Clamp shaft eyelet securely in vise, and place seal bullet tool on end of shaft. Reverse the procedures to install the fuel valve. Clean the thread--locking compound from eyelet and shaft threads, and set it aside. The middle to upper portion of the needle contacts the needle jet and is the most likely wear point. Be sure the seals are seated washers and set aside.
Make sure you have a clean work area to Brake Lines disassemble brake components. Theodore painted the plastic with a camo pattern to match the camo Polaris bag. Remove caliper mounting bolts and lift caliper off of disc. Reassemble the pump in the reverse order of Loose jets disassembly. Turn the puller T-Handle clockwise until it contacts the water pump shaft. Lubricate new seals and O-ring with Polaris shock remove nut, washer, and valve piston with valving oil and install. The problem is that once you have gotten your nifty new product, the Polaris Predator 500 Atv Service Repair Workshop Manual Pdf gets a brief glance, maybe a once over, but it often tends to get discarded or lost with the original packaging.
Be sure machine is secure before beginning this service procedure. Install split keepers with the gap even on both sides. Install piston with a twisting motion while pushing inward. Unscrew body cap and remove. Remove the wire harness connector from the battery voltage across the connections. Do not rotate engine until the tensioner has been installed to avoid chain slip and loss of timing reference. Place a shop towel under brake line connection at master cylinder.
Inspect the drive gear teeth, bearings and thrust surfaces for excessive wear or damage. Install master cylinder on handlebars. To free the cam assembly, lift one cam assembly rotate the tensioner assembly counter--clockwise and slightly rotate it while removing the chain from if desired. Removing the flywheel exposes the starter drive housing A and the crankcase and record. Remove dowel pins from crankcase. By far the smoothest riding bike I've personally owned, and with the power in all the right places, Rediculous Midrange, Fast Top end.
Lubricate the flat end of the metering rod with a small amount of assembly lube. The compression damping is machine when turned fully to the left or right. I recently bought a 2005 tld predator 500 , I have owned a quadzilla 450 before , I can honestly say that the polaris is a far better bike , the build quality is first rate and I'm not having to tighten every nut and bolt after a hard ride like I used to have to do with the quadzilla, my bike has a. Clean master cylinder and reservoir assembly. Seal should be installed with lip protruding from the flat side of 57.
Use only electrical contact cleaner to clean starter Engine problem - seized or binding motor parts. Lubricate the axle housing through the grease Torque the brake disc nuts to 16- -19 ft. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Set the nitrogen tank pressure regulator to 200 - 19. Caliper Mount Bolt 15 ft. All diagnostic and repair procedures are covered. Clean the gasket surfaces on the cylinder head and cylinder.
Front Wheel Nuts 4 30 ft. The pump is located in the front fender cavity of the machine. Note the direction and position of all internal parts for 1. Inspect the friction 66- -81 Ft Lbs. Start engine and inspect for leaks. This manual can also be used for the 2004, 2005, 2006, 2007 model Polaris Predator 500 All-Terrain Vehicles.
This Polaris Predator manual is 352 pages. Torque mounting bolts to 25 in. Place cylinder head on cylinder head table. Do not re-use old circlips. Place shims on drive end of armature shaft with 2. This manual can also be used for the 2004, 2005, 2006, 2007 model Polaris Predator 500 All-Terrain Vehicles. Start engine and warm it up thoroughly.