Polaris Sportsman 500 User Manual
PN 9918062
PN 9918062
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)
ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the
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.
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.
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
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMA
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........................
TION
1
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
A03GJ50AA
Emissions &
Year Designation
Basic Chassis
Designation Engine Designation
Model Option
ENGINE DESIGNATION NUMBER
ES50PLE01 Single, Water Cooled, Electric Start, Manual 5--Speed, DOHC 4 Stroke................
VIN IDENTIFICATION
World Mfg. ID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4XA GA
Body Style
Vehicle Descriptor
50A* 3P0 00 000
Engine
Powertrain
Emissions
Check Digit*
Model
Year
Plant No.*
Vehicle Identifier
Individual Serial No.
* 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)
LH View
B
ENGINE SERIAL NUMBER LOCATION
This information can be found on the clutch housing
on the left side of engine.(A)
1.2
RH View
A
PUBLICATION NUMBERS
PREDATORA03GJ50CA
GENERAL INFORMATION
Year Model Model No. Owner’s
Manual PN
2003
NOTE: When ordering service parts be sure to use the correct parts manual.
9917574 9917576 9917577
Parts
Manual PN
Parts
Micro Fiche PN
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
31XX
Key Series
Number
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
T orque 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.
1.3
GENERAL INFORMATION
PREDATOR MODELS
1.4
PREDATOR 500
TROY LEE LIMITED EDITION
PREDATOR 500
MODEL: 2003 PREDA TOR 500..........
MODEL NUMBER: A03GJ50AA.
ENGINE MODEL: ES50PLX..
GENERAL INFORMATION
Catagory
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
Dimension
Dune PackageShown
1.5
GENERAL INFORMATION
MODEL: 2003 PREDA TOR 500..........
MODEL NUMBER: A03GJ50AA.
ENGINE MODEL: ES50PLE01..
Engine
Platform Fuji DOHC 4 stroke
Engine Model Number ES50PLE01
Engine Displacement 499cc
Number of Cylinders 1
Bore & Stroke (mm) 99.2 x 64.6 mm
Compression Ratio 10.8:1
Compression Pressure 130 psi
Engine Idle Speed 1600 Rpm
Cooling System Liquid
Thermostat Opening
Temperature
Overheat Warning High Temp Light
Lubrication Pressurized Dry Sump
Oil Requirements PS--4 Synthetic
Exhaust System 2 to 1 canister style
Carburetion
Carburetor model Mikuni BSR 42mm
Main Jet 150
Pilot jet 45
Jet Needle 6CGY07-060-3
Needle Jet O-OM
Pilot Screw 2.5 Turns Out
Pilot Air Jet 110
Float Height 13--14 mm (0.51-- 0.55“)
Fuel Delivery Fuel Pump
Fuel Requirement 87 Octane (minimum)
Electrical
Alternator Output 200 w @ 3000 RPM
Voltage Regulator 3--Phase PN 4010654
Lghts : Main Headlights Dual Beam 35 watts / 35 watts
Tai l 8.26 watts
Brake 26.9 watts
Neutral / Hot
Indicator lights
Ignition System DC/CDI Ignition
RPM Limit 9005
Ignition Timing 30qr3q BTDC @ 3500 RPM
Spark plug / Gap NGK DCPR8E/ .035 in./0.9mm
Battery / Model / Amp Hr Maintenance--Free
Circuit Breakers Fan10amp/Harness20amp
Starting Electric -- Standard
Instrument Cluster N/A
160qF(71qC)
1 watt (ea.)
YuasaYTX99AmpHr
Drivetrain
Transmission Type Manual 5 speed
Main Sprocket -- # Tooth 14
Rear Sprocket -- # Tooth 37
Axle Runout -- Maximum .020” (.51 mm)
Gear Ratio : 1st
2nd
3rd
4th
5th
Primary
Chain Size / Deflection 520 O-- ring
Clutch Type Wet Multi Plate
Clutch Lever Freeplay 1/8s -3/16s / 3.1 - 4.7 mm
2.615
1.765
1.350
1.091
0.958
2.792
Steering / Suspension
Front Suspension
Style / Shock
Front Travel 10 in. / 25.4 cm
Rear Suspension
Style / Shock
Rear Travel 11 in. / 27.94 cm
Ground Clearance 4.5 in. / 11.43 cm
Shock Preload Adjustment
Front / Rear
Turning Radius 67 in. / 170.18 cm
Toe O u t 0 -- 1/16 in / .0 -- .159 cm
Dual A-- arm / Fox Shock
Linkless Swing Arm / Fox Shock
w/ remote reservoir
Front -- Spring tension -- Std.
Rear -- Fox Dual Clicker -- Std.
Wheels / Brakes
Wheel Size -- Front 21x7-- 10 Aluminum
Wheel Size -- Rear 20x11-- 10 Aluminum
Front Tire
Make / Model / Size
Rear Tire
Make / Model / Size
Recommended Air Pressure
F/R
Brake -- Front Dual Hydraulic Disc
Brake -- Rear Single Hydraulic Disc
Maxxis Razr 21x7-- 10
Maxxis Razr 20x11--10
5 psi Front
5 psi Rear
JETTING CHART
AMBIENT TEMPERATURE
Altitude
Meters
(Feet)
0--1800
(0--6000)
above 1800
(above 6000)
Below 40qF
Below 5qC
155 150
147.5
+40qFto+80qF
+5qCto+28qC
142.5
1.6
GENERAL INFORMATION
SAE TAP DRILL SIZES
Thread Size/Drill Size Thread Size/Drill 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
7/16-20 25/64
1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4
METRIC TAP DRILL SIZES
Tap Size Drill Size Decimal
Equivalent
3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75
#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
0.0995
0.0937
0.1285
0.125
0.166
0.161
0.196
0.234
0.277
0.265
0.3125
0.3125
0.3437
0.339
0.375
0.406
0.406
Nearest
Fraction
3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32
DECIMAL EQUIVALENTS
1/64 .0156................
1/32 .0312 1 mm = .0394s........... ...
3/64 .0469................
1/16 .0625...........
5/64 .0781 2 mm = .0787s................ ...
3/32 .0938...........
7/64 .1094 3 mm = .1181s.............. ...
1/8. .1250...
9/64 .1406................
5/32 .1563 4 mm = .1575s........... ...
11/64 .1719...............
3/16 .1875 5 mm = .1969s........... ...
13/64 .2031...............
7/32 .2188...........
15/64 .2344 6 mm = .2362s............... ...
1/4 .25....
17/64 .2656 7 mm = .2756s............... ...
9/32 .2813...........
19/64 .2969...............
5/16 .3125 8 mm = .3150s........... ...
21/64 .3281...............
11/32 .3438 9 mm = .3543s.......... ...
23/64 .3594...............
3/8 .375....
25/64 .3906 10 mm = .3937s............... ...
13/32 .4063.........
27/64 .4219 11 mm = .4331s............... ...
7/16 .4375...........
29/64 .4531...............
15/32 .4688 12 mm = .4724s......... ...
31/64 .4844...............
1/2 .5 13 mm = .5118.... ..............
33/64 .5156...............
17/32 .5313.........
35/64 .5469 14 mm = .5512s............... ...
9/16 .5625...........
37/64 .5781 15 mm = .5906s............... ...
19/32 .5938.........
39/64 .6094...............
5/8 .625 16 mm = .6299s.... ............
41/64 .6406...............
21/32 .6563 17 mm = .6693s......... ...
43/64 .6719..............
11/16 .6875..........
45/64 .7031 18 mm = .7087s............... ...
23/32 .7188.........
47/64 .7344 19 mm = .7480s............... ...
3/4 .75....
49/64 .7656...............
25/32 .7813 20 mm = .7874s......... ...
51/64 .7969...............
13/16 .8125 21 mm = .8268s......... ...
53/64 .8281...............
27/32 .8438.........
55/64 .8594 22 mm = .8661s............... ...
7/8 .875....
57/64 .8906 23 mm = .9055s............... ...
29/32 .9063.........
59/64 .9219..............
15/16 .9375 24 mm = .9449s......... ...
61/64 .9531...............
31/32 .9688 25 mm = .9843......... ...
63/64 .9844...............
11.0.....
1.7
GENERAL INFORMATION
CONVERSION TABLE
Unit of Measure Multiplied by Converts to
ft. lbs. x12 =in.lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x1.356 =Nm
in. lbs. x .0115 =kg-m
Nm x .7376 = ft. lbs.
kg-m x7.233 = ft. lbs.
kg-m x 86.796 =in.lbs.
kg-m x9.807 =Nm
in. x25.4 =mm
mm x .03937 =in.
in. x2.54 =cm
mile (mi.) x1.6 =km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x0.035 = Ounces (oz)
lb. x.454 =kg
kg x 2.2046 =lb.
Cubic inches (cu in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x0.061 = Cubic inches (cu in)
Imperial pints (Imp pt) x0.568 = Liters (l)
Liters (l) x1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x1.137 = Liters (l)
Liters (l) x0.88 = Imperial quarts (Imp qt)
Imperial quarts (Imp qt) x1.201 =USquarts(USqt)
US quarts (US qt) x0.833 = Imperial quarts (Imp qt)
US quarts (US qt) x0.946 = Liters (l)
Liters (l) x1.057 =USquarts(USqt)
US gallons (US gal) x3.785 =Liters (l)
Liters (l) x0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x6.895 = Kilopascals (kPa)
Kilopascals (kPa) x0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x0.01 = Kilograms - force per square cm
Kilograms - force per square cm x98.1 = Kilopascals (kPa)
S xR2x H (height) = Cylinder Volume
qCtoqF: 9 (qC + 40) y 5-40=qF
qFtoqC: 5 (qF+40)y 9-40=qC
1.8
GENERAL INFORMATION
GLOSSARY OF TERMS
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8s or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive
clutch to close and grip the drive belt.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported
between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and
out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load.
(i.e. a bare wire touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
lorltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040s.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
SeizedPiston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Vol t: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.9
GENERAL INFORMATION
NOTES
1.10
MAINTENANCE
CHAPTER 2 MAINTENANCE
Periodic Maintenance Chart 2.2-2.3...............
Pre-Ride Inspection 2.4......................
Lubricant and Maintenance Product Numbers 2.5
Special Tools 2.6............................
Lubrication Charts 2.7-2.8........................
Clutch Freeplay Adjustment 2.9...............
Throttle Inspection 2.9.......................
Carburetor Adjustments 2.9-2.10...................
Throttle Adjustment 2.10-2.11.......................
Fuel System 2.11-2.12.............................
2
Compression Test 2.12........................
Spark Plug Maintenance 2.13..................
Battery Maintenance 2.13--2.14......................
Electrical 2.14-2.15................................
Coolant System Maintenance 2.15-2.16..............
Radiator Screen Removal 2.17.................
Air Filter Service 2.17.........................
Air Box Sediment Tube Service 2.17............
Crankcase Breather Filter 2.18.................
Oil Change/Filter 2.18.........................
Steering and Toe Alignment 2.19-2.20...............
Exhaust System Maintenance 2.21.............
Brake System Service 2.22-2.23....................
Suspension Adjustment 2.23-2.26...................
Controls / Handlebar Adjustment 2.26...........
Wheel Removal/Installation 2.26................
Tire Inspection 2.27...........................
2.1
MAINTENANCE
PERIODIC MAINTENANCE CHART
Inspection, adjustment and lubrication intervals of important components are listed in the following chart.
Maintenance intervals are based upon average riding conditions and vehicle speed.
The following symbols denote potential items to be aware of during maintenance:
H= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed
by an authorized Polaris dealer.
"= SEVERE USE ITEM -- --If vehicle is subjected to severe use, decrease interval by 50% (Severe Use is defined
as frequent vehicle immersion in mud, water or sand, racing or race- style high rpm use, manual slipping of the clutch
prolonged low speed - heavy load operation or extended idle. More preventati ve maintenance is required under these
conditions. Fluid changes, cable, chain and chassis lubri cat i on are required more frequently. For engine oil, short trip cold
weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate
contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise,
discontinue use and determine cause.
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
ENGINE / COOLING / CONTROLS
Item Maintenance Interval
(Whichever comes first)
Hours Calendar Miles
(Km)
"
"
"
"
" Air Box Sediment Tube -- Daily -- Drain deposits whenever visible
" Engine Breather Filter 20 hrs Monthly 200 (320) Inspect and clean if necessary
H
H
" Radiator 100 hrs 12 months 1000 (1600) Inspect / Clean external surfaces
" Cooling and Oil System Hoses 100 hrs 12 months 1000 (1600) Pre--ride / Inspect for leaks
" Engine Mounts 100 hrs 12 months 1000 (1600) Pre-- ride / Inspect
Engine Oil - Level/Change 10 hrs -- 100 (160) Check level pre-- ride
E
Oil Filter 10 hrs -- 100 (160) Replace with oil change
E
Air Filter - Pre-Filter Daily Daily -- Inspect, clean more often
E
Air Filter - Main Element Weekly Weekly -- Inspect - Replace if necessary
E
Idle Speed As required As required -- Adjust as required
E
Throttle Cable / ETC Switch 50 hrs 6months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Choke (Enricher) Cable 50 hrs 6months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6months 500 (800) Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6months 500 (800) Inspect all ducts for proper sealing/air leaks
Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,
E
Coolant/Level Inspection Daily Daily Replace engine coolant every 2 years
Coolant Strength /
System Pressure Test
Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600) Pre--ride / Inspect
100 hrs 6months 1000 (1600) Inspect strength seasonally;
pump & carburetor. Replace lines every 2 years.
Pressure test system annually
Remarks
Break-- In service at 1 hour
in dirty or wet conditions
2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART CONT’D
ELECTRICAL
Item Maintenance Interval
(Whichever comes first)
Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary
E
" Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security.
H
" Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Test
Ignition Timing 100 hrs 12 months 1000 (1600) Inspect
Headlight Aim As required As required -- Adjust as Necessary
Headlamp Inspection Daily Daily -- Check operation daily; Apply dielectric
Tail Lamp Inspection Daily Daily -- Check operation daily; Apply dielectric
Apply Dielectric grease to connectors that are
grease whenever lamp is replaced
grease whenever lamp is replaced
CHASSIS / SUSPENSION / BRAKE
Item Maintenance Interval
(Whichever comes first)
Hours Calendar Miles
(Km)
" General Lubrication 50 hrs 3months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc.
Drive Chain Pre--ride Pre--ride Pre--ride Clean and Inspect, Adjust, Lubricate
H
H
" Front Suspension Pre--ride Pre--ride Pre--ride Inspect - Lubricate
" Rear Suspension Pre--ride Pre--ride Pre--ride Inspect - Lubricate
H
" Brake Fluid Level Pre-ride Pre-ride -- Inspect Sight Glass Daily
" Brake Lever Travel Pre-ride Pre-ride -- Inspect Daily
"
H
Steering Pre--ride Pre--ride Pre--ride Inspect Daily, Lubricate
Toe Adjustment As required As required -- Periodic Inspection, Adjust Whenever
Tires Pre-ride Pre-ride -- Inspect Daily, Pre-Ride Inspection Item
Brake Fluid 200 hrs 24 months 2000 (3200) Change Every Two Years
Brake Pad Wear 10 hrs Monthly 100 (160) Inspect Periodically
Brake Adjustment As required As required -- Inspect Deflection Daily; Adjust
Brake System Pre-ride Pre-ride -- Pre-Ride Inspection Item
Wheels / Fasteners Pre-ride Pre-ride -- Pre-Ride Inspection Item
Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride -- Pre-Ride Inspection Item
Remarks
subjected to water, mud, etc.
Remarks
Parts are Replaced
Pre-Ride Inspection Item
Pre-Ride Inspection Item
2.3
MAINTENANCE
PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
G Tires - check condition and pressures
G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
G All brakes - check operation and adjustment (includes auxiliary brake)
G Throttle - check for free operation
G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
G Engine stop switch - check for proper function
G Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by
cotter pins
G Air cleaner element - check for dirt or water; clean or replace
G Steering - check for free operation, noting any unusual looseness in any area
G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
G Engine coolant - check for proper level at the recovery bottle
RECOMMENDED PRE--RIDE FLUID
LEVEL
Engine Oil / Transmission Polaris PS 4
Coolant / Level Polaris Premium 60/40
Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir.
NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2.5
CHECKS
Item Type Notes See
Add to proper level on dipstick. 2.18
Synthetic
Allow engine and cooling system to cool
Pre-mixed Antifreeze/
Coolant or a 50/50 mixture
high quality antifreeze/
coolant and distilled water
completely and check level in radiator.
Fill to top of filler neck. If reservoir was
empty or extremely low, fill radiator be-
fore filling reservoir tank to full line.
Sight glass should appear dark when
installed, indicating proper fluid level.
Pages
2.15
2.22
2.4
MAINTENANCE
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS
Part No. Description
Engine Lubricant
2874414 Engine Oil (Quart) PS 4 Synthetic (4-- Cycle)
2874415 Engine Oil (Gallon) PS 4 Synthetic (4--Cycle)
Grease / Specialized Lubricants
2871322 Premium All Season Grease (3 oz. cartridge)
2871423 Premium All Season Grease (14 oz. cartridge)
2871460 Starter Drive Grease
2871312 Grease Gun Kit
2871329 Dielectric Grease
2872073 Chain Lube (Aerosol)
Coolant
2871323 60/40 Coolant (Gallon)
2871534 60/40 Coolant (Quart)
Additives / Sealants / Thread Locking Agents / Misc.
2870791 Fogging Oil (12 oz. Aerosol)
2871326 Premium Carbon Clean (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2870585 Loctitet Primer N, Aerosol, 25 g
2870990 DOT3 Brake Fluid
2871956 Loctitet Thread Sealant 565 (50 ml.)
2871949 Loctitet Threadlock 242 (50 ml.)
2871950 Loctitet Threadlock 242 (6 ml.)
2871951 Loctitet Threadlock 262 (50 ml.)
2871952 Loctitet Threadlock 262 (6 ml.)
2871953 Loctitet Threadlock 271 (6 ml.)
2871954 Loctitet Threadlock 271 (36 ml.)
2870584 Loctitet RC 680-Retaining Compound (10 ml.)
2870587 Loctitet 518 Gasket Eliminator / Flange Sealant (50 ml.)
2872113 Disk Brake Quiet (12 oz.)
2872113 Disc Brake Quiet, Aerosol, (9 oz.)
2871957 Black RTV Silicone Sealer (3 oz. tube)
2871958 Black RTV Silicone Sealer (11 oz. cartridge)
8560054 Marine Grade Silicone Sealer (14 oz. cartridge)
2871557 Crankcase Sealant, 3-Bond 1215
2872893 Engine Degreaser
2.5
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN
8712100 or 8712500 Tachometer 2,7
2200634 Valve Seat Reconditioning Kit 3
PU--45257 Valve Spring Compressor 3
PA-- 46075 Flywheel Puller 3
PA-- 46087 Crankcase Separator 3
2870390 Piston Support Block 3
2872105 Water Pump Mechanical Seal Puller 3
PA-- 45958 Cam Chain Tensioner Assembly Tool 3
PA-- 46076 MAG End Crankshaft Nut Remover/Installer 3
PA-- 46077 MAG End Crankshaft Installer 3
2871283 Crankshaft/Water Pump Seal Install Kit 3
5131135 Water Pump Install Kit 3
PA-- 46502 Valve Spring Compressor 3
2870975 Mity Vact Pressure Test Tool 3, 4
2872314 Carburetor Float Adjustment Tool 4
2870623 Shock Absorber Spring Compression Tool 5
7052069 Charging Needle 5
2200421 Gas Shock Recharging Kit 5
2871352 Shock Rod Holding Tool 5
2871351 Foxt Shock IFP Depth Tool 5
2870386 Piston Pin Puller 6
PV--43568 Fluket77 Digital Multimeter 7
2870630 Timing Light 7
*Special Tools Can be ordered through a Polaris Dealer or SPX Corporation (1--800--328--6657).
MAINTENANCE
2.6
MAINTENANCE
LUBRICATION
1. Engine Oil and Filter ¡
2. Brake Fluid ©
(Right hand and Foot
Brake Master Cylinder)
3. Rear Drive Chain
Ill.
#
1. Engine Oil /
2. Brake Fluid Polaris
3 Drive Chain Polaris Chain Lube Apply to chain link plates and rollers. As required*
Item Lube Rec. Method Frequency*
Transmission
Polaris PS--4
Synthetic
Dot 3 Brake Fluid
Check dipstick and add to
proper level.
Fill master cylinder reservoir to in-
dicated level inside reservoir.
See Ch. 6.
Perform break-in oil/filter change at one
hour; change oil every 10hrs/100mi.¡
As required. Change fluid every
2 years or 200 hours.©
* More often under severe use, such as operation in mud, water, sand or under severe loads.
¡ Every 10 hours of operation (refer to Maintenance Schedule for additional information) Change more
often in extremely dirty conditions (continuous operation in water, mud or sand), continuous hot, cold, or short
trip cold weather operation. NOTE: Excessive clutch plate residue will accelerate oil change intervals
© Every 24 months or 200 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (continuous operation in water, mud or sand)
2.7
LUBRICATION, CONT.
8. Upper Steering Post Bushing
7. Rear Axle Eccentric
MAINTENANCE
5. Upper Control Arm
6. Lower Control Arm
Ill.
#
5. Upper Control Arms Polaris All Season
6. Lower Control Arms Polaris All Season
7. Rear Axle Eccentric Polaris All Season
8. Upper Steering Post Bushing Polaris All Season
Item Lube Rec. Method Frequency*
Grease¢
Grease¢
Grease¢
Grease¢
Locate fittings and grease
(also grease after washing ATV)
Locate fittings and grease
(also grease after washing ATV)
Locate and grease
(also grease after washing ATV)
Locate fittings and grease
(also grease after washing ATV)
Every 3 months ¡
Every 3 months ¡
Every 3 months ¡
Semi-annually ©
* More often under severe use, such as operation in water or under severe loads.
¡ Every 3 months or 50 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (continuous operation in water, mud or sand)
© Every 6 months or 50 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (continuous operation in water, mud or sand)
¢ Use grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease.
2.8
MAINTENANCE
CLUTCH ADJUSTMENT
Clutch Lever Freeplay
1. Measure clutch lever freeplay between the perch
and the lever (A). This distance should be 1/8s -
3/16s (3.1 mm - 4.7 mm).
C
B
2. If adjustment is required, slide the clutch perch
pivot boot down the clutch cable to access the
clutch adjustment screw (B) and lock ring (C).
3. Loosen the lock ring and turn the screw in
(clockwise) to increase lever travel. Turn the
screw out (counterclockwise) to decrease lever
travel. Tighten the lock ring.
4. Squeeze the lever fully and release. Slightly
squeeze the lever again until a slight resistance is
felt. Measure the freeplay again. If necessary,
repeat the adjustment procedure until proper
freeplay is attained.
5. Replace the clutch perch pivot boot over the
screw and lock ring.
A
THROTTLE INSPECTION
Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle
speed increases at any point in the turning range,
inspect throttle cable routing and condition.
Adjust cable tension as needed until lock--to--lock
turning can be accomplished with no rise in
engine rpm.
5. Replace the throttle cable if worn, kinked, or
damaged.
6. Inspect ETC cover seal and switch cavity by
removing the cover. Verify that no dirt, water or
mud is present.
To remove the ETC cover:
1. Use a medium flat blade screwdriver and insert
blade into the pocket of the cover starting on the
#1 position.
2. Twist screwdriver slightly while lifting on the cover
to release snap.
3. Repeat procedure at the other five locations as
shown.
NOTE: Do not attempt to remove cover until all
latch points are released.
2
1
5
5
4
ETC Cover
Removal Sequence
Ill. 1
3
6
6
CHOKE (ENRICHER)
ADJUSTMENT
If the choke knob does not stay out when pulled,
adjust the choke tension by tightening (clockwise) the
jam nut under the rubber boot between the choke
knob and nut. Firmly grasp the rubber boot and
tighten until the choke slides freely but stays out when
pulled.
Verify free play of 1/16--3/16” (1.6--4.76 mm) and
smooth operation of choke cable.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.
Choke
2.9
MAINTENANCE
CARBURETOR PILOT SCREW
ADJUSTMENT
FRONT
(Engine)
Ill.2
NOTE: Pilot screw is covered by a welsh plug. Plug
removal will be required to perform these procedures.
1. Start engine and warm it up to operating
temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated.
Turn screw out the specified number of turns.
NOTE: Do not tighten the pilot screw forcefully
against the seat or the screw and/or seat will be
permanently damaged. (Ill. 2)
Pilot Screw
IDLE SPEED ADJUSTMENT
BSR Carburetor
Idle Screw
Ill.3
1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the idle adjustment
screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM. (Ill.3)
NOTE: Adjusting the idle speed affects throttle cable
freeplay and electronic throttle control (ETC)
adjustment. Always check throttle cable freeplay
after adjusting idle speed and adjust if necessary.
Idle Speed:
Pilot Screw Adjustment
Refer to Specifications in Chapter 1
3. Connect an accurate tachometer that will read in
increments of + or -- 50 RPM such as the PET
2100DX (PN 8712100DX)orthePET2500(PN
8712500).
4. Set idle speed to 1600 RPM. Always check
throttle cable freeplay after adjusting idle speed
and adjust if necessary.
5. Slowly turn mixture screw clockwise using the
pilot screw wrench until engine begins to miss.
6. Slowly turn mixture screw counterclockwise until
idle speed increases to maximum RPM.
Continue turning counterclockwise until idle RPM
begins to drop.
7. Center the pilot screw between the points in Step
5 and 6.
8. Re adjust idle speed to specification.
1600 +/-- 50 RPM
THROTTLE CABLE /
ELECTRONIC
CONTROL (ETC
THROTTLE
SWITCH)
ADJUSTMENT
1. Slide boot off throttle cable adjuster and jam nut.
2. Place shift selector in neutral and set parking
brake.
3. Start engine and set idle to 1600 RPM.
Boot
Adjuster
Sleeve
Locknut
Boot
2.10
Ill. 1
MAINTENANCE
NOTE: Be sure the engine is at operating
temperature. See Idle Speed Adjustment.
4. Loosen lock nut on in-line cable adjuster (Ill. 1).
5. Turn adjuster until 1/16s to 1/8s freeplay is
achieved at thumb lever. (Ill. 2). After making
adjustments, quickly actuate the thumb lever
several times and reverify freeplay.
Direction
of travel
Ill. 2
6. Tighten lock nut securely and slide boot
completely in place to ensure a water-tight seal.
7. Turn handlebars from left to right through the
entire turning range. If idle speed increases,
check for proper cable routing. If cable is routed
properly and in good condition, repeat adjustment
procedure.
1/16s -1/8s
Freeplay
loss of consciousness or death in a
short time.
G Never drain the float bowl when the
engine is hot. Severe burns may
result.
FUEL LINES
Fuel In
Fuel Out
Fuel Pump
Pulse Line
Ill.1
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are
not kinked or pinched.
3. Replace all fuel lines every two years.
FUEL SYSTEM
WARNING
Gasoline is extremely flammable and explosive
under certain conditions.
G Always stop the engine and refuel
outdoors or in a well ventilated area.
G Do not smoke or allow open flames
or sparks in or near the area where
refueling is performed or where
gasoline is stored.
G Do not overfill the tank. Do not fill the
tank neck.
G If you get gasoline in your eyes or if
you swallow gasoline, seek medical
attention immediately.
G If you spill gasoline on your skin or
clothing, immediately wash it off with
soap and water and change clothing.
G Never start the engine or let it run in
an enclosed area. Engine exhaust
fumes are poisonous and can result
VENT LINES
Check engine, fuel tank, oil tank and carburetor vent
lines for signs of wear, deterioration, damage or
leakage. Replace every two years.
Be sure vent lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are not
kinked or pinched.
FUEL VALVE
The Predator fuel system strains the fuel through
screens located in the fuel valve. There is no fuel filter
to service. To service the fuel valve:
1. Shut off fuel supply at fuel valve. Remove line
clamps and fuel lines from the tank.
2. Remove the tank and drain remainder of fuel into
a appropriate container.
3. Remove fuel valve by loosening the screws
holding the valve to the tank.
4. Inspect the valve for damage or debris. Replace
the valve if problems are found.
2.11
MAINTENANCE
5. Reverse the procedures to install the fuel valve.
6. Start engine and inspect for leaks.
CARBURETOR DRAINING
The carburetor float bowl should be drained
periodically to remove moisture or sediment from the
bowl, or before extended periods of storage.
NOTE: The bowl drain screw is located on the bottom
left side of the float bowl.
1. Turn fuel valve to the off position.
2. Place a clean container beneath the bowl drain
spigot or bowl drain hose.
3. Turn drain screw out two turns and allow fuel in
the float bowl and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
6. Turn fuel valve to “ON”.
7. Start machine and check for leaks.
NOTE: All tubes attached to the carburetor must be
check for pinching or blockage, as this will effect
engine performance.
A cylinder leakdown test is the best indication of
engine condition. Follow manufacturer’s instructions
to perform a cylinder leakage test. (Never use high
pressure leakage testers, as crankshaft seals may
dislodge and leak).
Cylinder Compression
w/ decompression
Standard: 85--90 PSI @ 400 RPM
Cylinder Leakdown
Service Limit 10 %
(Inspect for cause if leakage exceeds 10%)
ENGINE MOUNTS
Inspect engine mounts and frame for cracks or
damage. (Ill.3)
Check engine fasteners and ensure they are tight.
Drain Screw
Ill. 1
COMPRESSION TEST
NOTE: This engine has built--in decompression
components. Compression readings will vary in
proportion to cranking speed during the test. Average
compression (measured) is about 85--90 psi @ 400
RPM during a compression test.
A smooth idle generally indicates good compression.
Low engine compression is rarely a factor in running
condition problems above idle speed. Abnormally
high compression can be caused by carbon deposits
in the combustion chamber or worn, damaged
exhaust cam lobes. Inspect camshaft and
combustion chamber if compression is abnormally
high.
2.12
Ill. 3
MAINTENANCE
SPARK PLUG INSPECTION
Spark Plug Removal and Replacement
1. Turn the fuel valve to OFF.
2. Remove the front cab.
3. Move the fuel valve hose clamp (1) forward and
gently remove the hose from the fuel valve fitting
on the gas tank.
3
2
1
4. Remove the vent hose (2) from the instrument
panel, taking note of the hose routing for
reinstallation.
5. Remove the tank mounting bolt (3) at the rear of
the gas tank.
6. Move the tank rearward and upward over the
engine. Slowly remove the tank, being careful not
to catch any hoses, wires or other components.
Place the tank on a stable surface or work bench
to protect the valve from contamination or
damage.
7. Remove spark plug high tension lead. Clean plug
area so no dirt and debris can fall into engine
when plug is removed.
8. Remove spark plug. and inspect electrodes for
wear and carbon buildup. The insulator tip should
be a light tan color, indicating good combustion.
Look for a sharp outer electrode edge with no
rounding or erosion.
9. If needed, clean spark plug with electrical contact
cleaner or a glass bead spark plug cleaner only.
CAUTION: Wire brushes or coated abrasives
should not be used.
10. Measure gap with a wire gauge. Refer to
specifications for proper spark plug type and gap.
Adjust gap if necessary by bending the side
electrode carefully.
11. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if
the incorrect spark plug is used.
12. Apply a small amount of anti-seize compound to
the spark plug threads.
13. Install spark plug and torque to specification.
Reverse steps as needed for reassembly.
Recommended Spark Plug:
NGK DCPR8E
Spark Plug Torque:
14 Ft. Lbs. (19 Nm)
Spark Plug Gap
.035s (0.9 mm)
IGNITION TIMING
Refer to Chapter 10 for ignition timing checks.
BATTERY MAINTENANCE
WARNING
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space.
Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
The battery is located under the left rear fender.
NOTE: All Predator ATV batteries are
Maintenance --Free design and construction.
Before placing the battery into service, check the
battery condition and charge accordingly. Use
Conventional Lead--Acid batteries is
recommended.
of
not
2.13
MAINTENANCE
New Batteries: Batteries must be fully charged
before use or battery life will be reduced by
10-30% of full potential. Charge battery for 3--5
hours at a current equivalent of 1/10 of the
battery’s rated amp/hour capacity (i.e. 9 amp hr x
.10 = .9 amp charging). Do not use the alternator
to charge a new battery.
Maintenance--Free batteries are sealed at the
factory. The use of lead--calcium instead of
lead--antimony allows the battery acid to be fully
absorbed by the plates. Therefore, a
Maintenance--Free battery case is opaque and the
sealing caps are not removable, since there is no
need to check electrolyte level.
NEVER attempt to add electrolyte or water to a
Maintenance --Free battery. Doing so will damage
the case and shorten the life of the battery. Refer
to the Battery Maintenance Video (PN 9917987)
for proper instruction on servicing
Maintenance--Free batteries.
BATTERY
INSPECTION/REMOV
The battery is located under the left rear fender.
Battery
Location
To remove the battery:
1. Disconnect holder strap.
2. Disconnect battery negative (-) (black) cable first,
followed by the positive (+) (red) cable.
AL
Rinse well with clean water and dry thoroughly. Test
battery for condition and charge accordingly.
5. Reinstall battery, attaching positive (+) (red) cable
first and then the negative (-) (black) cable.
6. Coat terminals and bolt threads with Dielectric
Grease (PN 2871329).
7. Reinstall battery cover and holder strap.
8. Reinstall the battery caps.
9. Charge battery at 1/10 of its amp/hour rating.
Example: 1/10 of 14 amp battery = 1.4 amp
10. Reinstall the battery after testing.
BATTERY TERMINALS/BOLTS
Use Polaris corrosion resistant Dielectric Grease (PN
2871329) on battery bolts.
OFF SEASON STORAGE
To prevent battery damage during extended periods
of non-use, the following basic battery maintenance
items must be performed:
G Remove the battery from the
machine and wash the case and
battery tray with a mild solution of
baking soda and water. Rinse with
lots of fresh water after cleaning.
NOTE: Do not get any of the baking
soda into the battery or the acid will
be neutralized.
G Using a wire brush or knife, remove
any corrosion from the cables and
terminals.
G Never add water to a sealed
maintenance free battery.
G Charge at a rate no greater than 1/10
of the battery’s amp/hr capacity until
the open circuit voltage is 12.9V or
greater.
G Store the battery either in the machine
with the cables disconnected, or store
in a cool place.
CAUTION
To reduce the chance of sparks: Whenever
removing the battery, disconnect the negative
(black) cable first. When reinstalling the battery,
install the negative cable last.
3. Remove the battery.
4. Clean battery cables and terminals with a stiff wire
brush. Corrosion can be removed using a solution
of one cup water and one tablespoon baking soda.
2.14
CHARGING PROCEDURE
1. Remove the battery from the ATV to prevent
damage from leaking or spilled acid during
charging.
2. Charge the battery with a charging output no
larger than 1/10 of the battery’s amp/hr rating.
Charge as needed to raise the battery open circuit
voltage to 12.9V or greater.
MAINTENANCE
3. Install battery in vehicle with positive terminal
toward the front. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
Dielectric Grease
(PN 2871329)
4. Connect the battery cables.
ENGINE-TO-FRAME GROUND
Inspect engine-to-frame ground cable connection. Be
sure it is clean and tight. The engine to frame ground
runs under the seat and rear cab back to the battery
area.
Ground Cable
Battery Ground
LIQUID COOLING SYSTEM
G Some coolant level drop on new
machinesis normalas the system is
purgingitselfof trappedair. Observe
coolant levels often during the
break-in period.
G Overheating of engine could occur if
air is not fully purged from system.
G Polaris Premium 60/40 anti--freeze is
premixed and ready to use. Do not
dilute with water.
COOLANT STRENGTH / TYPE
Test the strength of the coolant using an antifreeze
hydrometer.
Antifreeze Hydrometer
G A 50/50 or 60/40 mixture of
antifreeze and distilled water will
provide the optimum cooling,
corrosion protection, and antifreeze
protection.
G Do not use tap water. Tap water
contains minerals and impurities
which build up in the system. Do not
add straight antifreeze or straight
water to the system. Straight water
or antifreeze may cause the system
to freeze, corrode, or overheat.
OVER
The engine coolant level is maintained by the
recoverysystem. The recovery systemcomponents
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coolant operating temperature increases, the
expanding(heated)excesscoolantisforcedoutofthe
radiator past the pressure cap and into the recovery
bottle. As engine coolant temperature decreasesthe
contracting(cooled)coolant isdrawnbackupfromthe
tank past the pressure cap and into the radiator.
VIEW
Polaris 60/40 Anti-Freeze / Coolant
(PN 2871323)
2.15
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