2004 Polaris Predator Owners Manual
2004 Polaris Predator Manual
2004 Polaris Predator manual content summary:
- 2004 Polaris Predator | Owners Manual - Page 1
- 2004 Polaris Predator | Owners Manual - Page 2
- 2004 Polaris Predator | Owners Manual - Page 3
contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance. - 2004 Polaris Predator | Owners Manual - Page 4
We've created a web site just for YOU! S S S S S Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out...www.polarisindustries.com/owner 1 - 2004 Polaris Predator | Owners Manual - Page 5
Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc. Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and - 2004 Polaris Predator | Owners Manual - Page 6
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft S RANGER utility vehicles S - 2004 Polaris Predator | Owners Manual - Page 7
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master - 2004 Polaris Predator | Owners Manual - Page 8
IDENTIFICATION NUMBERS ...6 SAFETY ...8 FEATURES AND CONTROLS ...52 OPERATION ...69 EMISSION CONTROL SYSTEMS ...89 MAINTENANCE AND LUBRICATION ...91 ADJUSTMENTS ...142 CLEANING AND STORAGE ...160 TROUBLESHOOTING ...167 POLARIS PRODUCTS ...175 SPECIFICATIONS ...176 WARRANTY ...178 INDEX ...185 5 - 2004 Polaris Predator | Owners Manual - Page 9
VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are - 2004 Polaris Predator | Owners Manual - Page 10
VEHICLE IDENTIFICATION NUMBERS Frame VIN: Vehicle Model Number: Engine Serial Number: Key Number: 7 - 2004 Polaris Predator | Owners Manual - Page 11
of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a C replacement. Replacement - 2004 Polaris Predator | Owners Manual - Page 12
of 16 increases your chance of severe injury or death. NEVER operate this vehicle if you are under age 16. 7078253 Location C Location A IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. E1997, 2000 7079083 Location B 9 - 2004 Polaris Predator | Owners Manual - Page 13
SAFETY Safety Decals and Locations G 7077920 Location E H I E D 10 Location F F - 2004 Polaris Predator | Owners Manual - Page 14
-center, or unsecured loads will increase your risk of losing control. For stability on rough or hilly terrain, reduce speed and cargo. Read Owner's Manual for more detailed loading information. 7171022 Location I (under seat) THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON - 2004 Polaris Predator | Owners Manual - Page 15
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. - 2004 Polaris Predator | Owners Manual - Page 16
Safe Riding Gear SAFETY 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8). 3. Gloves Off-road - 2004 Polaris Predator | Owners Manual - Page 17
maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner's manual and all warnings before operating your Polaris ATV. Operator Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under - 2004 Polaris Predator | Owners Manual - Page 18
ATV, you are responsible for your safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your ATV, including safe operating procedures. Safety Training When you purchased your new Polaris - 2004 Polaris Predator | Owners Manual - Page 19
safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that - 2004 Polaris Predator | Owners Manual - Page 20
damage to the vehicle. CAUTION A caution indicates a situation that may result in damage to the vehicle. NOTE: A note will alert you to important information or instructions. 17 - 2004 Polaris Predator | Owners Manual - Page 21
Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV - 2004 Polaris Predator | Owners Manual - Page 22
before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner's manual. S Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation. S Always travel slowly and use - 2004 Polaris Predator | Owners Manual - Page 23
SAFETY Operator Safety S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. S Always have the ATV inspected - 2004 Polaris Predator | Owners Manual - Page 24
. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following - 2004 Polaris Predator | Owners Manual - Page 25
SAFETY Operator Safety S Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes. - 2004 Polaris Predator | Owners Manual - Page 26
Operator Safety SAFETY Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other - 2004 Polaris Predator | Owners Manual - Page 27
Safety WARNING POTENTIAL HAZARD: Operating this ATV without proper instruction. WHAT CAN HAPPEN: The risk of an accident the skills learned in the course and the operating techniques described in the owner's manual. For more information about the training course, contact an authorized ATV dealer or - 2004 Polaris Predator | Owners Manual - Page 28
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN: Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD: Only operators with advanced skills - 2004 Polaris Predator | Owners Manual - Page 29
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN: Severe injury and/or death could occur if a child under the minimum age recommendation operates this ATV. Even though a child may be within the recommended age group for - 2004 Polaris Predator | Owners Manual - Page 30
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Carrying a passenger on an ATV. WHAT CAN HAPPEN: Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD: Never - 2004 Polaris Predator | Owners Manual - Page 31
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN: ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss - 2004 Polaris Predator | Owners Manual - Page 32
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN: The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD: Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many - 2004 Polaris Predator | Owners Manual - Page 33
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN: Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating - 2004 Polaris Predator | Owners Manual - Page 34
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN: Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol - 2004 Polaris Predator | Owners Manual - Page 35
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating the ATV at excessive speeds. WHAT CAN HAPPEN: Excessive speed increases the operator's chance of losing control of the ATV, which can result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD: Always operate the ATV at - 2004 Polaris Predator | Owners Manual - Page 36
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN: Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD: Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. 33 - 2004 Polaris Predator | Owners Manual - Page 37
ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner's manual. 34 - 2004 Polaris Predator | Owners Manual - Page 38
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Removing hands from the handlebars or feet from the footpegs during operation. WHAT CAN HAPPEN: Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot - 2004 Polaris Predator | Owners Manual - Page 39
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN: Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Travel slowly and use - 2004 Polaris Predator | Owners Manual - Page 40
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN: Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an - 2004 Polaris Predator | Owners Manual - Page 41
loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 38 - 2004 Polaris Predator | Owners Manual - Page 42
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Operating on excessively steep hills. WHAT CAN HAPPEN: The vehicle may overturn. HOW TO AVOID THE HAZARD: Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees 25_. Practice on - 2004 Polaris Predator | Owners Manual - Page 43
could cause loss of control or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for climbing hills as described in the owner's manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively - 2004 Polaris Predator | Owners Manual - Page 44
of control or overturn. HOW TO AVOID THE HAZARD: Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 84. Always check the terrain carefully before descending a hill. Shift - 2004 Polaris Predator | Owners Manual - Page 45
: Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 82. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always - 2004 Polaris Predator | Owners Manual - Page 46
uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 82. 43 - 2004 Polaris Predator | Owners Manual - Page 47
large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. 44 - 2004 Polaris Predator | Owners Manual - Page 48
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Skidding or sliding. WHAT CAN HAPPEN: Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD: On slippery surfaces such as ice, travel slowly and use extra caution to - 2004 Polaris Predator | Owners Manual - Page 49
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN: Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD: Avoid operating the ATV through deep or fast- - 2004 Polaris Predator | Owners Manual - Page 50
loss of control or accident. HOW TO AVOID THE HAZARD: Always use the size and type of tires specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner - 2004 Polaris Predator | Owners Manual - Page 51
vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. 48 - 2004 Polaris Predator | Owners Manual - Page 52
Operator Safety SAFETY WARNING POTENTIAL HAZARD: Overloading the ATV or carrying/towing cargo. WHAT CAN HAPPEN: Overloading or carrying/towing cargo can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD: Never haul cargo or tow a load - 2004 Polaris Predator | Owners Manual - Page 53
SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating on frozen bodies of water. WHAT CAN HAPPEN: Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD: Never operate the ATV on a frozen body of water. 50 - 2004 Polaris Predator | Owners Manual - Page 54
SAFETY Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of - 2004 Polaris Predator | Owners Manual - Page 55
FEATURES AND CONTROLS Engine Electrical Switches 3 2 1 52 - 2004 Polaris Predator | Owners Manual - Page 56
Engine Electrical Switches FEATURES AND CONTROLS 1. Start Button - The start button engages the starter. Always release the start button as soon as the engine starts. 2. Engine Stop Switch - The purpose of this switch is to OFF RUN OFF provide the operator with a quick means of engine shutdown in - 2004 Polaris Predator | Owners Manual - Page 57
FEATURES AND CONTROLS Lights 1 2 3 1. Headlight HI/LO Switch 2. Neutral Indicator Lamp 3. High Temp Indicator Lamp 54 - 2004 Polaris Predator | Owners Manual - Page 58
Light Switches FEATURES AND CONTROLS The light switch is located on the left handlebar. It's used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won't work unless the key is in the ON position and the engine stop switch is in the RUN position. WARNING - 2004 Polaris Predator | Owners Manual - Page 59
to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks - 2004 Polaris Predator | Owners Manual - Page 60
Electronic Throttle Control FEATURES AND CONTROLS This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the - 2004 Polaris Predator | Owners Manual - Page 61
FEATURES AND CONTROLS Foot Brake Your Polaris ATV has a foot pedal (1) that activates the rear brakes. It's located in front of the right-hand footpeg (2) and is operated by the right foot. If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without - 2004 Polaris Predator | Owners Manual - Page 62
Brake Lever FEATURES AND CONTROLS 1 The Predator ATV has a single brake lever for the front 2 3 brakes. It's located on the right handlebar. The front brakes are applied by squeezing the brake lever (1) toward the handlebar. The front brakes are hydraulically activated disc type brakes. Always - 2004 Polaris Predator | Owners Manual - Page 63
FEATURES AND CONTROLS Master Cylinder The master cylinder (2) is located on the right-hand handlebar. The brake fluid level should be checked before each ride. The fluid level can be seen through the indicator window (3) on the top of the master cylinder. This eye will appear dark when the fluid - 2004 Polaris Predator | Owners Manual - Page 64
Parking Brake FEATURES AND CONTROLS WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in first gear or - 2004 Polaris Predator | Owners Manual - Page 65
FEATURES AND CONTROLS Parking Brake Important Safeguards S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a - 2004 Polaris Predator | Owners Manual - Page 66
Fuel Valve FEATURES AND CONTROLS The fuel valve (1) is located under the fuel tank on the left side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There's about a 5 to 8 mile - 2004 Polaris Predator | Owners Manual - Page 67
87=(R+ M/2) octane. Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged. Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 74 - 2004 Polaris Predator | Owners Manual - Page 68
Manual Shift FEATURES AND CONTROLS Shift Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal - 2004 Polaris Predator | Owners Manual - Page 69
FEATURES AND CONTROLS Manual Shift The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. Place the stop switch - 2004 Polaris Predator | Owners Manual - Page 70
Manual Shift FEATURES AND CONTROLS Shifting Gears NOTE: Always allow the engine to warm up before shifting gears. 1. When starting from a stopped position with the transmission - 2004 Polaris Predator | Owners Manual - Page 71
FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine - 2004 Polaris Predator | Owners Manual - Page 72
Fuel Safety OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or - 2004 Polaris Predator | Owners Manual - Page 73
OPERATION Break-In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The break-in period for your new Polaris Predator is defined as the first one hour of operation (followed by an additional two hours of cautious operation - 2004 Polaris Predator | Owners Manual - Page 74
Break-In Period OPERATION 1. Fill the fuel tank with gasoline. See page 64. 2. Check the oil level on the dipstick. See page 105. Add oil if necessary to maintain the level between the safe and add marks. 3. Allow the engine sufficient time to warm up before operating. 4. Drive slowly at first. - 2004 Polaris Predator | Owners Manual - Page 75
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Use the following checklist to verify that your vehicle is in proper working - 2004 Polaris Predator | Owners Manual - Page 76
Pre-Ride Inspection 5. 6. 7. 8. 9. 10. 11. OPERATION Throttle - Check for free operation and closing. See page 156. Steering - Check for free operation, noting any unusual looseness in any area. Headlight/Taillight/Brakelight - Check operation of all indicator lights and switches. Engine stop - 2004 Polaris Predator | Owners Manual - Page 77
OPERATION Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. Allow - 2004 Polaris Predator | Owners Manual - Page 78
Starting a Cold Engine OPERATION NOTE: The variable choke is fully on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, - 2004 Polaris Predator | Owners Manual - Page 79
while cranking to aid in starting. Release the throttle lever immediately after the engine starts. 4. If the engine does not start, review the engine troubleshooting information beginning on page 167. If all conditions are favorable and the engine still does not start, see your Polaris dealer for - 2004 Polaris Predator | Owners Manual - Page 80
Driving Safely Driving Procedures 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. See page 67. 3. Check your surroundings and determine your path of travel. 4. Release the parking - 2004 Polaris Predator | Owners Manual - Page 81
inside tire slips traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. NOTE - 2004 Polaris Predator | Owners Manual - Page 82
Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp - 2004 Polaris Predator | Owners Manual - Page 83
control or overturn and result in serious injury or death. Use extreme caution when operating on hills, and follow all procedures outlined in the owner's manual. 80 - 2004 Polaris Predator | Owners Manual - Page 84
, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. If you enter into a situation where sidehilling is unavoidable: 1. Slow down. 2. Lean into the hill, transferring your upper body weight toward the - 2004 Polaris Predator | Owners Manual - Page 85
death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. WARNING If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it's necessary - 2004 Polaris Predator | Owners Manual - Page 86
Driving Safely OPERATION Turning Around on a Hill 5. Staying uphill of the ATV, turn the handlebars full left. Reach across the handlebar and apply the front brakes to unlock the park brake. 6. With the front brakes applied, pull in the clutch 8' lever. Use the brakes to slowly allow the vehicle - 2004 Polaris Predator | Owners Manual - Page 87
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid - 2004 Polaris Predator | Owners Manual - Page 88
Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. See illustration. 5. Shut off - 2004 Polaris Predator | Owners Manual - Page 89
the brakes by applying light pressure to the lever until braking action is normal. After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 91. The engine oil and all grease fittings need special attention. 86 - 2004 Polaris Predator | Owners Manual - Page 90
the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footpeg level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended - 2004 Polaris Predator | Owners Manual - Page 91
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. - 2004 Polaris Predator | Owners Manual - Page 92
local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands - 2004 Polaris Predator | Owners Manual - Page 93
EMISSION CONTROL SYSTEMS Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set carburetion and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance. 1 - 2004 Polaris Predator | Owners Manual - Page 94
approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris - 2004 Polaris Predator | Owners Manual - Page 95
the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. WARNING Maintenance Chart Key " Perform these operations more often under severe use, such as in dirty or wet conditions, to purge water - 2004 Polaris Predator | Owners Manual - Page 96
Periodic Maintenance Schedule Item Brake systems/fluid Hours/Miles Pre-Ride MAINTENANCE AND LUBRICATION Frequency Pre-Ride Remarks Inspect; maintain fluid level between fill lines (see page 60); change every 200 mi. or 24 months Inspect Inspect; tighten Inspect; tighten Inspect; clean Inspect level - 2004 Polaris Predator | Owners Manual - Page 97
Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have a Polaris dealer perform these services. Item " " Steering Air box sediment tubes Headlamp Tail lamp/brake lamp J A-arm ball joint Hours/Miles Pre-Ride Pre-Ride Pre-Ride - 2004 Polaris Predator | Owners Manual - Page 98
filter General lubrication MAINTENANCE AND LUBRICATION Frequency Weekly 6 months 6 months Monthly Monthly Monthly 3 months Remarks Inspect; replace as needed Perform break-in service at one hour; change oil more often in very cold or hot weather or under severe use Replace with oil change; perform - 2004 Polaris Predator | Owners Manual - Page 99
performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have a Polaris dealer perform these services. Item " F " F " F " F A-Arm (A) Rear axle/ Rear eccentric (B) Swing arm pivot Upper steering post (C) Hours/Miles 50 hrs. 25 hrs. 25 hrs. 50 - 2004 Polaris Predator | Owners Manual - Page 100
Periodic Maintenance Schedule Lubrication Points MAINTENANCE AND LUBRICATION A A C B 97 - 2004 Polaris Predator | Owners Manual - Page 101
the procedures marked with a J could result in component failure and lead to serious injury or death. Have a Polaris dealer perform these services. Item Carburetor float bowl J Throttle Cable/ETC Switch Choke (enricher) cable Drive chain(s) Engine breather hose and filter (in airbox) Hours - 2004 Polaris Predator | Owners Manual - Page 102
; replace lines every two years L J Spark plug Ignition Timing Fuel system L J L " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California) J Dealer service item F Polaris Premium All Season Grease 99 - 2004 Polaris Predator | Owners Manual - Page 103
Adjust Periodic inspection; adjust when parts are replaced Adjust as needed L J " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California) J Dealer service item F Polaris Premium All Season Grease 100 - 2004 Polaris Predator | Owners Manual - Page 104
NOTES 101 - 2004 Polaris Predator | Owners Manual - Page 105
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs. Servicing Date Use the following chart to record periodic maintenance. Servicing Dealer or Person Remarks 102 - 2004 Polaris Predator | Owners Manual - Page 106
Periodic Maintenance Record Maintenance Interval Performed Servicing Date MAINTENANCE AND LUBRICATION Remarks Servicing Dealer or Person 103 - 2004 Polaris Predator | Owners Manual - Page 107
Performance Synthetic 4-Stroke (PS-4) Oil Polaris highly recommends the use of Polaris PS-4 or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. PS-4 has been specifically formulated for use in high performance engines. PS-4 is a fully synthetic, high - 2004 Polaris Predator | Owners Manual - Page 108
Engine Oil Level MAINTENANCE AND LUBRICATION Check the oil level before each use of the vehicle. The dipstick (1) is located on the left side of the ATV. 1. Position the ATV on a level surface. 2. Start the engine and let it idle for one minute. 3. Stop the engine and remove the dipstick. Wipe it - 2004 Polaris Predator | Owners Manual - Page 109
MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and - 2004 Polaris Predator | Owners Manual - Page 110
first. Perform the next oil and filter changes every 10 hours or every six months, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and operating in very cold or very hot weather. Severe use cold weather riding - 2004 Polaris Predator | Owners Manual - Page 111
MAINTENANCE AND LUBRICATION Oil and Filter Change 1. Place the vehicle on a level surface. 2. Clean the area around the oil tank (1) and crankcase (2) drain plugs with clean shop towels. 3. Run the engine for two to three minutes until warm, then stop the engine. 4. Place a drain pan beneath the oil - 2004 Polaris Predator | Owners Manual - Page 112
Oil and Filter Change 7. 8. 9. 10. 11. MAINTENANCE AND LUBRICATION Place a drain pan beneath the crankcase and remove the drain plug. Allow the oil to drain completely. Replace the sealing washer and reinstall the plug. Torque to 14 ft. lbs. (19 Nm). Place shop towels beneath the oil filter. - 2004 Polaris Predator | Owners Manual - Page 113
MAINTENANCE AND LUBRICATION Oil and Filter Change 14. Replace the o-ring in the cover. 15. Lubricate the gasket on the new filter with a film of fresh engine oil. 16. Reinstall the spring and install the new filter with the open end facing outward. 17. Install the cover and torque the bolts to 72-78 - 2004 Polaris Predator | Owners Manual - Page 114
Oil and Filter Change MAINTENANCE AND LUBRICATION 18. Remove the dipstick and fill the oil tank with 2 quarts (1.9 l) of recommended oil. 19. Place the transmission in neutral and set the parking brake. 20. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for - 2004 Polaris Predator | Owners Manual - Page 115
MAINTENANCE AND LUBRICATION Air Filter Systems 1. Unlatch and remove the seat. 2. Loosen the intake duct clamp (1) on the carburetor. 3. Pull the duct (2) off the carburetor. 4. Release the eight airbox cover clips (3) and remove the cover (4). 5. Remove the air filter (5). Inspect and replace if - 2004 Polaris Predator | Owners Manual - Page 116
, or leaks. Replace as needed. CAUTION Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service. 113 - 2004 Polaris Predator | Owners Manual - Page 117
MAINTENANCE AND LUBRICATION Engine Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. To ensure that the coolant maintains its ability to - 2004 Polaris Predator | Owners Manual - Page 118
Engine Cooling System MAINTENANCE AND LUBRICATION 1 Coolant Level The recovery bottle (1) is located on the left side of the machine under the front fender. The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool). As coolant operating - 2004 Polaris Predator | Owners Manual - Page 119
MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the cap. Radiator Coolant Level NOTE: This procedure is required only if the cooling - 2004 Polaris Predator | Owners Manual - Page 120
Lights MAINTENANCE AND LUBRICATION When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. 117 - 2004 Polaris Predator | Owners Manual - Page 121
MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise (1) to remove the bulb. On the right headlamp, turn the bulb housing clockwise (2) to remove - 2004 Polaris Predator | Owners Manual - Page 122
Lights MAINTENANCE AND LUBRICATION Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2 2. Remove the front cab (see page 124). Position the cab upside down on a soft protective surface to prevent scratching. 3. Remove the small adjuster bracket (1) and - 2004 Polaris Predator | Owners Manual - Page 123
MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement 5. Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab. 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. 7. Adjust for approximately 1/16" clearance - 2004 Polaris Predator | Owners Manual - Page 124
Lights MAINTENANCE AND LUBRICATION Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws (1). Remove the lens cover (2) and gasket and set aside for reassembly. 2. Remove the lamp (3) and - 2004 Polaris Predator | Owners Manual - Page 125
MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1. Position the ATV on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of 1 the headlight and make a mark on the wall at the same height. 3. Start the engine - 2004 Polaris Predator | Owners Manual - Page 126
fenders of the cab and the two bolts (3), washers and grommets (4) on the top of the cab. 3. Remove the two screws (5) from the rear cab supports. 4. Remove the cab. 1 2 5 2 123 - 2004 Polaris Predator | Owners Manual - Page 127
MAINTENANCE AND LUBRICATION Front Cab Removal 1. Remove the screws and washers (1) from the front left-hand and right-hand cab mounts. 2. Remove the wire harness connector from the headlights. 3. Loosen the screw (2) located inside the cab under the front cover. 4. Gently pull the cab forward to - 2004 Polaris Predator | Owners Manual - Page 128
Spark Plugs MAINTENANCE AND LUBRICATION S Use NGK DCPR8E spark plugs. S Proper electrode gap is .035″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Always use Polaris- - 2004 Polaris Predator | Owners Manual - Page 129
will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion - 2004 Polaris Predator | Owners Manual - Page 130
Spark Plugs MAINTENANCE AND LUBRICATION Spark Plug Removal and Replacement 1. Remove the side panels and front cab (see pages 123-124). 2. Turn the fuel valve to OFF. WARNING A hot ember on the ATV could cause fuel to ignite. Allow all components to cool sufficiently before accessing the spark - 2004 Polaris Predator | Owners Manual - Page 131
MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3. Move the fuel valve hose clamp (1) forward and gently remove the hose from the fuel valve fitting on the gas tank. 4. Remove the vent hose (2) from the instrument panel, taking note of the hose 2 routing for reinstallation - 2004 Polaris Predator | Owners Manual - Page 132
Spark Plugs MAINTENANCE AND LUBRICATION Spark Plug Removal and Replacement 7. Using the forked end of the spark plug wrench handle, remove the spark plug boot. IMPORTANT: Do not pull on the wire to remove the boot. Doing so may cause a wire disconnection inside the boot. 8. Using the spark plug - 2004 Polaris Predator | Owners Manual - Page 133
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components - 2004 Polaris Predator | Owners Manual - Page 134
Spark Arrestor MAINTENANCE AND LUBRICATION Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if - 2004 Polaris Predator | Owners Manual - Page 135
an ATV has been in water that exceeds the recommended depth. Serious engine damage WILL occur. Tow or trailer the ATV to your dealer for service. In an emergency, perform the temporary drying out procedure outlined below, which will allow short-term operation only, to drive the ATV to a trailer or - 2004 Polaris Predator | Owners Manual - Page 136
Vehicle Immersion MAINTENANCE AND LUBRICATION Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts. Stand clear of the spark plug while performing the following steps. WARNING 5. Intermittently and briefly touch the starter button in half- - 2004 Polaris Predator | Owners Manual - Page 137
MAINTENANCE AND LUBRICATION Battery The YUASA sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. Keep battery terminals and connections free of corrosion. If cleaning is - 2004 Polaris Predator | Owners Manual - Page 138
Battery Installation MAINTENANCE AND LUBRICATION 1. Set the battery in the battery holder. 2. Connect and tighten the red (positive) cable first, then connect and tighten the black (negative) cable. 3. Attach the hold-down strap and reinstall the rear cab. 4. Verify that cables are properly routed - 2004 Polaris Predator | Owners Manual - Page 139
a pre-determined point (see page 175). When using an automatic charger such as the Polaris Battery Tendert, refer to the manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging. WARNING An overheated battery could - 2004 Polaris Predator | Owners Manual - Page 140
Battery Charging (Sealed Battery) State of Charge 100% Voltage MAINTENANCE AND LUBRICATION Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) NOTE: Always verify battery condition before and 1-2 hours after charging. 12.8-13.0 volts None, check at 3 - 2004 Polaris Predator | Owners Manual - Page 141
and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the ATV decal and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread - 2004 Polaris Predator | Owners Manual - Page 142
Tire Tread Depth Wheel Removal MAINTENANCE AND LUBRICATION 1/8I (.3 cm) Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration. 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of - 2004 Polaris Predator | Owners Manual - Page 143
to the ground. 5. Torque the wheel nuts according to the wheel nut torque specifications chart. NOTE: Any nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer. 140 - 2004 Polaris Predator | Owners Manual - Page 144
Wheel Nut Torque Specifications MAINTENANCE AND LUBRICATION Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Bolt Size Front 3/8″ Rear 3/8″ Specification 25 ft. lbs. (34 Nm) 25 ft. lbs. (34 Nm) 141 - 2004 Polaris Predator | Owners Manual - Page 145
ADJUSTMENTS Brakes Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed - 2004 Polaris Predator | Owners Manual - Page 146
Brakes 1. Always maintain the brake fluid at an adequate level (see page 60). 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. 6. - 2004 Polaris Predator | Owners Manual - Page 147
ADJUSTMENTS WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the - 2004 Polaris Predator | Owners Manual - Page 148
rim (3). The difference between these two measurements should be between 0″ and 1/16″ toe out. NOTE: If you discover improper alignment, see your Polaris dealer for service. ADJUSTMENTS 2 3 1 145 - 2004 Polaris Predator | Owners Manual - Page 149
ADJUSTMENTS Chain Tension Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Chain tension must be inspected with the swing arm in the position shown in the illustration so that the axle, swing arm - 2004 Polaris Predator | Owners Manual - Page 150
side of the chain. NOTE: The chain has a press-on master link. A chain tool must be used if it's necessary to remove the chain for service. 1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (A). Fasten the strap around the axle and rear bumper tube. 2. Tighten the - 2004 Polaris Predator | Owners Manual - Page 151
ADJUSTMENTS Chain Tension 1. 2. 3. 4. Loosen the two eccentric locking bolts. Insert a pin punch into the eccentric axle housing. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. Tighten the eccentric locking bolts to 35 ft. lbs. (47.5 Nm). Step 2 Step 1 Proper - 2004 Polaris Predator | Owners Manual - Page 152
the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Suspension Settings Setting Softest Factory Firmest Compression Damping - 2004 Polaris Predator | Owners Manual - Page 153
ADJUSTMENTS Front Suspension The front suspension preload may be adjusted to suit different riding conditions and operator weight. WARNING Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left and right - 2004 Polaris Predator | Owners Manual - Page 154
Front Suspension Spring Preload 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring to the left (A) to increase preload. - 2004 Polaris Predator | Owners Manual - Page 155
preload, shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend. 2. Loosen the jam nut (1) and back it away from - 2004 Polaris Predator | Owners Manual - Page 156
Rear Suspension Rebound Damping 1. Locate the rebound damping clicker drum between the lower spring seat and the lower shock mount. 2. Turn the clicker to the left (A) to decrease the rebound damping. Turn it to the right (B) to increase rebound damping. NOTE: The rebound damping is factory set at - 2004 Polaris Predator | Owners Manual - Page 157
ADJUSTMENTS Rear Suspension Compression Damping The compression damping clicker drum is located on top of the shock reservoir, under the left rear fender. It has eight possible positions ranging from position 1 (softest) to 8 (firmest). The compression damping is factory set at position 4. To adjust - 2004 Polaris Predator | Owners Manual - Page 158
Clutch Lever Freeplay ADJUSTMENTS 1. Measure clutch lever freeplay between C the perch and the lever (A). This distance should be 1/8″ - 3/16″ (3.1 mm - 4.7 mm). 2. If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch B A adjustment screw (B) and - 2004 Polaris Predator | Owners Manual - Page 159
ADJUSTMENTS Throttle Cable Freeplay WARNING Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it's done correctly. Mechanically - 2004 Polaris Predator | Owners Manual - Page 160
, which could result in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the instrument panel and locate the handlebar bolts (1). 2. Loosen the four bolts and adjust the handlebar to the desired height. Be sure - 2004 Polaris Predator | Owners Manual - Page 161
ADJUSTMENTS Carburetor/Idle RPM If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Warm up the engine by running the vehicle for five minutes, or until operating temperature is reached. 2. Apply the park brake and place the - 2004 Polaris Predator | Owners Manual - Page 162
Carburetor/Idle RPM ADJUSTMENTS If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power - 2004 Polaris Predator | Owners Manual - Page 163
CLEANING AND STORAGE Cleaning the ATV See page 175 for the part numbers of Polaris products. Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV - 2004 Polaris Predator | Owners Manual - Page 164
Waxing the ATV CLEANING AND STORAGE Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish. CAUTION Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when using - 2004 Polaris Predator | Owners Manual - Page 165
as outlined on page 160. Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank, following the instructions on the container for the recommended amount. Fill the fuel tank with fuel. Allow 15-20 minutes of operation for the stabilizer to disperse - 2004 Polaris Predator | Owners Manual - Page 166
Storage Recommendations CLEANING AND STORAGE Oil and Filter Warm the engine and change the oil and filter. See page 107. Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube. Breather Filter Inspect and clean or replace the - 2004 Polaris Predator | Owners Manual - Page 167
and pull the duct off the carburetor. 4. Start the engine and spray Polaris fogging oil or a comparable product into the carburetor, following the instructions on the fogging oil container. 5. Turn the engine off, reassemble the intake duct to the carburetor, secure the clamp, and reinstall the seat - 2004 Polaris Predator | Owners Manual - Page 168
CLEANING AND STORAGE Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner's manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Engine Anti-Freeze Test engine coolant - 2004 Polaris Predator | Owners Manual - Page 169
CLEANING AND STORAGE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly. 4. Always tie the frame of - 2004 Polaris Predator | Owners Manual - Page 170
Contact your Polaris dealer for service if you're unable to identify solutions using the following charts. Engine Doesn't Turn Over Possible Cause Fuseable link Low battery voltage Loose battery connections Loose solenoid connections TROUBLESHOOTING Solution See Polaris dealer for replacement - 2004 Polaris Predator | Owners Manual - Page 171
TROUBLESHOOTING Engine Turns Over, Fails to Start Possible Cause Out of fuel Clogged fuel valve Water is present in fuel Fuel valve is turned off Old, - 2004 Polaris Predator | Owners Manual - Page 172
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with - 2004 Polaris Predator | Owners Manual - Page 173
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat - 2004 Polaris Predator | Owners Manual - Page 174
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Low or contaminated fuel Low octane fuel Old, poor or non-recommended fuel Clogged - 2004 Polaris Predator | Owners Manual - Page 175
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or - 2004 Polaris Predator | Owners Manual - Page 176
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Clogged, dirty or wet air filter Electronic throttle control (ETC) malfunction Other mechanical failure Overheated engine Solution Inspect - 2004 Polaris Predator | Owners Manual - Page 177
NOTES 174 - 2004 Polaris Predator | Owners Manual - Page 178
POLARIS PRODUCTS Part # Description Engine Lubricant 2874414 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2874415 PS-4 Oil (gal.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season - 2004 Polaris Predator | Owners Manual - Page 179
SPECIFICATIONS Predator 500 Gross Vehicle Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 645 lbs./292 kg 3.25 gal./12.3 l 71.5 in./182 cm 47.5 in./121 - 2004 Polaris Predator | Owners Manual - Page 180
Drive Ratio - Final Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Rear Two-Wheel Drive 5-Speed Manual Shift 14/37 2.6 1.7 1.3 1.1 0.9 Tire Size/Pressure - Front Tire Size/Pressure - Rear Front Brake Rear Brake Parking Brake Headlights Taillights Brakelight 21 - 2004 Polaris Predator | Owners Manual - Page 181
COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 178 - 2004 Polaris Predator | Owners Manual - Page 182
for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing - 2004 Polaris Predator | Owners Manual - Page 183
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER - 2004 Polaris Predator | Owners Manual - Page 184
THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will - 2004 Polaris Predator | Owners Manual - Page 185
Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on - 2004 Polaris Predator | Owners Manual - Page 186
must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle - 2004 Polaris Predator | Owners Manual - Page 187
where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was - 2004 Polaris Predator | Owners Manual - Page 188
A ADJUSTMENTS ...142-159 Air Filter Systems ...112-113 C Coolant Level, Radiator ...116 Coolant Level, Recovery Bottle ...115 Cooling System ...114-115 F Index B Battery ...134 Battery Charging ...136-137 Battery Installation ...135 Battery Removal ...134 Battery Storage ...135 Brake Fluid ...60 - 2004 Polaris Predator | Owners Manual - Page 189
Tires ...138-139 Toe Alignment ...144-145 Transporting the ATV ...166 TROUBLESHOOTING ...167-173 Turning Around on a Hill ...82-83 MAINTENANCE AND LUBRICATION ...91-141 Maintenance Record ...102-103 Making Turns ...78 Manual Shift ...65-68 Master Cylinder ...60 S Safe Riding Gear ...12-13
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