2003 Polaris Predator 500 Service Manual

This manual contains diagnostic procedures, component identification, and repair instructions for the 2003 Polaris Predator ATV. PN 9918062.

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Document Details

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Document Number / Seller:
31937 / Donald Thompson
File Size:
24.20 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
Jun 27, 2025

Models Covered & Key Technical Specifications

Polaris Predator 500 (9918062) - 2003 2003 Polaris Predator 500 documentation | Polaris Predator | ATV Bundle.

  • Engine Specifications: 499cc displacement establishes the engine's core displacement.
  • Engine Lubrication: PS-4 Synthetic oil is used for the engine and clutch system.
  • Fuel Capacity: 3.25 gal./12.3 ltr defines the fuel capacity.
  • Transmission Type: Manual 5 speed indicates the transmission type.
  • Front Suspension: Dual A-arm / Fox Shock details the front suspension.
  • Ground Clearance: 4.5 in. / 11 cm specifies the ground clearance.

Professional Workshop Service Manual & Technical Specifications

Polaris Predator 500 (9918062) - 2003

Maintenance-Category: Engine / Calibration-Scope: Carburetor / Maintenance-Category: Electrical.

Engine

Exploded views of engine components, including the crankcase/transmission and cylinder/cylinder head, are provided. Procedures cover engine removal, installation, and general maintenance.

Carburetor System

Detailed information on the Mikuni BSR 42 Carburetor is included, covering its operation, system function, and troubleshooting. Jetting guidelines for various altitudes and temperatures are also provided.

Ignition System

This section focuses on the DC/CDI ignition system, detailing its advantages, operation, and troubleshooting steps for no spark or intermittent spark issues.

Suspension and Brakes

Information on front and rear suspension servicing, including shock adjustments and wheel hub inspection, is available. Brake system service notes, troubleshooting, and procedures for front and rear brake calipers are also documented.

Electrical System

This manual covers the electrical system comprehensively, including testing procedures for the starter system, charging system, ignition system, and lighting.

This document documents torque specifications for various engine components to ensure proper assembly and bolt stretch prevention.

FAQ

What is the **exact** assembly sequence for the front hub? keyboard_arrow_down

30 ft. lbs. (41 Nm) is the torque specification for the front A-arm attaching bolts, and 35 ft. lbs. (48 Nm) for the front A-arm ball joint stud nut, which are part of the front hub assembly.

Reference the **specific** service interval parameters for the drive chain. keyboard_arrow_down

Pre-ride inspection is required for the drive chain, with cleaning and inspection every 50 hrs / 3 months / 500 (800) miles (Km).

What are the **designated** system architecture for the brake calipers? keyboard_arrow_down

18 ft. lbs. (25 Nm) is the torque for the front caliper mounting bolts, and 33 ft. lbs. (45 Nm) for the caliper slide bolts, which are critical for the brake caliper's system architecture.

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Reviews (3)

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The email with the download link arrived quickly, and the manual covers everything I needed for maintenance. Professional service all the way!
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The service manual was incredibly detailed and easy to navigate. Downloading was a breeze, and I received the link almost instantly. Highly recommend!
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Rated 4 out of 5 stars