Predator 500
WARNING
The engine exhaust from this
product contains chemicals
known to cause cancer, birth de-
fects or other reproductive harm.
A card containing important ATV safety information should be attached to the owner’s
manual on the next page. If you cannot locate this card, or if it has been removed,
please call 1-800-342-3764 for assistance.
2
Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product
information at the time of publication. Due to constant improvements in the design and quality of production
components, some minor discrepancies 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.
2005 Predator 500 Owner’s Manual P/N 9919510
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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of
Polaris owners. We proudly produce an exciting line of utility and recreational products.
Polaris Recreational Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Personal watercraft
S RANGER utility vehicles
S Victory motorcycles
4
WELCOME
We believe Polaris sets a standard of excellence for all utility and recreational vehicles
manufactured in the world today. Many years of experience have gone into the engineering,
design, and development of your Polaris vehicle, making it t he finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and
recommendations in this owner’s manual. Your manual contains instructions for minor
maintenance, but information about major repairs is outlined in the Polaris Service Manual
and should be performed only by a Factory Certified Master Service Dealer (MSD)
Technician. Your Polaris dealer knows your vehicle best and is interested in your total
satisfaction. Be sure to return to your dealership for all of your service needs during, and
after, the warranty period.
We also take great pride in our Parts, Apparel and Accessories (PAA) products, available
through our online store at www.purepolaris.com. Have your accessories and clothing
delivered right to your door!
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TABLE OF CONTENTS
WELCOME 3.......................................................
VEHICLE IDENTIFICATION NUMBERS 6..............................
SAFETY 8.........................................................
FEATURES AND CONTROLS 48.....................................
OPERATION 65....................................................
EMISSION CONTROL SYSTEMS 88..................................
MAINTENANCE AND LUBRICATION 90...............................
ADJUSTMENTS 140................................................
CLEANING AND STORAGE 159......................................
TROUBLESHOOTING 166...........................................
POLARIS PRODUCTS 173...........................................
SPECIFICATIONS 174...............................................
WARRANTY 176....................................................
INDEX 183.........................................................
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VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers and key number in the spaces provided.
Remove the spare key and store it in a safe place. Your key can be duplicated only by
mating a Polaris key blank with one of your existing keys. If both keys are lost, the
ignition switch must be replaced.
2
1
31XX
3
7
VEHICLE IDENTIFICATION NUMBERS
Vehicle Model Number:
Frame VIN (1)(left side):
Engine Serial Number (2)(right side):
Key Number (3):
8
SAFETY
Safety Decals and Location s
Warning decals have been placed on the ATV for your protection. Read and follow the
instructions of the decals on the ATV carefully. If any of the decals depicted in this manual
differ from the decals on your ATV, always read and follow the instructions of the decals on
the ATV.
If any decal becomes
illegible or comes off,
contact your Polaris
dealer to purchase a
replacement.
Replacement safety
decals are provided
by Polaris at no
charge. The part
number is printed on
the decal.
A
B
C
9
SAFETY
Safety Decals and Location s
Location B
DNever operate this vehicle on HILLS steeper than 25
degrees 25°. To prevent flipover on hilly terrain,
when going up or down, use throttle and brakes
gradually.
DREVERSE operation can be dangerous, even at low
speeds. Steering becomes difficult. To prevent flipover,
avoid sudden braking or sharp turns.
DPARKING BRAKE may relax when used for more than 5
minutes. When parking on grades, leave ATV in gear.
WARNING
7170906
Location A
Location C
WARNING
This ATV may exceed the performance of other ATVs y ou
may have ridden in the past. This category S (Sport)
ATV is a high performance vehicle for off-road use only,
in sport type recreation and competitive use by operators
with advanced skills and substantial experience.
7172560
E1997, 2000
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACE MENT.
WARNING
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER opera te this ATV if you are
under age 16.
7172559
WARNING
10
SAFETY
Safety Decals and Location s
E
D
F
Location F
H
G
I
7172566
WARNING
Location E
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SAFETY
Safety Decals and Location s
ATTENTION
S Operation of this vehicle without the air filter
element will severely damage the engine.
S Clean pre-filter element often, more
frequent cleaning required in dusty
conditions. Do not operate vehicle
without pre-filter.
S Operation of this vehicle without engine
breather filter(s) can cause engine
damage. Consult owner’s manual or dealer
for details.
Factory setting:
40_ to 80_ F. at 0-3000 feet
(5_ to 27_ C. at 0-900 meters).
7079902
S Specific carburetor jetting and
adjustments are required depending on
temperature and altitude. See your Owner’s
Manual.
THIS VEHICLE IS AN ALL TERRAIN
VEHICLE AND IS NOT INTENDED FOR
USE ON PUBLIC ROADS.
7170983
CE VÉHICULE EST UN VÉHICULE TOUT
TERRAIN QUI NEST PAS DESTINE A
ETRE UTILISE SUR
LES CHEMINS
PUBLICS.
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 4 (27,6) REAR 4 (27,6)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 645 LBS. (293 kg).
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase
your risk of losing control. For stability on rough or hilly terrain, reduce
speed and cargo.
Read Owner’s Manual for more detailed loading information.
7172668
L
ocation D
Location I (under seat)
L
ocation H
Location G
WARNING
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SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV
riding requires special protective clothing for comfort and
to reduce the chance of injury.
1. Helmet
Your helmet is the most important piece of protective gear
for safe riding. A helmet can prevent a severe head injury.
Select an approved helmet that meets or exceeds your
state’s safety standards and bears either the Department of
Transportation (DOT) label, the American National
Standards Institute label (ANSI z90.1), or the Snell
Memorial Foundation label.
1
2
3
4
5
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SAFETY
Safe Riding Gear
2. Eye Protection
Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face
shield offer the best protection for your eyes. They should be kept clean and be of
shatterproof design (bearing the markings z2.1 or VESC 8).
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with
kneepads and a jersey with shoulder pads provide the best protection.
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SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result in serious injury or
death.
A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles
differently than other vehicles, such as motorcycles and cars. A collision or rollover
can occur quickly, even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings before operating a
Polaris ATV.
Operator Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16
years of age. This category S (Sport) ATV is a high performance vehicle intended for off
road use only, for sport-type recreation and for competitive use by operators with advanced
skills and substantial experience.
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SAFETY
Operator Safety
Know Your Vehicle
As the operator of the ATV, you are responsible for your safety, the safety of others, and the
protection of our environment. Read and understand your owner’s manual, which includes
valuable information about all aspects of your ATV, including safe operating procedures.
Safety Training
When you purchased your new Polaris ATV, your dealer offered a hands-on safety training
course covering all aspects of vehicle safety. You were also provided with printed materials
that explain safe operating procedures, which you should review on a regular basis. If your
model is recommended for use by experienced operators only, you also received a safety
video. Be sure to view it before operating the ATV.
If you purchased a used Polaris ATV from a party other than a Polaris dealer, you can
request this free safety training from any authorized Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations
concerning the operation of this vehicle in your area.
Follow the recommended maintenance program outlined in your owner’s manual. This
program is designed to ensure that all critical components on the ATV are thoroughly
inspected at specific intervals.
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SAFETY
Operator Safety
The following two pages identify signal words and symbols that appear in this manual.
Your safety is involved when these words and symbols are used. Become familiar with
their meanings before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the potential
for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious injury
or death.
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SAFETY
Operator Safety
CAUTION
The safety alert caution indicates a potential hazard that may result in minor personal
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE:
A note will alert you to important information or instructions.
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SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating procedures described.
S Never operate an ATV without proper instruction. Take a training course. Beginners
should receive training from a certified instructor. Contact an authorized Polaris ATV
dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest
you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read this manual and all
product labels and has completed a certified safety training course.
S Always avoid operating an ATV on paved surfaces, including sidewalks, driveways,
parking lots, and streets.
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SAFETY
Operator Safety
S Never operate an ATV on a public street, road or highway, including a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits properly. Always
wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket,
and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for the terrain, visibility
and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe operating condition.
Always follow the inspection and maintenance procedures and schedules outlined in your
owner’s manual.
S Always keep both hands on the handlebars and both feet on the footpegs of the ATV dur-
ing operation.
S Always travel slowly and use extra caution when operating on unfamiliar terrain. Be
alert to changing terrain conditions.
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SAFETY
Operator Safety
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manual. Practice turning at
low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.
S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in
an accident.
S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller
hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the terrain carefully before
ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift
your weight forward. Never open the throttle suddenly or make sudden gear changes.
Never go over the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking on hills. Check the
terrain carefully before you start down a hill. Shift your weight backward. Never go
down a hill at high speed. Avoid going down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill when possible.
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SAFETY
Operator Safety
S Always follow proper procedures for crossing the side of a hill. Avoid hills with exces-
sively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never
attempt to turn t he ATV around on any hill until you’ve mastered (on level ground) the
turning technique outlined in this manual. Avoid crossing the side of a steep hill when
possible.
S Always use proper procedures if you stall or roll backwards while climbing a hill. To
avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll back-
wards, follow the special procedure for braking described in this manual. Always dis-
mount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the
ATV around and remount following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never attempt to operate
over large obstacles, such as rocks or fallen trees. Always follow proper procedures
when operating over obstacles as described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and
use extra caution to reduce the chance of skidding or sliding out of control.
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SAFETY
Operator Safety
S Avoid operating the ATV through deep or fast-flowing water. If it’s unavoidable, travel
slowly, balance your weight carefully, avoid sudden m ovements, and maintain a slow
and steady forward motion. Do not make sudden turns or stops, and do not make sudden
throttle changes.
S Wet brakes may have reduced stopping ability. Test the brakes after l eaving water. If
necessary, apply them lightly several times to allow friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operating in reverse. When
it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and always maintain proper
tire pressure.
S Never modify an ATV through improper installation or use of accessories.
S Never exceed the stated load capacity for your ATV.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product
Safety Commission at 1 -800-638-2772, or call Polaris at 1-800-342-3764.
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SAFETY
Operator Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we
strongly recommend that consumers do not install on a P olaris ATV any equipment that
may increase the speed or power of the vehicle, or make any other modifications to the
vehicle for these purposes. Any modifications to the original equipment of the vehicle
create a substantial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris ATV is terminated if any equipment has been added to the
vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.
NOTE: The addition of certain accessories may change the handling characteristics of
the vehicle. Use only Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD: Operating this ATV without proper instruction.
WHAT CAN HAPPEN
: The risk of an accident is greatly increased if the operator
does not know how to operate the ATV properly in different situations and on different
types of terrain.
HOW TO AVOID THE HAZARD
: Beginning and inexperienced operators should
complete the certified training course offered by Polaris. Operators should regularly
practice the skills learned in the course and the operating techniques described in the
owner’s manual.
For more information about the training course, contact an authorized ATV dealer or
call Polaris at 1-800-342-3764.
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD: Failure to follow the skill and experience recommendations
for this ATV.
WHAT CAN HAPPEN
: Severe injury and/or death could occur if a beginner or
inexperienced driver operates this ATV.
HOW TO AVOID THE HAZARD
: Only operators with advanced skills and substantial
experience should operate this ATV.
26
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD: Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
: Severe injury and/or death could occur if a child under the
minimum age recommendation operates this ATV.
Even though a child may be within the recommended age group for operating some
ATVs, he/she may not have the skills, abilities, or judgment needed to operate an A TV
safely and could be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
: No one under the age of 16 should operate a
Polaris ATV. Only operators with advanced skills and substantial experience should
operate this ATV.
27
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD: Carrying a passenger on
an ATV.
WHAT CAN HAPPEN
: Carrying a passenger
greatly reduces the operator’s ability to balance and
control the ATV, which could cause an accident and
injury to the operator and/or passenger.
HOW TO AVOID THE HAZARD
: Never carry a
passenger. The purpose of the long seat is to allow
the operator to shift position as needed during
operation. It is not intended for carrying
passengers.
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