'04 Polaris Predator 500 service manual

   / '04 Polaris Predator 500 service manual #1  

cjfling

Silver Member
Joined
May 19, 2009
Messages
126
I've started on a project of sorts... I bought a Predator at an insurance salvage sale and am looking to get it back to running shape for kids to ride around farm. It was of course abused: switch drilled, body panels all damaged or missing, electrical items damaged, all tires flat, and etc. The positives are that the frame, controls, seat, rims, engine all appear to be in decent shape.

The first things I did was to get a battery on it to see if it would at least crank without trying to fully start it. I couldn't get any neutral light to show. After I was sure I learned the shift pattern and it was in neutral, I decided to remove what body panels where there to look at wiring. I found one set of wires that was supposed to be connected to the battery's positive post that had the crimped on connector broke. When I touched that wire to the positive post, I had a neutral light and then it would crank without me letting it start. Now I'm at the stage of draining the gas and oil. The gas was stale and there was only about 4 oz of oil in the crankcase. The magnet on the oil drain plug didn't have any shaving on it so that was a good sign. When I pulled the filter however, in the bottom of the housing there were some real small metal pieces, bad sign. I know the unit has some fluid leaks b\c there were leaked fluids under it at the sale. Hoping that is the reason the oil was so low.

I've ordered a oil filter, oil filter seal, oil plug seal, and a spark plug online. Going to change those out and check coolant levels before going any further and spending any more money. Trying to be careful to not spend to much before I can determine if it's basically sound. What I really could use is a repair manual, either after market or factory if anyone has access one. Polaris has a good parts diagram online, but I don't have access to it when I'm out in the garage. I'm a novice at this and any advise is appreciated.
 
   / '04 Polaris Predator 500 service manual
  • Thread Starter
#2  
Anyone? :)
 
   / '04 Polaris Predator 500 service manual
  • Thread Starter
#4  
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   / '04 Polaris Predator 500 service manual
  • Thread Starter
#5  
I've found a 2003 service manual and my parts are suppose to arrive today. Hopefully the 2003 and 2004 are fairly similar? Now when my wife give's me some garage time, we'll see what happens.
 
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