of 1/10 of the bat te ry ’ s rate d a mp/hour ca pac ity (i.e. 9 amp hr x .10 = .9 a mp c harging). Do not us e the a lterna tor to ch arg[...]

MAINTENANCE 2.15 3. Inst all batt ery in vehic le with pos itive t erminal towar d the f ront. Coat threads of bat ter y bolt with a corr osion resist ant dielect ric greas e. Diel ectric G rease (PN 2871329) 4. Connect t he batt ery cables . ENGI NE -T O -FRAME GROUND Inspec t engine-t o-fr ame ground cable connec tion. Be sure it is clean and tig[...]

MAINTENANCE 2.16 COO LING SYSTEM H OSES Inspect a ll hose s for cracks, deteri oration, ab rasion or leaks. Replace if nec essary . 1. Check t ightness of all hose clam ps. 2. Do not over -tight en hose c lamps at r adiator or radiat or fit ting may dis tort , causing a r estric tion or leak. Radiat or hose clam p torque is 36 in. lbs. ( 4 Nm). RAD[...]

MAINTENANCE 2.17 COOLING SYSTEM PRESSU RE TEST See Chapt er 3 for t esting pr ocedures. RADIA TOR SCREE N REMO V AL 1. Remove t he 4 s crews ret aining t he radiator scr een for acc ess to the radiat or f ins when cleaning. AIR F IL TE R AND PRE - - FI L TER SER VICE It is r ecommended t hat the air f ilter and pre - - filt er be inspect ed frequen[...]

MAINTENANCE 2.18 CRANKCASE BRE A THER FIL TER INSPEC TION Predat or A TV engines ar e equipped with a crankcas e breather f ilter in the air box . The filter is similar in appearance t o a small f oam block, and is vis ible on the left side (Loc ation G, Ill 1) . The air br eather f ilter should be inspected or replaced whenever the air f ilter is [...]

MAINTENANCE 2.19 STEERIN G The s teering com ponents should be checked periodically f or loose f astener s, worn t ie rod ends, ball joints, and damage. A lso check t o make s ure all cot ter pins are in place. If c otter pins ar e remov ed, they must not be r e-used. A lways use new cot ter pins . Replace any worn or damaged steer ing com ponents.[...]

MAINTENANCE 2.20 METHOD 2: CHALK 1. Place m achine on a smoot h level surf ace. 2. Set handlebars in a st raight ahead position and secur e handlebars in this pos ition. NOT E: The steer ing post arm “f rog” can be used as an indicator of whether t he handlebar s are s traight . The f rog should be cent ered with equal clear ance between t he s[...]

MAINTENANCE 2.21 CAMBE R AND CASTE R The c amber and cast er are non-adjus table. TOE AL IGNM ENT ADJUST MENT If toe alignment is incorrect , measure t he distanc e between vehic le center and each wheel. T his will t ell you which t ie rod needs adjust ing. NO TE: Be sure handlebars ar e straight ahead before det ermining which tie r od(s) need ad[...]

MAINTENANCE 2.22 BRAKE SY ST EM INSPEC TION The f ollowing checks ar e recomm ended to keep t he brake system in good operat ing c ondition. Service lif e of brake system component s depends on operating conditions . Inspec t brakes in ac cordance wit h the maint enance schedule and bef ore each ride. G Keep fluid lev el in t he m aster c ylinder r[...]

MAINTENANCE 2.23 Ble eding: If fr ee play is c orrect and brake pedal travel is st ill excess ive, air may be tr apped somewhere in the system. Bleed t he hydraulic auxiliary brake system in a convent ional manner , following the pr ocedure outlined in Br ake Chapter 6. SUSPEN SION: SPR ING PRELOA D ADJUS TME NT Oper ator weight and v ehicle loadin[...]

MAINTENANCE 2.24 SPRO CKET IN SPECTIO N Inspec t the sprock et for worn, broken or bent teet h. Chain T ens ion Limit: 1/4 s (6mm) Inspec t chain f or exces sive wear , mis sing o- - rings, et c. T o check f or wear , pull upward on the chain. Replace sproc ket if chain movement exc eeds 1/4 s (.6 cm). DRIV E CHAIN INSPECTION The c hain must be r e[...]

MAINTENANCE 2.25 B C A B C A C ADJUST MENT P ROCEDURE - SWIN GAR M / REA R AX LE Loo sen Eccentric cl amp bolts (Step 2 ) 1. Loosen tw o eccentr ic locking bolt s. 2. Inser t a pin punch int o t he eccent ric axle housing. Step 1 Step 2 3. Roll the v ehicle ahead or back t o adjus t chain slack t o the pr oper dimension. 4. T ight en the ecc entric[...]

MAINTENANCE 2.26 It has eight possible positions ranging fr om pos ition 1 (sof test ) to 8 ( firmes t). The com pression damping is fact ory set at posit ion 4. T o adjust , turn the click er drum t o the desir ed sett ing. Adjust CONTROLS Check cont rols for proper operat ion, posit ioning and adjustm ent. Han dlebars If des ired, t he handlebars[...]

MAINTENANCE 2.27 Im properly inst alled wheels could affec t vehicle handling and t ire wear . O n vehic les with tapered r ear wheel nuts , m ake sure tapered end of nut goes int o taper on wheel. Flange Nut s: Flat s ide against wheel TIRE PR ESSURE CA UTION: Maint ain proper tir e pressure. Ref er t o t he warning tir e pressure dec al applied t[...]

MAINTENANCE 2.28 NOTES Enfocus Software - Customer Support[...]

3 ENGINE 3.1 CHAPTER 3 ENGINE T orque Specifications 3.2-3.3 ........................ ES50P L Service Data 3.3 - 3.4 ........................ Special T ools 3.5 ............................... T orque Patterns 3.5 ............................. Piston Identif ication / Compressi on T est 3.5 ........ Cooling System Pressure T est 3.6 ...............[...]

ENGINE 3.2 T ORQU E SPECIFICA TIONS TORQUE SPECIFICA TI ONS Fast ener Thre ad ES50PL Ft. Lbs . (Nm ) Blind Plug (Cr ankcase) 1/8 PT 6.6-1 1.1 (9-15 Nm) Blind Plug (O il Filt er Cover) 1/4 PT 12. 5-17 (17- 23 Nm) B e a r i n gS t o pP l a t e s 6m m 8.1-9. 6 (1 1-13 Nm) Camshaf t Chain T ensioner B lade Bolt 8mm 10-12.2 (13. 5-16.5 Nm ) Camshaf t Ch[...]

ENGINE 3.3 T ORQU E SPECIFICA TIONS TORQUE SPECIFICA TI ONS Fast ener Thre ad ES50PL Ft. Lbs . (Nm ) V alve Cover 6mm 6.6-8. 1 (9-1 1 Nm) W at er Pump I mpeller 6mm 6.6-8. 1 (9-1 1 Nm) W at er Pump Hous ing Cover 6mm 6.6-8. 1 (9-1 1 Nm) ES50 PL ENGIN E SERVIC E DA T A Cylind er Head / V alve ES50PL Cam shaft Cam lobe height In Std 1.667-1.671 s ( 4[...]

ENGINE 3.4 ES50 PL ENGIN E SERVIC E DA T A V alve Sp ring Overall l ength Inner 1.575 s (40 .0 mm) Lim it = - - .079 s (- -2. 0 m m ) Outer 1.650 s (41 .9 mm) Squarenes s Inner .067- s (1. 7 mm) q Outer .071 s (1. 8 mm) Cyli nder / Pi ston / Connec ting Rod EH50PL 12 Cy li nder Surface war page lim it (m ating wi th cyl inder head) .002 s (.0 5 mm)[...]

ENGINE 3.5 SPECIA L T OOLS P ART NUMBER TOOL DESCRIPTI ON 2872105 Wa te r P um p Mechanical Seal Pul ler 2200634 V al ve Seat Recondit ioning Ki t 2870390 Pist on Support Bl ock P A- - 45958 Cam Chain T ensionor Assembly T ool P A- - 46075 Flywheel Pul ler P A- - 46076 MAG End Crankshaf t Nut Remover /Inst aller P A- - 46087 Crankcase Separ ator P [...]

ENGINE 3.6 COOLING SYSTEM W ARNI NG: Never r emove r adiator cap when engine is warm or hot. T he cooling system is under pressure and s erious burns m ay r esult. A llow the engine and cool ing system to cool b efore servicing . Radiator Ther mostat Cylinder Head Wa t e r Pump Cylinder FLOW RADIA TOR CAP / SYSTEM PRESSU RE TEST 1. Remove r ecovery[...]

ENGINE 3.7 AC CESSIBLE COMPONENTS The following com ponent s ca n be ser vice d or removed w ith t he engi ne in stall ed in th e frame: G Fly wheel G Alte rna tor/Sta tor G Star ter Mot or/S tart er Drive G Wa t e r P um p / Wa t e r P um p Mechanic al Seal* * Mechanical Water Pump Seal Removal T ool ( PN 2872105 ) is r equired to replac e mec han[...]

ENGINE 3.8 ENGIN E INST ALLA TION NOTES Aft er t he engine is installed in t he fram e, rev iew t his checklis t and perf orm all st eps that apply: Gen eral Items G Install pre viously remove d component s using new gas kets, seals, and f asteners where applicable. G Perf orm chec ks on fluid lev els, contr ols, and all im portant areas on the veh[...]

ENGINE 3.9 CRANKSHAF T ST RAIGHT ENI NG Lubricat e the bearings and clamp t he crankshaf t secur ely in the cr ankshaft alignment f ixture. Refer to the illust rat ions below . Cranksh aft Ali gn ment F ixtu re (PN 2870569) NOTE: T he rod pin posit ion in relation t o t he dial indicator position t ells you what act ion is r equired to str aighten [...]

ENGINE 3.10 OIL PUMP PRIMIN G PROCE DURE NOTE :Oil pump pr iming proce dures must be perf ormed w hen ever t he oi l ho se c onnec tion bet wee n the oil ta nk a nd pump inle t has bee n disc onnect ed. 1. Clamp or pinc h off vent line approximat ely 2 I fr om oil tank, between t he end of oil tank vent fit ting and t he vent line. Oil T ank V ent [...]

ENGINE 3.1 1 ES 50PL OIL FLOW ES5 0PL O IL FLOW CHART Oil T ank Oil Hose Crankcase ( Mag Side) Oil Ga llery Oil Pump (Feed) One Way V alve Crankcase ( Clut c h Si de) Oil Ga llery Oil Filte r By pas s De livery P ipe Crankshaft Cyl inder Head Oil Ga llery Crank Pi n Large End Beari ng Ball Bear ing (Mag Si de) Cyli nder Pist on Connecti ng Rod (Sma[...]

ENGINE 3.12 ES50 PL ENGINE EXPLODED VIEW S Crankcase/T ransmission Cyli nder/C ylinder He ad Cr ankshaft and Piston V alve T rain A Enfocus Software - Customer Support[...]

ENGINE 3.13 ENG INE D ISASSEMBL Y REFER TO P AGE 3.6 - - 3 .7 FOR ENGINE REMOV AL / INST AL LA TION NOTES CAM CHAI N TENS IONE R/ CAMS HAFT REM OV AL AND INSPEC TION 1. Remove ignit ion timing ins pection plug f rom recoil housing. T o po siti on cranksh aft at T op Dead Cen ter (TDC) on t he compressi on st roke: 2. Rotat e engine slowly in the di[...]

ENGINE 3.14 4. T o r etract t he plunger , rotat e the s pecial tool clockwis e while holding the t ensioner stationar y . Y ou may also hold t he special t ool st ationary and rot ate the t ensioner ass embly count er- - c lockwise if desired. I MPO RT ANT : Do not grind edges of key f lange into t ensioner to pr event damage t o the tool or loc k[...]

ENGINE 3.15 1. Check r elease cam (A ) for s mooth operat ion thr oughout the ent ire range of m ovement. T he spring ( B) should hold the cam agains t the s top. In t his posit ion, the ac tuator (C) will be held outwar d in the compr ession release m ode. 2. Inspec t lobe on end of r elease cam f or wear . Replace cam assem bly if necess ary . CA[...]

ENGINE 3.16 CYL INDER HE AD INSPEC TION (A) 1. Thor oughly clean cylinder head ( A) surf ace t o remov e all t races of gasket mat erial and c arbon. CAUTI ON: Use c are not t o damage sealing surf ace. CYL INDER HE AD W ARP AGE 1. Lay a st raight edge ac ross t he sur face of the cylinder head at several dif f erent points and measur e warpage by [...]

ENGINE 3.17 4. Using V alve Spring Com pressor ( P A - - 46502 )( A ) , compre ss the valve sp rings and remo ve the split keepers . N OTE: T o pr event loss of t ension, do not compre ss the valve sprin gs more than nece ssary . A 5 . Rem ove s pring retainer , inner and out er springs and spring was her . Spring was her located below A NOTE: The [...]

ENGINE 3.18 3. Check end of valve s tem for flar ing, pitt ing, wear or damage ( A). A B 4. Inspec t split k eeper groove for wear or flaring of the keeper seat area (B) . NOTE : The val ves cannot be r e-faced or end gr ound. V alves m ust be replaced if worn, bent, or damaged. 5. M easure diamet er of valve s tem wit h a micr ometer in t hree pla[...]

ENGINE 3.19 6. Place r etainer on spr ings and install v alve spring compr essor . Compr ess springs only enough t o allow split k eeper installat ion and pr event loss of spring t ension. I nstall s plit keepers with the gap even on both s ides. A 7. Repeat pr ocedure for r emaining valves . 8. When all v alves are inst alled, tap light ly with s [...]

ENGINE 3.20 ES 50PL Adjusting P ad Selection Matrix 1. M easure valve c learance at T DC (Compr ession st roke) using t hickness gauge wit h original adjusting pad ins talled. 2. Ref erence t he measurement and the 3 digit s mar ked on the exis ting adjust ing pad on the m atrix below 3. Selec t a suit able adjusting pad f rom t he matrix below and[...]

ENGINE 3.21 CYL INDER/ PI STON REM OV AL AND INSPEC TION NOTE: Follow engine dis assembly proc edures t o remov e valve cover, camshaf ts and c ylinder head. Removal of c lutch basket is required for this procedur e. 1. Using a 9/32” Allen wrench, rem ove the rear cam chain tens ioner blade fr om the cy linder . 2. Loosen the 3 oil pipe banjo bol[...]

ENGINE 3.22 5. T he oil contr ol ring is a thr ee piece design cons isting of a t op and bott om s teel rail and center expander sect ion. Rem ove the t op rail fir st followed by the bott om rail, then r emove the ex pander . F or installat ion, r efer t o Page 3.35. CYL INDER INSPECTION 1. Remove all gask et m aterial f rom t he cylinder seal ing[...]

ENGINE 3.23 PIST ON/R OD IN SPECTION 1. Measur e piston pin bore. Piston Pin Bore Pist on Pi n Bore: .9055 -.9057 I (23. 001-23.007 mm) 2. Measur e piston pin O .D. Replace piston and/ or piston pin if out of toleranc e. Piston Pin Mea surement Locatio ns Piston Pin O .D. .9053 -.9065 I (22. 994-23 mm) 3. Meas ure pist on ring to groov e clearance [...]

ENGINE 3.24 PIST ON RING IN ST ALLED GAP 1. Place each pis ton ring inside c ylinder using pist on to push r ing squarely int o place. 25-50mm Cylinder Piston Rin g Feeler Gauge Pist on Ri ng In stall ed Gap T op R ing Std : .008 -.012 I (. 20-.30 mm) Li mit: . 027 I (.7 mm) Se cond R ing Std : .014 -.019 I (. 35-.50 mm) Li mit: . 031 I (.8 mm) Oil[...]

ENGINE 3.25 5. Measur e the ID of the bus hing in t he stat or housing (A ) and the crankc ase and record. Measur e in t wo directions 90 q apart to det ermine if cover is out of r ound. Replace cover if clearance is deter mined to be ex cessive. A 6. I nspect gear teet h on star ter driv e gears. Replac e gears if gear t eeth are crac ked, worn, o[...]

ENGINE 3.26 CRANKSHAFT NUT REM OV AL 1. Remov e t he stat or - - side c rankshaf t nut us ing MA G End Cr ankshaf t Nut Rem over/ Inst aller ( PN P A - - 46076 ) while using a s uitable holding fix ture to keep the c rankshaf t f rom tur ning. 2. T o r einstall, use a suit able holding fixt ure and MAG E nd Crankshaf t Nut Remover/ Inst aller ( PN [...]

ENGINE 3.27 6. R emove the cl utch plates and friction d iscs, keeping them in or der . I nspect t he pressur e plates f or wear and warpage. Inspect t he fric tion plates f or wear or damage to fr iction mat erial. If either are damaged or wor n excess ively , replace the com ponents as a s et. NOT E: Removal of t he clutch pac k is not required t[...]

ENGINE 3.28 2. Remove t he 3 bolt s holding t he oil pum p cover . Inspec t t he inside of t he cover f or wear or scoring. 3. Remove t he outer pum p rotor as sembly . Inspect for signs of sc oring or exc ess wear . NOTE : Cross pins f or the pump r otors ar e loose and m ay become los t. K eep pins in a secure loc ation. 4. Remove t he inner pump[...]

ENGINE 3.29 CAM CHAIN/TENSIONER BL ADE REMOV A L 1. Remove bolt secur ing tensioner pivot blade t o crankca se (A). 2. R emove the b lade and i nspect for cracks, wear , or damage. 3. Remove cam chain (B). Ins pect chain f or worn or miss ing rollers or dam age. St retch chain tight on a flat surf ace and apply a 10 lb. (4.53 k g) load. Measur e le[...]

ENGINE 3.30 TRANSM ISS ION REM OV AL/INSPEC TION 1. Remove t he shift f orks, shif t for k tubes and shif t drum f rom t he transm ission assem bly . 2. Remove t he main and counter t ransmiss ion s haft assem blies and disas semble, keeping the parts remov ed in order for ease of reassembly . Inspect the shift f orks , shift drum , shift dogs, gea[...]

ENGINE 3.31 2. Inser t t he “M” and R” s hift f orks ( face up) . 3. I nsert and rot ate the s hift drum t o align t he loc tating pin at appr oximately the 1 o’c lock posit ion. Align t he “L” s hift f ork f irst, t hen align the ot her shift f orks int o the shif t dr um, inst alling each shift f ork pin as they are ass embled. NO TE:[...]

ENGINE 3.32 6. Using MA G End Crank shaft Inst aller (P A - - 46077) , draw the cr ankshaft int o the bearing assem bly by sliding t he collar and t hrust washer over t he cranks haft end, t hreading the inner puller onto t he cranks haft end. Turn the outer nut clockwis e while holding the inner t o pull t he crank shaft int o the bear ing. MAG En[...]

ENGINE 3.33 CRANKCASE BE ARING INSPEC TION/REMO V AL / INST ALLA TION 1. Inspec t the c rankshaf t main bearings, balanc er shaft bear ings, output s haft and pump s haft bearings. NOTE: Due to extr emely close t olerances and minimal wear, the bear ings must be inspect ed visually , and by feel. Look f or s igns of discolor ation, scor ing or gall[...]

ENGINE 3.34 WA T E R P U M P M ECHANI CAL SEAL R EMOV AL W at er Pu mp Mech anical S eal Pu ller: ( PN 2872105) Repl acement T - - Han dle: (PN 2872106) CA UTION: Im proper or careless us e of this tool or procedur e can result in a bent wat er pump shaft . Pump s haft r eplacement requir es engine remov al and crankcas e separa- tion. Use c aution[...]

ENGINE 3.35 6. T ur n t he puller T-Handle clockwis e unt il it contac ts t he water pump shaf t. Continue rotat ing until t he remaining port ion of mec hanical seal has been remov ed from t he cases. (I ll. 5). Ill. 5 7. The Water Pump I nst all Kit ( P N 5131 135 )i s required t o install t he new m echanical seal. This tool is av ailable separa[...]

ENGINE 3.36 4. Check t o mak e sur e t he rings rot ate f reely in the groove when c ompressed Ring Pr ofile T op - - Chrom e Inst all with m ark fac ing up Second - - Cas t Ill. 1 5. Or ientate t he rings f or installat ion by rotat ing until the end - - gaps are 120 degr ees apart. PIST ON INST ALLA TION 1. Clean the gask et sur faces on t he cyl[...]

ENGINE 3.37 3. Apply c lean engine oil to the r ing compress or and instal l the compre ssor accord ing to the manuf acturer s instruc tions. CAUTIO N: V erify al l ring end gaps ar e correct ly locat ed. 4. Apply c lean engine oil liber ally to the cylinder bore and taper ed area of the sleeve. Inst all the cylinder wit h a s light roc king m otio[...]

ENGINE 3.38 CAM CHAI N INS T ALL A TION NOTE: The cams hafts , crankshaf t s procket and clutc h basket mus t be remov ed to perf orm this procedur e. 1. Inst all t he c am c hain by dr opping it down through the chain r oom and over the cranks haft s procket . B 2. Use a suit able device t o hold the c hain in plac e to keep it f rom dropping t hr[...]

ENGINE 3.39 6. Re- - c heck all c am t iming m arks to verify pr oper cam tim ing, and ins tall the cam t ower . Tighten the bolts evenly in a cr iss - - c ross pat tern to specif ication. Do not rota te engine until the ten sion er has b een i nstal led t o avo id ch ain sli p and l oss of timi ng ref erence. 7. Inst all the t ensioner ass embly .[...]

ENGINE 3.40 INT AKE TIMING M ARK EXHAUST TIMING M ARK TIMING PL A TE ( COLD) HEAD COVER FITTI NG SURF ACE A T CYLINDE R HEAD Enfocus Software - Customer Support[...]

ENGINE 3.41 CYL INDER HONE SELECTION AND HONING PRO CEDU RE CA UTION: A hone which will s traight en as well as remove mat erial from t he cylinder is very impor tant. Using a comm on spring loaded glaze break er for honing is not advised for nicasil cy linders. Polaris rec ommends using a rigid hone or ar bor honing machine. Cylinders m ay be wet [...]

ENGINE 3.42 5. Using valve guide driver, drive guides out of t he cylinder head f rom t he combust ion chamber s ide. Be car eful not t o damage guide bore or v alve seat when remov ing guides. 6. Place cylinder head on cy linder head t able. NOT E: Be sur e cylinder head is still at 212 q F (100 q C) bef ore inst alling new guides. 7. Place a new [...]

ENGINE 3.43 G If the conta ct are a of the cu tter is in the same plac e, the v alve guide is dis tort ed fr om improper inst allation and mus t be replaced. Be sur e t he cylinder head is at the pr oper t emperat ure and r eplace the guide. G If t he contact area of the initial cut is great er than 75%, c ontinue to cut the seat unt il all pits ar[...]

ENGINE 3.44 TROUBLESHOOTI NG Engine T urns Ove r But Fails to Star t G No fuel G Dirt in f uel line or filt er G Fuel will not pass t hrough fuel v alve G Fuel pum p inoperative/ rest ricted G T ank vent plugged G Carb st arter c ircuit G Engine flooded G Low c ompress ion (high c ylinder leakage) G No spark ( Spark plug f ouled) Engine D oes N ot [...]

ENGINE 3.45 SP ARK PLU G FOULING G Spark plug c ap loose or fault y G Choke cable adjust ment or plunger/ cable stic king G For eign material on c hoke plunger seat or plunger G Incor rect spark plug heat range or gap G Carburet or inlet needle and s eat worn G Jet needle and/ or needle jet worn or improper ly adjusted G Excessive ca rbure t or vib[...]

ENGINE 3.46 NOTES Enfocus Software - Customer Support[...]

4 FUEL SYST EM/CARBURETI ON 4.1 CHAPTER 4 FUEL SYST EM/CARBURETION Expl oded V iew , Mikuni B SR 42 Carburetor 4.2 .. Fuel T ank Asm. E xploded Vi ew 4.3 ............ Fuel Flow Diagram 4.3 ....................... Special T ool & Jetting Guidelines 4.4 .......... Carburetor Jetting 4.4 ........................ Main Je t / Pilot Jet Part Num bers[...]

FUEL SYST EM/CARBURETI ON 4.2 BSR 42 CARBURE TOR EXPLO DED VIEW Ref. Desc ription Ref. Des criptio n Ref. Descrip tion Ref. Des cription 1. Cover , Diaphragm 17. O-Rin g 2. Spring 18. Cover 3. Di aphragm 19. Screw 4. V alve, Piston 20. A- Shaft, Th rottle 5. Hol der 21. Scr ew 6. Spring 22. Bolt 7. Washer 23. Spring, Throttl e Adjust 8. Washer 24. [...]

FUEL SYST EM/CARBURETI ON 4.3 FUEL T AN K ASSEMBL Y Im pulse Line Fuel V alve Fuel T ank Fuel Line Fue l Pump T ank Cap V ent Line Fuel T ank Fuel V alve Engine Fue l Pump Carburet or Fuel T ank Vent Carburet or V ent Fuel S creens L L Located on upper fr ame FUEL FLOW (Filter Built In) Enfocus Software - Customer Support[...]

FUEL SYST EM/CARBURETI ON 4.4 SPECIA L T OOLS P ART NUMBER TOOL DESCRIPTI ON 2870975 Mity V ac t Pressur e T est T ool 2872314 Carbur etor Float Adjust ment T ool W ARNING Gasoline is ext remely f lammable and explos ive under cert ain conditions . Always s top t he engine and refuel outdoor s or in a well vent ilated area. Do not ov erfill t he ta[...]

FUEL SYST EM/CARBURETI ON 4.5 CV CARBURE TOR SYSTEM FUNCTI ON Carbur etor Component Funct ion System Main Components Main Function Main Affect Float System (Lev el Control) Inle t Pipe , Needle and Seat, Fl oat, Float Pi n Ma intain s sp ec ified fuel l evel in fl oat cham- ber (car bu- ret or float bowl) All syst ems All t hrott le ranges V enti n[...]

FUEL SYST EM/CARBURETI ON 4.6 CARBURETOR O PERA TIO N CONT ’D When t he throt tle plat e is opened and engine speed begins to inc rease, the press ure in the v enturi (and ther efore in t he chamber above the diaphr agm) becomes s ignificant ly lower than atmos pheric. Atm ospheric pr essure in t he chamber below the diaphragm f orces the diaphra[...]

FUEL SYST EM/CARBURETI ON 4.7 FLOA T SYSTEM Fuel ent ers the float cham ber (3) by means of the inlet pipe and passage, thr ough a s creen on the bac k of t he inlet needle seat (4) , and around t he inlet needle (2). As t he fuel f ills the f loat chamber, the f loat (1) rises and for ces the inlet needle against the seat , shut ting off the or if[...]

FUEL SYST EM/CARBURETI ON 4.8 CARBURETOR DISASSEMBL Y CONT’ D 2. Remove f loat bowl. Remove t he float pin s crew . The f loat and f loat pin can be rem oved. Remo ve Screw Float P in 3. Remove inlet needle s eat retaining scr ew along with plat e, and car efully rem ove needle seat . NOTE: Do not use a pliers to rem ove t he seat or permanent da[...]

FUEL SYST EM/CARBURETI ON 4.9 CARBURETOR INSPEC TION 1. Inspec t jet needle and needle jet f or wear . Look for disc oloration, shiny spot s, or an ar ea that looks different t han the rest of the needle. The middle t o upper por tion of t he needle c ontact s the needle jet and is t he most likely wear point. I f jet needle shows signs of wear rep[...]

FUEL SYST EM/CARBURETI ON 4.10 FLOA T HEI GHT ADJUST MENT 1. Ilust ra tion 1 : Plac e the the thr ottle side o f the carbur etor on a level s urface t o rem ove weight fr om float ar m. I n this posit ion, the f loat tongue will rest slight ly outward. Carburet or Level Flo at Outw ard Ill. 1 2. Illust ra tion 2 : W ith the c arburetor st ill r est[...]

FUEL SYST EM/CARBURETI ON 4.1 1 fit ting. A pply 5 P SI pres sure to inlet fit ting. T he needle and seat s hould hold pr essure indef initely . If not , inspect needle and seat and seat O -ring. Mity V ac t (PN 2870975) FUEL LEVEL A fuel lev el test can be perf ormed on s ome models if the dr ain hose f itt ing is ac cessible. Be s ure to re- atta[...]

FUEL SYST EM/CARBURETI ON 4.12 and check the sur faces f or damage. Replac e diaphragms and gask ets as a set. 4. Reassem ble the pump in t he reverse or der of disassem bly . T ight en all screws ev enly . TROUBLE SHOOTING FUEL ST AR V A TI ON/LEAN MIXTURE Sympt oms: Hard start or no start , bog, bac kfire, popping thr ough intake / exhaust , hesi[...]

5 BODY / STEERING / SUSPENSI ON 5.1 CHAPTER 5 BODY AND ST EERING T orque Specifications and S pecial T ools 5.2 ........ Body Assembl y , Exploded V iew 5.3 ............... Steering A ssembly , Exploded V iew 5.4 ............ Front Hub Removal 5.5 - - 5.6 ......................... Front Hub Assembly/Installati on 5.6 - - 5.7 ............... Steerin[...]

BODY / STEERING / SUSPENSI ON 5.2 T ORQU E SPECIFICA TIONS P ART NUMBER TOOL DESCRIPTI ON Fr ont A-A rm At taching Bolt s 30 ft. lbs . (41 Nm) Fr ont A-Arm Ball Joint St ud Nut 35 ft. lb s. (47 Nm) Handlebar Adjust er Block 10-12 ft . lbs. (14-17 Nm ) Mast er Cylinder Mount Bolts 45-55 in. lbs . (5.2-6.3 Nm) Rear Ax le Nut 8- - 1 0 ft. lbs (1 1 - -[...]

BODY / STEERING / SUSPENSI ON 5.3 BO DY ASSEMB L Y EXPLOD ED VIEW B F A C G H E J I A. Seat B. Seat Release Latc h C. Rear Cab D. Side P anel E. F ront Cover F . Front Cab G. Heel Pock et H. Heel Suppor t I. Gra b Bar J. F uel T ank Support K. Rear F rame L. Foot P eg M. Roc k Guard N. Fr ont Bumper O. F ront Cab Support K L M N O D Enfocus Softwar[...]

BODY / STEERING / SUSPENSI ON 5.4 STEERIN G ASSEMBL Y , EXPLODED VIEW A B C D E F G H A. HANDL EBAR B. BLOCK CLAMPS C. STE ERING B USHING S D. STEERING POST E. CENT ERLINK F . I DL ER ASSEMBL Y G. STEERING MOUNT BLOCK H. TIE ROD ASSEMBL Y I. UPPER A - - ARM J. LOWER A - - ARM K. ST EERI NG KNUCKLE L. BALL JOINT I J K L F E BALL JOINT A- - A RM RE T[...]

BODY / STEERING / SUSPENSI ON 5.5 FRONT HU B REMOV AL / DISA SSEMBL Y 1. Elevat e front end and s afely suppor t machine under footr est / fr ame area. Serious injur y m ay result if machine tips or falls. Be sure m achine is secur e before beginning t his service procedur e. Wear ey e protect ion when r emoving bearings and s eals. 2. Check bearin[...]

BODY / STEERING / SUSPENSI ON 5.6 9. Place a s hop t owel on hub t o prot ect s urfac e. Caref ully pry seal out of hub. Seal 10. Using a brass dr ift, t ap bearing s pacer t o one side to expos e inner bearing rac e. Dr ive bearing out using a drif t t hrough opposit e s ide of hub and disca rd. T ap spacer t o side 1 1. Remove spac er . Drive ot [...]

BODY / STEERING / SUSPENSI ON 5.7 FRON T HUB IN ST ALLA TION 1. Apply gr ease to spindle. 2. Inspec t spindle and bearing s urface f or wear or damage. I nstall t he inner spac er . Insp ect an d Greas e Inner Spac er 3. Inst all hub on spindle. I nstall t he outer s pacer . Oute r- Spacer 4. Inst all t he washer and s pindle nut . T orque t he spi[...]

BODY / STEERING / SUSPENSI ON 5.8 STEERIN G KNUCKL E REM OV AL / I NST ALLA TION Removal 1. Follow t he steps in t he “Front Hub Removal” sect ion to rem ove the hub, if needed. 2. Remove t he upper and lower ball joint cot ter keys and cast le nuts. 3. Lift up on t he upper A - - arm and pull t he top ball joint f rom t he steering k nuckle. P[...]

BODY / STEERING / SUSPENSI ON 5.9 Press Driver Ball Joint Ill. 3 T h ed r i v e rm u s tf i t t h ei n s i d e diamet er of the A - - arm end. Dri ver Placement Co rrec t Ball Joint In stallation 5. Place t he A - - ar m in the c orrect pos ition f or ball joint inst allation. F ace the A - - arm end f lat on t op of t he driver . Car efully dr ive[...]

BODY / STEERING / SUSPENSI ON 5.10 FRON T H UB EXPLODED VIEW Ref. Q ty . Descri pt ion 1. 2 Hub, Dus t Cover 2. 2 Nut, Castle 3. 2 Pin , Cotte r 4. 2 Washer 5. 2 Spacer , Outer 6. 2 Seal 7. 2 Bearing, Ball, Seal ed 8. 2 Hub, Wheel , Front, Indy Red 9. 8 Stud 10. 2 Spacer , T apered 11 . 2 Bearing, Ball 12. 2 Seal 13. 2 Disc, B rake 14. 2 Spacer , I[...]

BODY / STEERING / SUSPENSI ON 5.1 1 A-ARM REP LACEM ENT A. Spri ng B. IFP Shock C. Upper A- - Arm D. Bolt E. A- - Arm Shaft F. B o l t G. Bushing H. Lower A- - Arm I. Lower Ball Joint J. Steer ing Knuckle K. C otter P ins L. Upper Ball Joi nt M. Shock Bolt A B C D E F E H I J K L M G G 30 ft. lb s. (41 Nm) 1 Use new bolt s upon reassembly . 1 2 Use[...]

BODY / STEERING / SUSPENSI ON 5.12 CONCENT RIC SWI NG ARM RE MOV AL A A. Chain Sli d e B. Mount Bolt C. Spacer D. Seal E. Needle Beari ng F . Thrust Bushi ng B C D E F G H I J K Swing Arm G F G. W asher H. Nylok Nut I. Chain Gui de J. Sprocket Guar d K. Swing Arm Bolt & Nut L. Rear Foot Brake Assy . L 95 ft.l bs. (129 Nm) Removal / Disassem bly[...]

BODY / STEERING / SUSPENSI ON 5.13 REAR AX LE REMOV AL/DISA SSEMBL Y 1. Sec urely support rear of m achine with r ear wheels off t he floor . R emove rear wheels and hubs . 2. Remove t he brake caliper bolts and remov e t he brake c aliper . 3. Remove t he mast er link from the driv e chain. Remo ve the drive ch ain. 4. Loosen t he hex screw (A ) t[...]

BODY / STEERING / SUSPENSI ON 5.14 6. Remo ve t he fou r bolts that secu re t he brake di sc (C) to the rear di sc hub a nd remove the brake di sc. NOTE: It is not necess ary to r emove t he brake disc at this tim e, only remove it if needed. C 7. Loosen and rem ove the axle nut (D) with a 1 3/ 4” Wrench ( P N 2870772 ). D 8. Remove t he retainin[...]

BODY / STEERING / SUSPENSI ON 5.15 13. With t he axle out, rem ove the ret aining ring (I ) and sproc ket hub (J ) from the axle. I J REAR AX LE I NST ALLA T ION / ASSEMB L Y 1. Slide the s procket hub (A ) ont o the s procket side of t he axle. Ins tall the r etaining ring (B ) ont o the axle and into the groove of the ax le. A pply Never Seize t [...]

BODY / STEERING / SUSPENSI ON 5.16 7. T ur n the axle nut (G ) outward with the 1 3/4” Wrench ( P N 2870772 ) until t he end of t he axle nut (G ) just c overs the ret aining ring ( H). The ret aining ring should st ill be vis ible under t he ax le nut f rom an angle. 8. T orque the ax le nut (G ) hex bolt to 8 - - 1 0 ft.lbs. (1 1 - - 14 N m) . [...]

BODY / STEERING / SUSPENSI ON 5.17 REA R SWING AR M / AXLE EXPLODED VIEW Ref Qty Desc ipt ion 1. 2 Seal 2. 2 O-Ring 3. 2 Bearing, Cone, T aper 4. 2 Bearing, Cup, T aper 5. 1 Housing, Axle, Rear 6. 1 Fit ting, Lubric ation 7. 1 Axle, Rear 8. 4 Nut, Nylok 9. 1 Sprocke t 10. 1 Hub , Sprocke t 11 . 4 Bolt 12. 1 Ring, Retaining 13. 1 Chain, 94P 14. 1 Li[...]

BODY / STEERING / SUSPENSI ON 5.18 STEERIN G POST ASSEMB L Y Grea se Fitti ng 30 ft. lbs. (41 Nm) 1. T orque t o 50 ft . lbs. 2. Align c otter pin hole. 3. I nstall cot ter pin. Bend both ends of c otter pin around nut in oppo- site dir ections . 4. Check s teering, m ust move f reely and easily from full lef t t o full right without binding. 17 ft[...]

Spacer Nut End 1.300 x . 008 1.300 x . 008 1.100 x . 008 1.00 x . 008 .700 x .008 .800 x .008 Piston .900 x .008 1.000 x . 008 .800 x .008 .900 x . 008 1.25 x . 008 Orific e Rebound Stack Compr ession Stack 1-R 2-R 3-R 4-R 5-R 6-R 4-C 3-C 2-C 1-C 5-C 6-C Pis ton Orie ntation Side with gr eater # of slot s must face nut end Piston * (T oward nut &am[...]

BODY / STEERING / SUSPENSI ON 5.20 BODY / STEERING / SUSPENSI ON Option al V alving List ed By Shock Par t Number Refer t o the appr opriate part s manual f or a complet e listing of Fox t shock par ts. Sh ock T ravel L imit ing Sp acer (1/4 s ) - Part Nu mber 5431355 V alve W ash er Part Nu mbers Part No. Descri ption Par t No. Descri ption 150005[...]

BODY / STEERING / SUSPENSI ON 5.21 Keep the par ts in or der as they ar e disassem bled. Note t he dir ection and posit ion of all int ernal part s for reasse mbly . 1 3 4 6 5 5 8 7 Int ernal Float ing Piston (IFP) Shock Body Bleed Screw 2 Body Cap Bearing Cap Jounce Bumpe r Damper Rod Ref. # Qty . Description 1 1 Pressure V a lve 2 2 O- Ring 3 1 R[...]

BODY / STEERING / SUSPENSI ON 5.22 3. Remove v alve and s ealing O-ring f rom body c ap. 4. Ext end shock s haft by pulling up on shock eyelet. Using a 1 s (25 mm ) or adjustable wrenc h, loosen shaft bearing c ap. 5. II f body of shoc k start s to unscrew from body , tight en and try again. T o k eep body f rom turning, it m ay be necessar y to us[...]

BODY / STEERING / SUSPENSI ON 5.23 9. I f bearing c ap and/or seals ar e to be r eplaced, remov e nut, was her , and valv e pist on with valving washers and set aside. Keep washers in order and note or ientation of s lots in pist on f or proper re-ins tallation. The side wit h the greater number of slot s must f ace the dam per rod nut ( toward I F[...]

BODY / STEERING / SUSPENSI ON 5.24 8. Posit ion shock in vise with Body Clamp T ool . Clean body clam p tool befor e installing. Shoc k Body C lamp T ool (PN 2871071) 9. Using an open end or lar ge adjustable wrench, unscr ew the body cap f rom t he body . 10. Inspect O- ring in body cap f or damage. 1 1. Note locat ion of Allen s crew in inter nal[...]

BODY / STEERING / SUSPENSI ON 5.25 3. Scr ew in bearing cap by hand until O-ring is fully seated. 4. I nvert shock and mount bear ing cap flat s lightly in vise. C aution: V erif y damper r od is fully ex tended. 5. Fill wit h shock f luid to approx imately 1 s (2.54 cm) fr om end of body . 6. Inse rt I FP . 7. Inst all body cap until O- ring is li[...]

BODY / STEERING / SUSPENSI ON 5.26 12. Insert I FP t ool and slowly push I FP to specif ied depth. Place a shop t owel ov er the end of IF P tool to cat ch any s pilled shock oil. 13. With the I FP set and the bleeder scr ew removed, slowly s troke s hock to f orce air t hrough pist on orif ace. Move t he shock body s lowly t o prevent aerat ion of[...]

BODY / STEERING / SUSPENSI ON 5.27 17. Set t he nitrogen t ank pressur e regulator to 200 - 205 PSI . 18 . In sert the Fox t Char ging Needle ( PN 7052069 ) and charge wit h nitrogen to 200 PS I. P ull the needle str aight outward and remove f rom the press urizing valve while holding t he pressur e hose on the f itt ing. Do not inser t the needle [...]

BODY / STEERING / SUSPENSI ON 5.28 FOX t FRON T SHO CK EXPLODED VIEW Ref. Qty Descrip tio n Ref . Qty Descrip tio n 15. 1 Nylon Preload Ring 1. 1 Body Cap 16. 1 Floating Pis ton 2. 1 O - - Ring 17. 1 Ext ernal Bearing 3. 1 O - - Ring 18. 1 Screw , O- - ring 4 . 1 Body 19. 1 Screw 5. 1 Back Up Plate 20. 4 A ir V alve 6. 1 Piston 21. 1 Bushing 7. 1 G[...]

BODY / STEERING / SUSPENSI ON 5.29 FOX t REA R SHO CK SER VICE When per forming m aintenance on F ox t shocks, use the G as Shock Rechar ging Kit ( PN 2200421 ), as it contains the nec essary v alves, pr essure gauge, and fittings to deflate an d pressurize sho cks. W ARNI NG: Fox t sho cks contain high p ressure nitr ogen gas. Ext reme caut ion mu[...]

BODY / STEERING / SUSPENSI ON 5.30 FOX t REA R SHO CK SER VICE 1. Read thr ough all of t hese instr uctions firs t t o fam iliarize yours elf with t he rebuild procedur e. Make s ure you have a clean wor k area, and all of the neces sary t ools are available. Al ways u se prope r sa fety equipme nt when wor king on shoc k absor bers . 2. Clean the [...]

BODY / STEERING / SUSPENSI ON 5.31 FOX t REA R SHO CK SER VICE 15. G ently t ap the res ervoir end cap wit h a rubber mallet t o expose the wire retaining ring. Locat e the end of the ring and push inwar d wit h fingert ip. Remove t he retaining r ing. A sc ribe or dent al pick can also be used f or t his s tep, but use ext reme caution not to scr [...]

BODY / STEERING / SUSPENSI ON 5.32 FOX t REA R SHO CK SER VICE 21. Remove the I FP o - - ring using a s cribe or dental pick. U se extreme cau t io n not to scratch the o- - r ing groove. S cratc hing t he o- - ring groove will compro mise the performance o f your shock. Place t he IF P on clean, lint fr ee paper towel. 22. Push the compr ession da[...]

BODY / STEERING / SUSPENSI ON 5.33 FOX t REA R SHO CK SER VICE 30. Push on the pr otruding adjust er drum stem to remov e it f rom CD housing. ( Fig. 12) 31. Remove the adjus ter drum sealing o- - ring using a scr ibe or dental pick . Use ext reme caut ion not t o scr atch o - - ring groove. Clean the adjus ter drum with cleaning s olvent. 32. Remo[...]

BODY / STEERING / SUSPENSI ON 5.34 FOX t REA R SHO CK SER VICE 37. Fill the t wo holes t hat ar e on eit her side of t he adjuster - - drum st ub with assem bly grease. I nsert one new spring int o each hole. Place one new clicker ball in the cent er of each spring. Orient the #1 position of k nob with t he position indicat or of the CD housing. ( [...]

BODY / STEERING / SUSPENSI ON 5.35 FOX t REA R SHO CK SER VICE 44. Slide only the t ip of Phillips Head S crewdriv er into hole at end of shaf t. Hold t he pist on assem bly under t he top - - out plat e and lift upwar ds. S lide the piston as sembly ont o the shaf t of the screwdr iver . Remove the sc rewdriver f rom shock s haft while support ing[...]

BODY / STEERING / SUSPENSI ON 5.36 FOX t REA R SHO CK SER VICE 50. Once t he eyelet has been giv en sufficient tim e to cool, us e an adjustable wrench t o rem ove it from the shaf t. Clean the t hread- - loc king compound fr om eyelet and shaf t threads , and set it aside. 51. Using a scribe or dent al pick , push the expos ed end of t he rebound [...]

BODY / STEERING / SUSPENSI ON 5.37 FOX t REA R SHO CK SER VICE 57. Using a small pair of needle nos e pliers, gr ab the lip of t he U- - cup s eal in the bearing ass embly . Use an inward pry ing motion t o remove the seal. (F ig. 26) Use a s cribe or a dent al pick to remove t he o- - r ing seal from cent er of the bearing assembly . (F ig. 27) NO[...]

BODY / STEERING / SUSPENSI ON 5.38 FOX t REA R SHO CK SER VICE 62. Clamp s haft eyelet sec urely in vise, and place seal bullet t ool on end of s haft. 63. Slide bott om- - out bumper onto s haft. NO TE: The taper ed side of the bott om - - out bumper should be facing away fr om the shaf t eyelet . 64 . Lubr icate t he seal bullet t ool with ass em[...]

BODY / STEERING / SUSPENSI ON 5.39 FOX t REA R SHO CK SER VICE 68. Lubricate t he flat end of the met ering rod with a small amount of ass embly lube. Insert m etering rod, flat end fir st, int o the shaft. (F ig. 35) Push needle down into t he shaft wit h a blunt object , until you f eel the m etering r od push pas t t he o- - ring seal. I nstall [...]

BODY / STEERING / SUSPENSI ON 5.40 FOX t REA R SHO CK SER VICE 73. Set compr ession adjust er t o the #3 posit ion. Fir mly grip t he reservoir hose at t he CD housing. Wit h your ot her hand pull back f orcef ully on t he IFP Dep th Setti ng T ool ( PN 2871351 ), unt il the edge of t he I FP is clos e to being flush with t he edge of t he reserv o[...]

BODY / STEERING / SUSPENSI ON 5.41 78. Push the I FP f urther int o the reser voir . As y ou do this, the shaf t and bear ing assembly s hould ris e until t he bear ing assembly engages with the wire ret aining ring inside the body t ube. Remove t he IF P depth s etting t ool by rot ating it 90 degr ees. 79. Inst all t he reserv oir end c ap wit h [...]

BODY / STEERING / SUSPENSI ON 5.42 well- - v entilated ar ea to allow t he solv ents t o evaporat e. 85. Clamp the body c ap of shock secur ely in vice, wit h shaft end up. Us e pin spanner tool to sec ure the bearing cap t o bearing. Using a 3/32” hex key , tight en t he set scr ew t o lock the bearing cap int o place. 86. Compr ess shock com pl[...]

BODY / STEERING / SUSPENSI ON 5.43 FOX t REAR SH OCK EXPLO DED VIEW 35. 69. 27. 23. 45. 57. 55. 68. 52. 51. 65. 56. 71. 70. 43. 18. 31. 30. 32. 29. 22. 21. 15. 16. 14. 12. 11 . 17. 20. 33. 19. 37. 40. 7. 5. 6. 39. 41. 8. 9. 50. 49. 10. 61. 28. 24. 26. 25. 53. 54. 46. 47. 4. 1. 3. 48. 44. 2. 13. 38. 42. 36. 60. 59. 66. 64. 62. 58. 63. 34. 61. 23. 23[...]

BODY / STEERING / SUSPENSI ON 5.44 FOX t REA R SHO CK EXPLODED VIEW , CONT ’D Ref. Qty Descrip tio n Ref . Qty Descrip tio n 1 Shock, Rem ote Reservoir, Rear 1. 1 Va l v e 2. 1 Plate, Dam p 3. 5 Va l v e 4. 1 Screw 5. 1 Screw 6. 1 O-Ring 7. 2 Ball 8. 2 Sprin g 9. 1 Drum, Dam ping 10. 1 Housing, CD 11 . 1 O-Ring 12. 1 Pist on, Float ing 13. 1 Scre[...]

6 BRAKES 6.1 CHAPTER 6 BRAKES Specifi cations/T orques 6.2 .............. Special T ools 6.2 ...................... Brake System S ervice Notes 6.3 ........ Brake Noise T roubleshooting 6.3 ........ Hydraulic B rake System Operation 6.4 ... Fluid Replacement/B leeding Procedure 6.5 -6.6 Master Cyli nder Removal 6.7 .......... Master Cylinder Instal[...]

BRAKES 6.2 SPECIFIC A TIONS Front Brake Calipe r Item Standard Service Limit Brak e Pad Thick ness .29 8 s /7 . 6 m m .180 s /4 . 6 m m Brak e Disc Thic kness .150- .165 s / 3.810- 4.166mm .140 s / 3. 556mm Brak e Disc Thicknes s V ar iance Bet ween Measur ements - .00 2 s / .051m m Brak e Disc Runout - .010 s /. 5 0 m m Rear B rake Caliper Item St[...]

BRAKES 6.3 BRAKE SYSTEM SER VICE NOTES Disc bra ke systems are lig ht weig ht, lo w maint enance, and per form well in the c onditions A TVs rout inely encounter. T here are a f ew things t o remem ber when replacing disc brake pads or performing brake system service to ensure proper system function an d maximum pad servi ce life. G Opt ional pads [...]

BRAKES 6.4 HYDRAUL IC BRAKE SYSTEM OPERA TION A B C D E F Must be clear t o allow proper diaphragm moveme nt Compensat ing port c ompensates for t emperat ure changes by allowing fluid back to m aster c ylinder Moveable Brak e Pad G T ypical Hydraulic Brake S ystem The Polaris brake system c onsists of the f ollowing components or assembli es: brak[...]

BRAKES 6.5 FLUID REPLA CEMENT/B LEEDING PROCE DURE NOTE: When bleeding the brak es or replacing the fluid always start wit h the c aliper far thest from the mast er cylinder . CA UTION: Always wear s afety glasses during t hese procedures. CA UTION: Brak e fluid will dam age finished surfac es. Do not allow brake f luid to com e in contact with f i[...]

BRAKES 6.6 lever . NO TE: Do not releas e lever befor e bleeder scr ew is tight or air may be dr awn into caliper. 9. Repeat pr ocedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as nec essary t o maint ain level in reserv oir . CA UTION: Maint ain at least 1/ 2 s (1.27 cm) of brake f luid in t he reser voir to[...]

BRAKES 6.7 MASTER CYLI NDER REM OV AL 1. Clean mas ter cylinder and r eservoir ass embly . Make sure you have a clean w ork area to disassem ble brake com ponents. 2. Place a shop t owel under brak e line connection at mast er c ylinder . Loosen banjo bolt (A); remove bolt and sealing was hers. A B CA UTION: Brak e fluid will dam age finished surfa[...]

BRAKES 6.8 MASTER CYLI NDER INST ALLA TION 1. Inst all mast er cylinder on handlebar s. T orque mount ing bolts t o 25 in. lbs. (3 N m) . T or que the top bolt fir st. 25 in. lbs . (3 Nm) 15 ft.l bs. (21 N m) NOTE: T o speed up the br ake bleeding pr ocedure t he mast er cylinder can be purged of air befor e brak e line is attac hed. F ill with DOT[...]

BRAKES 6.9 3. Remove the caliper bolts (B) and caliper f rom the mount brac ket. B 4. Wit h pads inst alled, push caliper pist on into caliper bor e slowly using a C-c lamp or locking pliers. Caliper Bore Clamp NOTE: Brake fluid will be f orced t hrough compens ating port into m aster c ylinder fluid reser voir when piston is pus hed back into cali[...]

BRAKES 6.10 FRON T P AD A SSEMBL Y 1. Inst all pads wit h frict ion mater ial facing each other. Inst all t he slide bolts t hrough the brak e pads and tight en the slide bolts hand t ight. Be sure pads and dis c are fr ee of dirt or greas e. 2. Inst all caliper on t he s teering knuc kle, and torque mount ing bolt s. (If pr eviously remov ed.) 18 [...]

BRAKES 6.1 1 FRONT D ISC INSPECTIO N 1. Vi sual ly inspect the b rake disc for ni cks, scr atches, or damage. 2. Measur e the dis c thicknes s at 8 differ ent points around t he pad contact sur face using a 0- 1 s micr ometer . Replace disc if worn bey ond service limit. Brake Disc T hi ckness Ser vice Lim it .140 s / 3.556 mm New .150 -.164 s ( 3.[...]

BRAKES 6.12 FRONT CAL IPE R REM OV AL CA UTION: Use car e when suppor ting vehicle so t hat it does not tip or fall. Sev ere injury may occ ur if m achine t ips or falls. 1. Remove br ake pads. S ee Page 6.8. - - 6.9. A B B 2. Using a line wr ench, loosen and r emove brake line (A) t o caliper . Place a c ontainer under c aliper to cat ch f luid dr[...]

BRAKES 6.13 REAR BRAKE P AD REM OV AL 1. Loosen the c aliper slide bolt with an Allen wrench befor e you remove t he brake caliper. 2. Remove c aliper m ounting bolts and lift caliper off of disc. NOTE: When r emoving caliper , be car eful not t o damage brak e line. S upport caliper so as not to k ink or bend brak e line. 3. Wit h pads inst alled,[...]

BRAKES 6.14 6. Measur e the thic kness of the pad mater ial. Replace pads if worn beyond t he servic e limit. Fro nt Brake P ad Th ickn ess New .298 s /7 . 6m m Ser vice Lim it .180 s /4 . 6m m Measu re Thic kness REAR BRAKE P AD INST ALLA TION 1. Inst all new pads (A ) in caliper body . Slide t he caliper s lide bolts (B ) into t he caliper and ha[...]

BRAKES 6.15 to st op machi ne. Rep eat th is pro cedu re 10 t imes, allowing bra kes to cool suf fic iently af ter ea ch run. REAR CALI PE R REMOV AL 1. Clean caliper ar ea before rem oval. 2. Using a flar e nut wrenc h, remov e the brake lines (A) . Place a cont ainer to cat ch brake fluid draining f rom brake lines . A 3. Remove t he caliper m ou[...]

BRAKES 6.16 3. Remove t he outside dus t boot ( E). E 4. Remove t he piston and dus t seal (F ). F 5. Remove t he caliper body bolts (G ). P ull t he caliper bodies apart (if nec essary) . G 6. Clean the caliper body , pis ton, and r etaining brack et with br ake cleaner or alc ohol. NOT E: Be sur e to clean seal gr ooves in caliper body . FRONT / [...]

BRAKES 6.17 2. Inspect pi st on for nicks, scratch es, we ar or damage. Replac e if damaged or wor n. Insp ect Pi ston 3. Inspec t t he brake disc and pads as outlined f or brake pad r eplacement t his sect ion. See Page 9.9 - - 9.1 1. FRONT / REAR CAL IP ER ASSEMB L Y 1. Reas semble t he two caliper halv es if prev iously disassem bled. T or que t[...]

BRAKES 6.18 REAR BRAKE DI SC INSPEC TION 1. Visually inspect dis c f or scoring, sc ratc hes, or gouges. Replac e the disc if any deep sc ratches are evident . Measur e Thic kness Rear Brak e Disc 2 . U s ea0 - 1 s m icromet er and measure disc thick ness at 8 different point s around perimet er of disc. Replace disc if worn bey ond service lim it.[...]

BRAKES 6.19 FRONT/ REAR BRAKE CALI PER EXPLODED VIEW B A. Anvil Body B. Bushing C. B rake Pads D. Caliper Brac ket E. Piston F . O - - Ring G. Dust B oot H. Caliper Body I. O - - Ring J. Sleeve K. S lide Bolt L. Caliper Bolt M. B leeder Screws N. Circlips A C D E 33 ft.l bs. (45 Nm) 18 ft.l bs. (25 Nm) 27 in.lbs. (3 Nm) APPL Y POLARI S DOT 3 BRAKE [...]

BRAKES 6.20 FRONT BRAKE SYSTEM - - CA LIPER/MAST ER CY LI NDER 18 ft. lb s. 24.8 Nm A B A. M aster Cylinder B. B rake Line C. Pressure Sw itch D. Junc tion Box E. W heel Hub F . Line Retainer G. Banjo Bolt & Washers H. Caliper I. Cali per Mount Bolt C D E F G H 15 ft. lb s. 21 Nm 15 ft. lb s. 21 Nm B B G I Enfocus Software - Customer Support[...]

BRAKES 6.21 REAR BRAKE SYSTEM - - CALIPER /MASTER CYL INDE R 18 ft. lb s. 24.8 Nm A O 8 ft. lbs. 11 N m A. Reserv oir B. Caliper M ount C. Rear Caliper D. Brake Di sc E. B rake Line F . Line Retainer G. Banjo Bolt & Washers H. Mas ter Cylinder C D E F G G H I J K L M N I. Foo t Brak e J. Switch K. Mount Bra cket L. Br ake Pedal Retur n Spring M[...]

BRAKES 6.22 NOTES Enfocus Software - Customer Support[...]

7 ELECT RICAL 7.1 CHAPTER 7 ELECTRICAL Special T ools/Service Notes 7.2 .................. T iming Check Procedure 7.2 - 7.3 ..................... Electrical Switch T esting 7 .3 ..................... Fan Motor Current Draw T est 7.3 ................ Electronic Throttle Ci r cuit S ystem Operation 7.4 .... Ignition System T roubleshooting 7.5 .....[...]

ELECT RICAL 7.2 SPECIA L T OOLS P ART NUMBER TOOL DESCRIPTI ON PV - - 43568 Fluke t 77 Digi tal Mu ltimete r 2870630 Ti ming Li ght 2870836 Ba ttery Hydromet er 2871745 Stat ic Ti ming Light Harness ELECTR ICAL SER VICE NOTES Keep the f ollowing notes in mind when diagnosing an electr ical problem. G Refer t o wiring diagram for st ator and electr [...]

ELECT RICAL 7.3 NEUTRAL POSIT ION INDICA T OR SWITCH T EST 1. V erif y that the t ransmiss ion is in neutr al and t he key is off . Connect an ohm met er lead to t he switc h lead and one t o engine gr ound. Met er resis tance should r ead in m egaohms or no continuit y . 2. Shift the t ransmis sion into gear . The ohm met er should show cont inuit[...]

ELECT RICAL 7.4 6. T ur n ignition key and engine s top swit ch t o “RUN” position. Read the curr ent draw on am meter with fan r unning. 7. During st art - - up, t he amperage should peak then decline rapidly . I f t he motor continues to dr aw more am perage than t he fan circ uit break er rating during st art - - up, r eplace the mot or . 8.[...]

ELECT RICAL 7.5 IGN ITION SYSTEM TROUBLESHOOTI NG No Spar k, W eak or Interm ittent Sp ark G No12 volt power or ground t o CDI G Spark plug gap inc orrect G Fouled s park plug G Fault y spark plug cap or poor connect ion to high t ension lead G Related wir ing loose, disc onnected, short ed, or corr oded G Engine St op switc h or ignition switc h f[...]

ELECT RICAL 7.6 -- + Current Draw I nspection Key Off YTX9- - BS Ill. 1 Curren t Draw - Key Of f: Maximu m of . 01 DCA (10 mA) CHARGING SYSTEM “ BREAK EVEN” TEST CA UTION: D o not allow the ba tte ry cable or ammeter to beco me d isco nn ected wi th the engine r unning. Follow the s teps below as outline d to re duce the cha nce of dam age to e[...]

ELECT RICAL 7.7 FL YWHEEL IDEN TIFICA TION A Flywheel Identification Stamp Location The f lywheel can be ident ified by t he casting m arks in loc ation A. Ref er t o “I .D.” loc ation in chart below . 2003 Engine Applicat ion Ty p e Stamp Comment I.D. Sta mp ES50PL E xter nal T r igger IJ09 DC/CDI Ign K1805 PRE DA TOR DC / CDI IGNITIO N The Pr[...]

ELECT RICAL 7.8 COMPONENTS OF E S50PL AL TE RNA T OR DC/CDI IGNITION Refer t o Page 7. 7 for Flywheel ident ific ation. Resi stor Cap CDI Box Stator Pulse Coil ( T rigger) Air G ap: .016-. 030 s (.4-.75mm) Meter : Ignit ion Coil .3 : Ign itio n Kill Wire (Black) Coil Lead Refer T o W iri ng Diag rams Fo r Sp ecifi ed Stato r Coil Resi stance Starte[...]

ELECT RICAL 7.9 IGN ITION SYSTEM TESTING Whenev er t roubleshoot ing an elect rical problem you should f irst c heck all t erminal connec tions to be s ure they are clean and t ight. Als o be sure that color s match when wires are connected . Use t he following pages as a guide for t roubleshoot ing. The r esistanc e values are als o given on the s[...]

ELECT RICAL 7.10 CHARGING SYSTEM TESTING FLOW CHART Whenever chargi ng system problems are suspect ed, proceed wit h the follow ing system check. Check for owner m odificat ion, and discuss operat ing habits. The bat tery will cont inually discharge if operat ed below the “ Break Ev en” RPM. Con- tinued pr oblems would call f or batt ery inspec[...]

ELECT RICAL 7.1 1 BA TTER Y MAI NTENANCE W ARNING Batt ery elect rolyt e is poisonous. I t contains sulfur ic acid. Serious bur ns can result f rom con- tact wit h skin, eyes or clot hing. Ant idote: Exter nal: Flus h with water. Inte rna l: Dr ink large quantities of water or milk. Follow wit h milk of magnesia, beaten egg, or vegetable oil. Call [...]

ELECT RICAL 7.12 BA TTER Y TESTING Whenev er a servic e complaint is relat ed t o either the start ing or charging syst ems, the bat tery should be checke d f irst. Following ar e test s which can easily be made on a maint enence- - f ree batt ery to det ermine its condition: The O CV T est and Load T es t. OCV - OPE N CI RCUIT V O LTA G E TEST Bat[...]

ELECT RICAL 7.13 W ARNING T o av oid t he possibility of explos ion or s parks, connect posit ive (red) cable f irst and negativ e (black) cable last . 5. Aft er connec ting the bat tery c ables, at tach t he hold down str ap. 6. Route cables so t hey are tucked away in fr ont and behind batt ery . HEADL IGHT ADJUST MENT The headlight beam can be a[...]

ELECT RICAL 7.14 HEADL IGHT LAMP REPLA CEMENT 1. Remove t he wire harness c onnector f rom t he back of the headlight . 2. On t he left headlam p, gras p the bulb housing and turn i t count erclock wise (1) t o remove t he bulb. On t he right headlam p, tur n the bulb housing clockw ise (2) t o remove t he bulb. 1 2 3. Apply dielec tric gr ease to [...]

ELECT RICAL 7.15 CLUTCH S WIT CH TEST 1. Disconnect t he switch by pulling apart the switch bullet connect or . Clutch S witch 2. Using an ohmm eter set t o the ohms scale, connect one lead to ground and one lead to t he switc h bullet connector. Replace switch if ther e is no continuit y or gr eater t han .5 ohms r esist ance. TETHER SWITC H (ACCE[...]

ELECT RICAL 7.16 G Faulty key sw itch G Fault y kill swit ch G Fault y star ter solenoid or st arter motor . G Engine problem - seized or binding (Can engine be rot ated easily ?) G NOT E: The P redator will not push star t or key start if t he battery is disconnect ed or complet ely dead. Start er Moto r T ur ns Over Slowly G Batt ery disc harged [...]

ELECT RICAL 7.17 3. Remove br ush term inal end of housing while holding other t wo sect ions toget her . 4. Remove shims f rom armature shaft. NO TE: All shims m ust be r eplaced during reass embly . BRUSH INSPEC TION/REPLA CEMENT Brush Set 1. Using a digit al mult itest er , measure t he r esistanc e between t he cable t erminal and t he ins ulat[...]

ELECT RICAL 7.18 ARMA T URE TESTING 1. Remove ar mature f rom st art er casing. Not e order of shims on dr ive end for r eassembly . 2. Inspec t sur face of commut ator . Replace if excess ively worn or damaged. 3. Using a digital mult itest er , m easure the resis tance bet ween each of t he commut ator segment s. The r eading should be .3 ohms or[...]

ELECT RICAL 7.19 ST AR TER ONE - - W A Y CLUTCH INSPEC TION Drive gear One - - way Clutc h Fly wheel 1. Inspec t t he drive gear t eeth, bear ings and thrus t surf aces for ex cessive wear or damage. 2. Inspec t t he one way driv e clutch roller s and spring s f or e xcessive wear o r damage. 3. Proper f unct ion can be determ ined by rot ating the[...]

ELECT RICAL 7.20 ST ARTER SYSTEM TESTING FLOW CHART Condition: S tarter fails to turn motor . NOTE: Make sure engine cranks haft is free to turn before proceedi ng with dynamic testing of star ter system. A digital multitester mu st be used for t his test. Wit h the test er on the VDC positi on, place t he tes- ter’ s black l ead on the batt ery [...]

EL ECTRI CAL 7.21 WIRI NG DIAGRAM 2003 PR EDA T OR No Neutral Li ght Neu tral Start Lo st if failed[...]

A A - - Arm Replacem ent, 5. 1 1 Air Filt er Serv ice, 2.17 Alte rna tor Outp ut T est, 7 .6 B Batt ery Charging, 2. 14, 7.12 Batt ery Maint enance, 2.13, 7. 1 1 Batt ery Serv ice, 2.14, 7. 1 1, 7. 12 Batt ery T erminal Bolt s, 2.14, 7. 1 1 Batt ery T est ing, 7.12 Batt ery , Off Seas on St orage, 2.14, 7. 12 Body Asse mbly Ex ploded V iew , 5. 3 B[...]

Contr ols Inspect ion, 2.26 Coolant Level I nspect ion , 2. 16 Coolant Str ength, 2. 15 Coolant T emp. Sensor T est , 7.3 Cooling System Hoses, 2.16 Cooling System Overview , 2.15 Coo ling System Pressure T est, 3.6 Coo ling System T est, 2.17 Cover/ Panel Removal, 5.2 Cran kcase Assembly , 3.36 Crankc ase Bearing I nspection, 3. 33, 3.34 Crankc as[...]

G Gear P osition Swit ch T est , 7. 3 H Handlebars, 2. 26 Headlamp Remov al, 7.14 Headlamp Ser vice, 7. 13 Headlamp Swit ch T esting, 7. 14 Headlight Adjust ment, 7. 13 Honing to O versiz e, 3.42 I Idle Speed A djustm ent, 2. 10 Ignit ion System Com ponents, 7.8 Ignit ion System T est ing, 7. 9 Indicat or Lamp Replac ement, 7.15 J Jett ing Guidelin[...]

Star ter Mot or Brush I nspection/ Replacement , 7.17 Starter System T est, 7.20 Steering Asse mbly , Ex ploded View , 5.4 Ball Joint, Remov e / Install, 5. 8 Steer ing Knuckle, Remove / Ins tall, 5.8 Steer ing Maintenanc e, 2.19 Steering Post Assemb ly , 5.18 Suspension P reload Adjust ment, 2. 23 Suspension S pecial T ools, 5. 2 Suspension, F ron[...]

2003 PRED A T OR SER VICE MANU AL 2003 PRED A T OR SER VICE MANU AL PN 9918062 PN 9918062 2003 PREDA TOR 500 SERVICE MANU AL PN 9918062 2003 PREDA TOR 500 SERVICE MANU AL PN 9918062 PN 9918062 PN 9918062 Printed in the USA Printed in the USA 230486_cov_01c.qxd 11/19/02 11:35 AM Page 1[...]