POLARIS PREDATOR ATV 500 2003 SERVICE REPAIR MANUAL

POLARIS PREDATOR ATV 500 2003 SERVICE REPAIR MANUAL

Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your ATV. Read and print pages or copy the entire manual to your hard drive.

193 Pages

MODELS COVERED:

 POLARIS PREDATOR 500

MODEL NUMBER: A03GJ50AA

MANUAL COVER:

– GENERAL

– MAINTENANCE

– ENGINE/TRANSMISSION

– FUEL SYSTEM

– BODY/SUSPENSION

– BRAKES

– 7 ELECTRICAL

MANUAL COVER ALSO:

• General Specifications
• Periodic Maintenance
  Engine Removal & Installation
• Clutch
• Transmission
• Lubrication System
  Fuel System
• Electrical System
• Brakes
• Suspension
• Wheels & Tires
• Frame
  Maintenance Schedule
• Wiring Diagrams
  Troubleshooting

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Engine: 499cc, liquid-cooled, single-cylinder, four-stroke with double overhead cams (DOHC).
• Horsepower: 41 horsepower.
• Transmission: Five-speed manual with reverse.
• Fuel system: Mikuni BSR 42mm carburetor.
• Suspension:
  • Front: Dual A-arm with Fox adjustable coil-over shocks and 10 inches of travel.
  • Rear: Linkless swingarm with a Fox remote reservoir shock featuring adjustable spring preload, rebound, and compression damping, and 11 inches of travel.
• Brakes: Dual hydraulic disc brakes on the front and a single hydraulic disc on the rear.
• Weight: 415 pounds (dry).
• Top speed: 73 mph in stock condition.
• Tires: Maxxis RAZR tires (21×7-10 front and 20×11-9 rear) on Douglas aluminum rims.
• Features: Stock features included a chromoly axle, braided stainless steel brake lines, and a polyethylene skid plate. 

• Frame cracking: A known weakness for the 2003 Predator 500 is a frame that can crack under the gas tank.
• Ignition issues: Some owners have reported problems with the ignition system.
• Electrical problems: Common issues include wiring harness failures and faulty voltage regulators.
• Valvetrain issues: Some used examples have been found with valve issues, requiring shims to be replaced. 

• Cylinder kit: A 
  Niche Cylinder Piston Gasket Kit

   is available for the 2003–2004 model years and can be found at retailers such as Walmart.

• Clutch components: Companies like Moose and Hinson offer clutch plates and springs.
• Aftermarket cams: High-performance camshafts are available for engine upgrades.
• Used OEM parts: You can find original equipment manufacturer (OEM) parts, including plastics and control arms, on marketplaces like eBay.