Positioning:
The 2004 Polaris Predator 500 was positioned as a high-performance, aggressive sport ATV designed for recreational trail riding and competitive off-road use.
Competitors:
Competed directly with other leading sport ATVs of the era such as the Yamaha YFZ450, Suzuki LT-R450, and Honda TRX450R.
Features:
Known for its potent 499cc engine, aggressive styling, and capable suspension system, offering a thrilling riding experience.
Purpose:
To provide owners with essential information regarding safe operation, regular maintenance, basic troubleshooting, and specifications for their 2004 Polaris Predator 500.
Engine:
Engine Oil Level, Cooling System, Carburetor/Idle RPM, Spark Plugs, Air Filter Systems, Fuel Filter
Transmission Drivetrain:
Chain Tension, Clutch Lever Freeplay, Manual Shift Operation
Brakes:
Brakes, Brake Levers, Foot Brake, Master Cylinder, Parking Brake
Electrical:
Electrical Switches, Lights, Headlight Assembly, Headlight Lamp Replacement, Taillight/Brakelight Lamp Replacement
Suspension Steering:
Suspension Adjustments, Front Suspension, Rear Suspension, Camber and Caster, Steering Assembly, Compression Damping, Rebound Damping, Spring Preload
Chassis Body:
Cab Removal (Front/Rear), Side Panel Removal, Wheel Installation/Removal
Fuel Exhaust:
Fuel Tank, Fuel Valve, Fuel Filter, Spark Arrestor, USFS Approved Spark Arrestor
Operation:
Break-In Period, Driving Procedures, Driving Safely, Making Turns, Driving Uphill/Downhill, Driving Through Water, Driving Across Hills, Driving Over Obstacles, Parking on an Incline, Turning Around on a Hill, K-turn
Maintenance:
Periodic Maintenance Schedule, Lubrication Points, Lubrication Recommendations, Oil Change, Oil Filter Change, Battery Maintenance (Charging, Installation, Removal, Storage), Tire Care
Adjustments:
Carburetor/Idle RPM, Chain Tension, Clutch Lever Freeplay, Throttle Cable Freeplay, Handlebars, Suspension Settings, Headlight Adjustment, Toe Alignment
Troubleshooting:
General Troubleshooting Guide for Common Issues
Cleaning Storage:
Cleaning Procedures, Storage Recommendations, Vehicle Immersion Recovery
Depth:
Comprehensive Owner-Level Maintenance and Operation, with foundational information for basic repairs and adjustments.
Detail Level:
Detailed instructions for routine checks, fluid changes, lubrication, and common adjustments. Includes safety guidelines and operational best practices. Limited in scope for complex internal engine or transmission rebuilds, but provides sufficient detail for owner maintenance.
Engine Type:
4-Stroke, Single Cylinder, Liquid-Cooled
Bore X Stroke:
Not explicitly listed, but typical for this class.
Horsepower:
Estimated to be in the high 30s to low 40s HP (specific figures not in TOC).
Torque:
Specific figures not in TOC, but characteristic of a strong mid-range pull.
Carburetor:
Mikuni BSR42 (typical for this model year, confirmed by index referencing Carburetor/Idle RPM and Jetting Chart).
Type:
Liquid-Cooled (Radiator, Fan, Coolant Recovery Bottle mentioned).
Oil Type:
Refer to Maintenance and Lubrication section for specific oil viscosity and API service classification.
System:
CDI (Capacitor Discharge Ignition) - common for this era.
Certification:
The manual covers safety warnings and procedures applicable to off-road use. Does not include road safety ratings like NCAP.
Braking:
Hydraulic Disc Brakes (Front and Rear), Parking Brake.
Throttle Control:
Electronic Throttle Control mentioned, likely referring to throttle limiter or governor.
Identification:
Vehicle Identification Numbers (VIN) section ensures proper identification. Safety decals and locations are detailed.
Gear Recommendations:
Safe Riding Gear section covers essential protective equipment.
Training:
Safety Training section emphasizes the importance of proper instruction.
Driving Hazards:
Detailed coverage on driving safely in various conditions including hills, slippery surfaces, water, and obstacles.
Periodic Schedule:
Comprehensive Periodic Maintenance Schedule (pages 91-100) outlining regular service tasks based on usage hours or time.
Engine Oil:
Refer to Maintenance and Lubrication section for recommended oil viscosity (e.g., SAE 10W-40, 20W-50) and API service classification. Capacity typically around 2.3-2.5 quarts.
Coolant:
Use a permanent type antifreeze with corrosion inhibitors. Specific type and capacity detailed in the Cooling System section.
Brake Fluid:
DOT 3 or DOT 4 brake fluid recommended (refer to Brake Fluid section).
Common Problems:
While not detailed in the TOC, common issues for this era of high-performance ATVs can include carburetor tuning, clutch wear, and electrical connector issues if not properly maintained or exposed to excessive moisture.
Points:
Specific lubrication points for suspension, steering, and cables detailed in the Lubrication Points section.
Air Filter:
Cleaning and replacement procedures for the air filter system are covered.
Oil Filter:
Replacement procedures for the oil filter are included with the oil change.
Replacement:
Detailed instructions for spark plug removal and replacement, including recommended plug types. Typically NGK CR9E or similar.
