2007 Polaris Predator 500 ATV Service Manual (P/N 9920782)

• Covers the 2007 Polaris Predator 500 White (A07GJ50AA), Black (A07GJ50AB), and Limited Edition (A07GJ50AC) variants, all with the ES500PLE022 engine.
• This 184-page PDF contains the 2007 Predator 500 factory service manual, P/N 9920782, organized around identification, maintenance, engine, carburetion, chassis, brakes, electrical diagnosis, and wire diagrams.
• Documents engine removal and installation, upper- and lower-end disassembly, crankcase separation, transmission and clutch repair, crankshaft service, camshaft timing, cylinder-head work, and water-pump seal replacement.
• Explains Mikuni BSR 42 carburetor operation, teardown, cleaning, inspection, float adjustment, needle-and-seat leak testing, fuel-level checks, fuel-pump service, and altitude/temperature jetting selection.
• Distinguishes the standard models’ non-rebuildable RydeFX front shocks from the L.E. Fox Podium X front units, and provides Fox rear-shock rebuild procedures plus steering, axle, hub, and hydraulic brake service.
• Provides DC/CDI ignition tests, Electronic Throttle Control checks, cooling-fan diagnosis, charging- and starting-system flowcharts, a wire-termination table, and separate ignition/charging circuit breakouts.

Built around full teardown, measurement, reassembly, and fault-isolation work, this manual is suited to experienced ATV mechanics and well-equipped owners already comfortable with precision tools, electrical meters, and special-service equipment. Routine maintenance is covered, but the repair depth and dedicated tooling put the advanced procedures beyond a beginner-level handbook.

Engine, Transmission, and Fuel Work

Testing coverage includes compression, leakdown, cooling-system pressure, engine oil pressure, and oil-pump priming. Internal repair sections address the automatic compression release, cam-chain tensioner, starter one-way clutch, wet multi-plate clutch, shift mechanism, oil pump, transmission shafts, crankshaft, bearings, piston, cylinder, and DOHC cylinder head. Valve-guide replacement and reaming, valve-seat reconditioning, an adjusting-pad selection matrix, cylinder honing, and water-pump mechanical-seal service are supported by the related torque patterns, wear limits, clearances, and inspection data.

Fuel-system material is specific to the BSR 42 CV carburetor. Separate explanations cover the pilot, enrichment, float, and main circuits, followed by lean, rich, poor-idle, and erratic-idle troubleshooting. The jetting references connect main-jet choice to operating altitude and temperature and list the corresponding Mikuni jet part numbers.

Chassis, Brakes, and Variant Differences

The AA and AB models use non-rebuildable RydeFX front shocks. The manual covers removal of the spring and preload components but specifies replacement of the shock as an assembly if the damper fails. The AC Limited Edition receives Fox Podium X piggyback front shocks with compression adjustment, while the rear Fox Podium X unit has compression and rebound adjustment. Fox service coverage includes internal floating-piston setup, disassembly, rebuilding, reassembly, and nitrogen charging requirements.

Chassis repair procedures extend through front hubs and bearings, steering and toe adjustment, A-arm and ball-joint service, swingarm removal, rear-axle assembly, bearing-carrier service, and axle runout inspection.

The hydraulic brake chapter covers system operation, fluid replacement and bleeding, front and rear caliper overhaul, master-cylinder removal and installation, disc inspection, pad replacement, burnishing, and brake-noise troubleshooting. Component-specific torque data, service limits, and exploded assemblies support these operations.

Electrical Diagnosis and Visual References

Switch-level testing covers the neutral/reverse, clutch, brake-light, optional tether, and ETC circuits. The electrical chapter then moves into DC/CDI ignition output checks, coolant-temperature and fan-control diagnosis, alternator testing, battery evaluation, starter voltage-drop testing, starter-motor teardown, brush inspection, armature testing, and starter one-way-clutch inspection.

Named visual references include the ES50PL oil-flow chart, Predator cam-timing exploded view, BSR 42 carburetor exploded view, Fox Podium X front and rear shock exploded views, and charging-system testing flowchart. The dedicated 2007 Predator 500 wire-diagram section adds a full vehicle schematic, termination table, and ignition- and charging-system breakouts.

Factory Tools, Specifications, and Repair Cautions

Special tools are identified by part number, including the PA-46087 crankcase separator, PA-45958 cam-chain tensioner tool, 2872105 water-pump seal puller, 2872314 carburetor float tool, 2870975 Mity Vac pressure tool, 2871351 Fox shock IFP depth tool, and PV-43568 digital multimeter. Reference data covers fastener torque, fluid and lubricant requirements, component wear limits, adjustment specifications, electrical test values, and jetting. Identification pages locate the machine VIN and engine serial number and list Cloud Silver (P-385) and Matte Black (P-458) frame paint codes. General shop references add SAE and metric tap-and-drill sizes and conversion tables.

The manual warns that incorrect cam timing can cause valve-to-piston contact and major engine damage. Side-loading the water-pump seal puller can bend the pump shaft, turning a seal repair into an engine-removal and crankcase-separation job. Fox shocks contain high-pressure nitrogen and must be depressurized before disassembly; brake, fuel, cooling, and heavy-component work likewise requires proper shop equipment and safe service practices.