PREDATOR 500 Model #A05GJ50AA PREDATOR 500 TROY LEE

PREDATOR 500 Model #A05GJ50AA PREDATOR 500 TROY LEE

PARTS MANUAL PN 9919511 and MICROFICHE PN 9919512 7/04
PREDATOR 500
Model #A05GJ50AA
PREDATOR 500 TROY LEE
Model #A05GJ50AB
E 2004 Polaris Sales Inc.
TABLE OF CONTENTS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
Parts Manual
A
H
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . B13
AXLE, REAR . . . . . . . . . . . . . . . . . . . . . . . . B7
I
B
BRAKE, FRONT . . . . . . . . . . . . . . . . . . . . . B11
BRAKE, REAR . . . . . . . . . . . . . . . . . . . . . . B9
C
CAB, FRONT . . . . . . . . . . . . . . . . . . . . . . . .
CAB, REAR . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPERS, FRONT . . . . . . . . . . . . . . . . . . .
CALIPERS, REAR . . . . . . . . . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CHAIN COVER . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH LEVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
A5
A4
B10
B10
C9-10
D8
D5-7
A10
A9
A11
C5
D1
C6
D
DECALS (AA) . . . . . . . . . . . . . . . . . . . . . . . . A7
DECALS (AB) . . . . . . . . . . . . . . . . . . . . . . . . A8
E
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MOUNTING . . . . . . . . . . . . . . . . . .
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . .
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . A6
HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . B7
HUB, FRONT . . . . . . . . . . . . . . . . . . . . . . . B5
B14
A13
C7-8
A12
F
FRAME, MAIN . . . . . . . . . . . . . . . . . . . . . . . A3
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . D4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . B1
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7-8
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . C14
MASTER CYLINDER, FRONT BRAKE . . . . . B12
O
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . C13
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . C12
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
P
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
S
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOCK, FRONT . . . . . . . . . . . . . . . . . . . . . .
SHOCK, FRONT . . . . . . . . . . . . . . . . . . . . .
SHOCK, REAR . . . . . . . . . . . . . . . . . . . . . .
SHOCK, REAR, RESERVOIR MOUNTING . . .
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION, FRONT . . . . . . . . . . . . . . . .
SWING ARM . . . . . . . . . . . . . . . . . . . . . . . .
A4
C1
C2
C3
C4
A5
D3
B2-3
B4
B8
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . C11
WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . B5
WHEEL, REAR . . . . . . . . . . . . . . . . . . . . . . B6
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
MAIN FRAME
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
E 2004 Polaris Sales Inc.
3
4 5
6
7
8
16
15
14
9
13
8
2
12
11
10
2
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
1013995-385
7515399
1014799-385
7556042
7517857
5412067
1013851-385
1013851-067
8 7517632
Qty. Description
1
8
1
2
2
2
1
1
4
Bar, Grab, Silver
Screw
Frame, Rear, Silver
Washer
Screw
Bumper, Rubber
Peg, Foot, LH, Silver (AA)
Peg, Foot, LH, Black (AB)
Screw
Ref. Part No.
9
10
11
12
13
14
15
16
1013774-385
7517386
7555859
5435737
1014780-385
7542343
1013852-385
7515307
Qty. Description
1
5
5
1
1
2
1
2
Bumper, Front, Silver
Screw
Washer, Flat
Guard, Rock
Frame, Main, Silver
Nut, Flange
Peg, Foot, RH, Silver
Screw
7/04
A3
REAR CAB and SEAT
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
19
2
E 2004 Polaris Sales Inc.
1
5
20
18
17
2
16
7
6
4
3
15
8
7
9
10
14
10
11
9
13
10
10
12
9
11
9
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 2683687-070
2683686-070
2683655
2683656
2 7518196
3 5412507
4 5435231-293
5435231-496
5 7515199
6 7541925
7 7555792
8 1014438-385
1014439-385
9 7542153
Qty. Description
1
1
1
1
6
2
1
1
4
2
6
1
1
12
Asm., Seat (AA)
Covering, Seat (AA)
Asm., Seat (AB)
Asm., Cover (AB)
Screw
Grommet
Cab, Rear, Indy Red (AA)
Cab, Rear, Cosmic Sun (AB)
Screw
Nut, Nylok
Washer
Support, Rear Cab, LH, Silver
Support, Rear Cab, RH, Silver
Nut, Nylok, Flange
Ref. Part No.
10 7512297
11 5434432-070
5434433-070
12 7552801
13 1014371-067
1014372-067
14 7547069
15 5412067
16 5431501
17 1013941
18 7621403
19 5211033
20 7041607
Qty. Description
20
1
1
4
1
1
8
4
1
1
1
1
1
Screw
Pocket, Heel, LH, Black
Pocket, Heel, RH, Black
Washer, Spring Lock
Support, Heel Pocket, LH, Black
Support, Heel Pocket, RH, Black
Nutsert
Bumper, Rubber
Strap, Hood Latch
Latch, Seat
Rivet
Bracket, Lever Retainer
Spring, Latch, Light
7/04
A4
FRONT CAB and SIDE PANELS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
19
3
E 2004 Polaris Sales Inc.
16
4
17 18
5
15
1
6
9
2
8
7
7
11
10
9
7
12
8
7
9
13
14
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5434430-070
5434431-070
2 7518196
3 5434434-070
5434434-177
4 5246919
5246920
5 7542153
6 2633008-293
2633008-496
7 7512297
8 7552604
Qty. Description
1
1
8
1
1
1
1
4
1
1
5
2
Panel, Side, LH, Black
Panel, Side, RH, Black
Screw
Cover, Front, Black (AA)
Cover, Front, Black Metallic (AB)
Bracket, Cab Mount, Front, LH
Bracket, Cab Mount, Front, RH
Nut, Nylok, Flange
Asm., Cab, Front, Indy Red. (AA)
Asm., Cab, Front, Comic Sun. (AB)
Screw
Washer
Ref. Part No.
9
10
11
12
13
14
15
16
17
18
19
7547069
7670154
1014575-385
7552604
5434906
7517455
5412334
7512076
7571602
7555799
7547247
Qty. Description
3
1
1
1
2
2
6
4
4
4
8
Nutsert
Retainer, Bolt
Support, Cab, Front, Silver
Washer
Pad, Front Cab Slider
Screw
Cap, Rubber
Screw
Washer
Washer
U-Nut, Chimney
7/04
A5
HEADLAMPS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
3
1
2
4
5
8
E 2004 Polaris Sales Inc.
6
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 4010894
2 2410303
2410304
3 5246589
5246590
4 7571602
Qty. Description
2
1
1
1
1
4
Ref. Part No.
Bulb
Asm., Headlight, LH (Incl. 1)
Asm., Headlight, RH (Incl. 1)
Bracket, Headlight, LH
Bracket, Headlight, RH
Washer, Lock
5
6
7
8
7512076
7517910
7512084
5246591
5246592
Qty. Description
4
4
2
1
1
Screw
Screw
Screw
Bracket, Headlight Adjuster, LH
Bracket, Headlight Adjuster, RH
7/04
A6
DECALS (AA)
PREDATOR A05GJ50AA
4
2
5
3
6
7
8
1
9
10
4
E 2004 Polaris Sales Inc.
12
13
11
16 17
15
18
14
19
20
1
21
22
13
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 7170621
7170622
2 7172855
7172856
3 7172853
7172854
4 7170896
5 7170623
7170624
6 7172851
7172852
7 7172843
7172844
8 7172847
7172848
9 7172849
7172850
Qty. Description
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
Decal, Reflector, Red, LH
Decal, Reflector, Red, RH
Decal, Fender, Outside, Rear, LH
Decal, Fender, Outside, Rear, RH
Decal, Fender, Inside, Rear , LH
Decal, Fender, Inside, Rear , RH
Decal, “POLARIS”, Front/Rear
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
Decal, Fender, Front, LH
Decal, Fender, Front, RH
Decal, “PREDATOR”, LH
Decal, “PREDATOR”, RH
Decal, Front Cab, LH
Decal, Front Cab, RH
Decal, Cover, Front, LH
Decal, Cover, Front, RH
Ref. Part No.
Qty. Description
10
11
12
13
14
15
16
1
1
1
1
1
1
1
1
1
1
1
1
1
1
17
18
19
20
21
22
7078465
7171030
7170982
7172669
7173013
7173297
7172845
7172846
7172559
7079902
7172566
7172668
7172560
7171545
Logo, Polaris Star
Decal, “PRO STEERING”
Decal, “FOX RACING SHOX”, Swing Arm
Decal, Discretion Warning
Urocal, 50th Anniversary
Decal, Reverse
Decal, Tank Side, LH
Decal, Tank Side, RH
Decal, Age Warning, 16, ATV
Decal, 4 Stroke, Carburetor/Filter Information
Decal, Passenger Warning
Decal, Tire Pressure
Decal, Warning, General, CPSC
Decal, “Chain Freeplay”
8/04
A7
DECALS (AB)
PREDATOR A05GJ50AB
7
8
9
10
11
12
6
E 2004 Polaris Sales Inc.
5
4
13
14
3
19
2
1
20
21
22
23
18
15
24
17
3
4
16
25
3
2
28
7
27
26
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
7170982
7172669
7172745
7170621
7170622
7172725
7172726
7172723
7172724
7171761
7170623
7170624
7172741
7172742
7172739
7172740
7172733
7172734
7172735
7172736
7172737
Qty. Description
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Decal, “FOX RACING SHOX”, Swing Arm
Decal, Discretion Warning
Decal, “PREDATOR”, Rim
Decal, Reflector, Red, LH
Decal, Reflector, Red, RH
Decal, Rear Fender, Outside, LH
Decal, Rear Fender, Outside, RH
Decal, Rear Fender, Inside, LH
Decal, Rear Fender, Inside, RH
Decal, “POLARIS”, Front
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
Decal, Tank Side, LH
Decal, Tank Side, RH
Decal, “PREDATOR”, LH
Decal, “PREDATOR”, RH
Decal, Front Cab, LH
Decal, Front Cab, RH
Decal, Front Cover, “TLD”
Decal, Cover, Front, Stripes, LH
Decal, Cover, Front, Stripes, RH
Ref. Part No.
Qty. Description
14
15
16
17
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
18
19
20
21
22
23
24
25
26
27
28
A8
7078465
7172042
7172738
7172721
7172722
5435424
7173297
7172559
7079902
7172566
7172727
7172728
7172668
7172729
7172730
7172560
7171545
7172731
7172732
Logo, Polaris Star
Decal, “PRO STEERING”
Decal, Emblem Stripes
Decal, Fender, Front, LH
Decal, Fender, Front, RH
Badge, 50 Years
Decal, Reverse
Decal, Age Warning, 16, ATV
Decal, 4 Stroke, Carburetor/Filter Information
Decal, Passenger Warning
Decal, Fender, Inside, Bottom, Rear, LH
Decal, Fender, Inside, Bottom, Rear, RH
Decal, Tire Pressure
Decal, Fender, Outside, Bottom, Rear, LH
Decal, Fender, Outside, Bottom, Rear, RH
Decal, Warning, General, CPSC
Decal, “Chain Freeplay”
Decal, Front Cab, “POLARIS”, LH
Decal, Front Cab, “POLARIS”, RH
7/04
CONTROLS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
E 2004 Polaris Sales Inc.
2
6
22
21
5
3
7
4
25
24
8
23
20
17
18
9
19
16
15
14
10
13
11
12
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 7080922
2 7081221
7081097
3 5435785-070
4 ------------5 4010594
6 5434628-070
7 7517625
8 5432952
9 -------
Qty. Description
1
1
1
1
1
2
1
2
1
1
1
10 7080138
11 7081034
12 - - - - - - -
5
1
1
13 2010191
1
Nut, Choke
Cable, Choke (If built before 10/04/04)
Cable, Choke (If built after 10/04/04)
Panel, Instrument
Holder (See Clutch Lever Pg. A10, Ref. 7)
Bolt (See Clutch Lever Pg. A10, Ref. 8)
Switch, Handlebar
Grip, Handlebar
Screw, Set
Plug, Hole
Asm., Clutch Lever
(See Clutch Lever Pg. A10 for Details)
Cable Tie
Cable, Clutch
Asm., Master Cylinder (See Front Brake
Master Cylinder Pg. B12 for Details)
Asm., Throttle Clamp
Ref. Part No.
14 - - - - - - ------15
16
17
18
19
20
21
22
2010204
5411439
5434113
5410193
7081170
5246383
7518176
4010728
4010729
4011112
23 2010248
24 5435971
25 7517756
A9
Qty. Description
1 Clamp (See Front Brake Master Cylinder Pg. B12, Ref. 6)
2 Screw (See Front Brake Master Cylinder
Pg. B12, Ref. 6)
1 Asm., Throttle Control
1 O-Ring
1 Cover, Throttle Control
1 O-Ring
1 Cable, Throttle
1 Bracket, Instrument Panel
2 Screw
1 Indicator, Hot Light
1 Indicator, Neutral Light
1 Indicator, Reverse
1 Lever, Reverse Lock Out
1 Bezel, Reverse Lever
3 Screw
7/04
CLUTCH LEVER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
3 4
2
9
E 2004 Polaris Sales Inc.
6
8
5
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
2010212
2010229
2010228
2010227
2010226
Qty. Description
1
1
1
1
1
Asm., Clutch Lever
Lever, Clutch
Holder, Clutch Lever
Nut, Clutch Adjuster Jam
Adjuster, Clutch Cable
Ref. Part No.
5
6
7
8
9
2410321
7518212
2010225
7518211
7547253
Qty. Description
1
1
1
1
1
Switch, Clutch Lever
Bolt, Clutch Pivot
Holder, Clutch Lever, Lower
Bolt, Clutch Holder
Nut, Clutch Pivot
7/02
A10
COOLING
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
E 2004 Polaris Sales Inc.
2
1
3
10
4
5
9
6
27
29
6
26
28
25
11
12
7
8
13
15
16
24
1
14
4
21
1
20
23
19
22
18
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
7080614
8450050-28
4010808
7547197
1240093
7558301
7542122
1240130
8450003-1525
5430743
5810279
5433774
7512084
5434856
7052065
Qty. Description
4
1
1
3
1
4
2
1
AR
1
1
1
2
1
1
Clamp, Hose
Hose, Water
Sensor, Thermal Harness
U-Clip
Cap, Pressure
Washer, Flat
Nut, Nylok
Radiator
Line, Fuel
Cap, Over Flow Bottle
Gasket, Over Flow Cap
Plug, Cap
Screw
Tank, Surge
Fitting
Ref. Part No.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
5247340
7517510
7558301
5410437
5333796
5435881
7547220
5410584
5412678
5411975
7080654
7512163
2520272
7517975
Qty. Description
1
2
2
2
2
1
2
2
1
2
1
2
1
3
Bracket, Surge Tank
Screw
Washer, Flat
Grommet
Spacer
Screen, Radiator
Screw w/Washer
Bushing, Mount, Lower Radiator
Hose, Radiator, Formed
Asm., Grommet and Insert
Retainer
Bolt
Asm., Fan and Motor
Bolt
7/04
A11
EXHAUST SYSTEM
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
4
2
3
5
6
7
9
10
11
E 2004 Polaris Sales Inc.
8
12
22
21
13
14
15
16
20 19
17
18
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7518164
1261413-029
7512392
7552901
7515339
7555959
5412289
5334210
5412508
7558402
7542324
7081244
Qty. Description
3
1
1
1
1
2
2
2
2
1
1
1
Screw
Arrestor, Spark
Screw
Washer, Spring Lock
Bolt
Washer, Flat
Washer, Rubber
Spacer
Dampener, Vibration
Washer, Flat
Nut, Nylok
Clamp, Exhaust
Ref. Part No.
13
14
15
16
17
18
19
20
21
5246375
1261318-029
3087957
3080051
3087199
5247122-385
7552604
7518337
1261438
1261385-029
22 5812719
Qty. Description
1
1
2
4
4
1
3
3
1
1
1
Seal, Exhaust
Headpipe
Asm., Gasket Exhaust
Washer, Spring
Nut
Shield, Exhaust, Front, Silver
Washer, Lock
Screw
Asm., Silencer (Incl. 1,2,22)
Silencer
Gasket, Spark Arrestor
7/04
A12
ENGINE MOUNTING
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
6
5
1
7
8
E 2004 Polaris Sales Inc.
4
2
11
10
3
9
12
25
12
15
14
13
14
16
15
17
6
24
4
18
7
19
20
21
23
7 22
7
6
6
21
7
22
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
8450003-1525
2530009
8360009-100
7556264
7518148
7547108
7555806
7515433
5248313
7518430
7518431
7517915
2520413
Qty. Description
AR
1
AR
2
1
6
6
1
1
1
1
2
1
Line, Fuel
Filter, Fuel
Line, Fuel
Washer
Bolt, Swing Arm
Nut, Flange
Washer, Flat
Screw
Bracket, Mount, Clutch Cable
Screw
Screw
Screw
Asm., Hose, Oil Return
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
5411356
7556113
2520414
7080474
7517653
5248314
7517507
5248315
5248316
7512457
7515514
7547096
7080138
Qty. Description
2
2
1
2
1
1
2
1
1
2
1
1
1
O-Ring
Washer, Flat
Asm., Hose, Oil Suction
Clamp, Hose
Screw
Bracket, Mount, Reverse Cable
Bolt
Mount, Motor, Lower, LH
Mount, Motor, Lower, RH
Bolt
Bolt
Nut, Lock
Tie, Cable
7/04
A13
OIL TANK
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
E 2004 Polaris Sales Inc.
1
3
4
5
9
10
11
8
7
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7080474
8450096-82
5434743
7052339
5434834
5412666
Qty. Description
2
AR
1
1
1
1
Clamp, Hose
Line
Dipstick
Screen, Oil Filter, 45 Degree
Tank, Oil
Grommet
Ref. Part No.
7
8
9
10
11
7051524
5850135
5333204
5410828
7517686
Qty. Description
1
1
2
2
2
Plug
Washer, Nylon
Bushing
Grommet
Screw
7/04
A14
FUEL TANK
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
4
3
2
5
1
6
9
8
10
7
E 2004 Polaris Sales Inc.
11
5
24
12
22
23
13
14
14
15
15
15
14
14
21
20
19
15 16
14
18
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
7555734
7552606
7515321
7515166
7555859
5334283
5434736
------------------2520271
5434452
12 7052331
Qty. Description
1
1
1
1
3
1
1
1
1
1
1
1
1
Washer, Flat
Washer, Split
Bolt
Screw
Washer, Flat
Spacer
Cap, Fuel Tank (Incl. 8,9,10)
Gasket
Fitting
Line, Vent
Asm., Fuel Tank (Incl. 12)
Tank, Fuel
Valve, Fuel, ON/OFF/RESERVE
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
7515136
7080003
8450103
8360052-15
3088070
7512084
5246593
7546601
8360012-07
7518243
5435065
7542105
Qty. Description
2
6
AR
2
1
2
1
2
1
2
2
2
Screw
Clamp, Hose, Red
Hose, Fuel
Tubing, Convoluted
Asm., Pump, Fuel
Screw
Bracket, Fuel Pump Mount
Nut
Trim, Edge
Screw
Spacer
Nut
7/04
B1
STEERING POST
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
3
2
1
4
11
10
7
9
8
6
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
5246156-385
5631517
7515189
5631516
1822684-385
7542122
Qty. Description
1
1
4
1
1
4
Tube, Handlebar, Silver
Block, Handlebar, Pegged
Screw
Block, Handlebar
Post, Steering
Nut, Nylok
Ref. Part No.
7
8
9
10
11
5433866
7542324
5246732
7517428
7080510
Qty. Description
2
2
1
2
1
Bushing, Steering, Upper
Nut, Nylok
Bracket, Upper Steering Bushing
Bolt, Carriage
Fitting, Zerk
7/04
B2
STEERING, LOWER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
3
E 2004 Polaris Sales Inc.
4
5
1
6
2
25
7
13
8
2
12
5
4
9
3
25
13
21
12
22
23
24
10
13
12
14 13
15
16
19
20
11
12
19
13
18
6
11
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
1821405
7518218
1520531
7518219
5133986
3514320
1821318
1821319
5334160
7515406
5133344
7558402
7518068
7555806
Qty. Description
2
1
2
2
4
4
1
1
2
2
1
2
4
8
Asm., Tie Rod (Incl. 20-24)
Screw
Asm., Centerlink
Screw
Bushing, Flange
Bearing, Ball
Asm., Idler, Steering, LH (Incl. 4-7)
Asm., Idler, Steering, RH (Incl. 4-7)
Spacer, Steering
Screw
Block, Steering Mount
Washer, Flat
Screw
Washer, Flat
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
25
7542439
3514464
7710531
7558707
7547065
7661402
7661011
7061112
7547254
5133933
7542432
7061113
7661203
Qty. Description
9
1
1
1
1
1
3
2
2
2
2
2
4
Nut, Nylok
Bearing, Ball, Sealed
Ring, Retaining
Bushing
Nut, Nylon
Pin, Cotter
Pin, Cotter
End, Rod, LH
Nut, Jam, LH
Rod, Tie
Nut, Jam
End, Rod, RH
Pin, Cotter
7/04
B3
FRONT SUSPENSION
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
3
5
4
4
6
2
7
3
4
1
8
9
3
4
10
17
4
5
9
4
8
6
12
18
E 2004 Polaris Sales Inc.
11
13
14 15
22
3
14
11
13
21
4
9
9
4
18
20
19
8
16
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5630580
2 7043092-293
7043092-446
3 7542439
4 7555806
5 5334149
6 7515415
7 ------8
9
10
11
12
7515406
5434575
7080433
5133406
1014612-385
1014613-385
Qty. Description
2
2
2
12
24
4
4
2
8
16
8
8
1
1
Retainer, Spring, Slotted
Spring, Compression, Red (AA)
Spring, Comp., Cosmic Sunburst (AB)
Nut, Nylok
Washer, Flat
Sleeve
Screw
Shock, IFP, Front
(See Front Shock Pg. C1 for Details)
Screw
Bushing, A-Arm
Fitting, Lubrication
Shaft, A-Arm
A-Arm, Upper, LH, Silver (Incl. 17)
A-Arm, Upper, RH, Silver (Incl. 17)
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
7555928
7542523
7661205
1013799-385
1013801-385
------7710533
5435727
5334653
7518426
7518441
1822643
1822644
Qty. Description
4
4
4
1
1
4
4
2
4
4
4
1
1
Washer
Nut, Castle
Pin, Cotter
A-Arm, Lower, LH, Silver (Incl. 17)
A-Arm, Lower, RH, Silver (Incl. 17)
Joint, Ball
Ring, Retainer
Guard, Disk, Inner
Bushing (If built before 9/15/04)
Screw (If built before 9/15/04)
Screw (If built after 9/15/04)
Asm., Knuckle, Steering, LH
Asm., Knuckle, Steering, RH
7/04
B4
FRONT HUB and FRONT WHEEL
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
12
13
11
7
5
2
3
8
10
14
9
15
6
4
1
18
16
17
19
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
7542712
7661401
7556333
5133342
3610090
3514464
5133294-293
5133294-446
8 7515513
9 5133343
10 3514463
Qty. Description
2
2
2
2
2
2
2
2
8
2
2
Nut, Castle
Pin, Cotter
Washer, Flat
Spacer, Spindle, Outer
Seal, Lip
Bearing, Ball, Sealed
Hub, Wheel, Front, Indy Red (AA)
Hub, Wheel, Frt., Cosmic Sunburst (AB)
Stud
Spacer, Tapered
Bearing, Ball, Sealed
Ref. Part No.
11
12
13
14
15
16
17
18
19
3610093
5247752
5133341
7512325
5248379
5248773
1520841
1525017
7542459
5412158
5412625
Qty. Description
2
2
2
8
2
2
2
2
8
2
2
Seal, Lip
Disc, Brake
Spacer, Spindle, Inner
Bolt
Guard, Disc, Outer (AA)
Guard, Disc, Outer (AB)
Rim, Front
Valve, Rim
Nut, Flange
Tire, Front, 21x7-10 (AA)
Tire, Front, Radial, 21x7-10 (AB)
7/04
B5
REAR WHEEL
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
10
9
6
E 2004 Polaris Sales Inc.
7
8
5
4
1
2
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 5412550
5412624
2 7542459
3 1525017
4 1520840
5 7543005
6 7661404
Qty. Description
2
2
8
2
2
2
2
Tire, Rear, 20x11-9 (AA)
Tire, Rear, Radial, 20x10-9 (AB)
Nut, Flange
Valve, Rim
Rim, Rear
Nut, Castle
Pin, Cotter
Ref. Part No.
7
8
9
10
7555796
7555745
7515513
1520728-293
1520728-446
Qty. Description
2
2
8
2
Washer, Cone
Washer, Flat
Stud
Asm., Hub, Rear, Indy Red
(Incl. 9)(AA)
2 Asm., Hub, Rear, Cosmic Sunburst
(Incl. 9)(AB)
7/04
B6
REAR AXLE and HOUSING
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
12
E 2004 Polaris Sales Inc.
11
10
13
9
14
8
15
5
1
2
3
6
4
3 2
7
4
18
20
21
24
16
19
22
25
17
23
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
3610105
5412220
3514393
3514394
5133248
7080306
3610089
5133722
7542439
3222135
5130001
7512405
7670147
Qty. Description
1
2
2
2
1
1
1
1
4
1
1
4
1
Seal, Double Lip
O-Ring
Bearing, Cone, Taper
Bearing, Cup, Taper
Housing, Axle, Rear
Fitting, Lubrication
Seal, Lip
Axle, Rear
Nut, Nylok
Sprocket, 38T, Rear
Hub, Sprocket
Screw
Ring, Retaining
Ref. Part No.
14 3221193-092
15 3221192
16 - - - - - - 17 - - - - - - 18
19
20
21
22
23
24
25
7710516
7547217
5246155
5133340
7512365
7515102
5133428
7710405
Qty. Description
1 Chain, 92P
1 Link, Connector
1 Bushing, Caliper Mount
(See Rear Brake Pg. B9, Ref. 27)
1 Mount, Caliper Axle
(See Rear Brake Pg. B9, Ref. 2)
1 Ring, Retaining, External
4 Nut, Nylok
1 Disc, Brake
1 Hub, Rear Disc
4 Screw
1 Screw
1 Nut, Axle
1 Ring, Retaining
7/04
B7
SWING ARM
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
3
4
2
E 2004 Polaris Sales Inc.
5
1
6
32
30
4 3
10
8
7
9
31
11
30
29
12
14
25
24
23
22
11
12
13
20
21
20
15
26
28
16
15
18
17
19
27
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 7043093-293
7043093-446
2 ------3
4
5
6
7
5412290
5334195
7547066
7518207
-------
8 5435676-070
9 7518196
10 - - - - - - 11 - - - - - - 12
13
14
15
5434754
5133796
1590360
7558402
Qty. Description
1 Spring, Compression, Red (AA)
1 Spring, Compression, Cosmic Sun (AB)
1 Shock, Remote Reservoir
(See Rear Shock Pg. C3 for Details)
4 O-Ring
4 Reducer, Bushing
2 Nut, Nylon
2 Bolt
1 Retainer, Spring
(See Rear Shock Pg. C3, Ref. 28)
1 Slide, Chain
4 Screw
1 Bolt, Swing Arm
(See Engine Mounting Pg. A13, Ref. 5)
2 Washer
(See Engine Mounting Pg. A13, Ref. 4)
2 Bushing, Thrust Washer
2 Spacer, Swing Arm
2 Asm., Roller, Chain
2 Washer, Flat
Ref. Part No.
Qty. Description
16
17
18
19
20
21
22
7515345
7517877
7547107
7542324
3610104
3514473
-------
1
1
1
2
4
4
1
23
24
25
26
7510006
7558301
5435411
1542101
7547277
7518181
7518179
7542439
7555832
1542023-385
7515417
2
2
1
1
2
2
2
2
4
1
2
27
28
29
30
31
32
Bolt (Upper)
Bolt (Lower)
Nut
Nut, Nylok
Seal
Bearing, Needle
Nut, Lock
(See Engine Mounting Pg. A13, Ref. 24)
Bolt
Washer, Flat
Guide, Chain
Asm., Guard, Swing Arm
T-Nut
Screw
Screw
Nut, Nylok
Washer
Asm., Swing Arm, Silver (Incl. 13,20,21)
Screw
7/04
B8
REAR BRAKE
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
7
8
5
3 4
9
6
2
1
23 24
27
13
12
11
12
11
10
14
26
E 2004 Polaris Sales Inc.
25
24
23
22
15
16
19
21
20
18
17
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1910689
5245939
7558402
7552901
7515335
7080003
7517560
1930854
1910438
7661401
7555919
5433189
7042185
1910728
Qty. Description
1
1
2
2
2
2
1
1
1
1
2
2
1
1
Asm., Caliper
Mount, Caliper, Axle
Washer, Flat
Washer, Spring Lock
Bolt
Clamp, Hose, Red
Screw
Asm., Reservoir, Rear Brake
Hose, Reservoir
Pin, Cotter
Washer
Bushing, Pedal Pivot
Spring, Torsion, Foot Brake
Line, Brake, Master Cylinder to Caliper
Ref. Part No.
15
16
17
18
19
20
21
22
23
24
25
26
27
4010991
5246844-385
7042266
1013704-385
7661103
7661013
7518264
1910627
5410988
1910499
7518196
5435451
5134441
Qty. Description
1
1
1
1
1
1
2
1
4
2
2
1
1
Switch
Bracket, Brake Switch Mount, Silver
Spring, Extension, Brake Switch
Brake, Foot, Silver
Pin, Cotter
Pin, Clevis
Screw
Asm., Cylinder, Master
Seal
Bolt, Banjo
Screw
Retainer, Brake Line, Rear
Bushing, Caliper Mount
7/03
B9
FRONT and REAR CALIPERS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
2
3
4
1
3
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1910689
1 2201870
2 2202402
Qty. Description
3 Asm., Caliper (Incl. All)
1 Kit, Slider Bolt (Incl. Slide Bolts,
Sleeves, O-Rings, Bushings, Clip)
1 Kit, Piston and Seals
(Incl. Piston, Seals, Dust Boot)
Ref. Part No.
3 2202403
4 2202412
Qty. Description
1 Kit, Anvil
(Incl. Anvil, Bushing, Hardware)
1 Kit, Brake Pad Assembly Front (2 Sets)
7/03
B10
FRONT BRAKE
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
2
E 2004 Polaris Sales Inc.
3
4
1
5
17
16
15
8
14
7
9
11
12
6
3
13
6
3
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 1910590
2 ------3
4
5
6
7
8
5410988
4010758
1910884
1910499
7542122
5248779
Qty. Description
1 Asm., Master Cylinder, RH
1 Kit, Master Cylinder Clamp (See Front
Brake Master Cylinder Pg. B12, Ref. 6)
6 Seal
1 Switch, Pressure
2 Line, Front Brake, J/B Crimped
2 Bolt, Banjo
1 Nut, Nylok
1 Bracket, Crimped Junction
Ref. Part No.
9
10
11
12
13
14
15
16
17
7541925
1910689
7558402
7552901
7512365
5435861
7517396
7518281
7512297
Qty. Description
2
2
4
4
4
2
2
2
1
Nut, Nylok
Asm., Caliper
Washer, Flat
Washer, Spring Lock
Screw
Retainer, Brake Line, Front
Screw
Screw
Screw
7/04
B11
FRONT BRAKE MASTER CYLINDER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
2
1
E 2004 Polaris Sales Inc.
4
3
6
3
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1910590
1 7517899
2 2202405
3 2202406
Qty. Description
1 Asm., Master Cylinder, RH (Incl. All)
2 Screw
1 Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight Glass, Gasket)
1 Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
Ref. Part No.
4 2202408
5 2202407
6 2202409
Qty. Description
1 Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)
1 Kit, Piston
(Incl. Pistons, Seals, Dust Boot, Spring)
1 Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)
7/02
B12
AIR INTAKE
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
3
4
21
20
19
E 2004 Polaris Sales Inc.
5
7
7
6
18
17
8
7
16
15
11
9
10
14
12
13
12
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
5435990
7081041
5434472
7080413
5812361
5434448
5334128
5412221
7080140
5434450
7670090
Qty. Description
1
1
1
1
1
1
3
1
1
1
1
Lid, Airbox
Clamp, Airbox
Duct, Airbox/Carburetor
Clamp, Narrow Band
Filter, Crankcase
Housing, Airbox
Bracket, Airbox
Boot, Airbox
Clamp
Duct, Intake, Airbox
Clip, Dart
Ref. Part No.
12
13
14
15
16
17
18
19
20
21
7080474
8450096
7052336
5411765
7080865
7518165
7670117
7518196
5812328
5830226
Qty. Description
2
AR
1
2
2
3
8
3
1
1
Clamp, Hose
Line
Fitting, Barbed
Cap, Drain
Clamp, Single Wire
Screw
Clip, Airbox
Screw
Foam, Airbox
Filter, Airbox
7/04
B13
ELECTRICAL
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
7
6
8
5
9
E 2004 Polaris Sales Inc.
12
13
10
11
3 4
2
14
16
15
18
17
19
1
20
22
35
21
22
34
23
28
30
33
29
32
29
27
29
26
31
25
24
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
Qty. Description
1
2
3
4
4110264
2410527
5433733
4110264
4010278
1
1
1
1
1
5
6
7
8
9
10
11
12
13
14
15
16
7541925
7556034
7512027
2410572
7518432
2410596
5812681
7555727
7547004
7670109
4020139
4020149
2
4
2
1
2
1
1
2
2
1
2
2
Switch, Ignition
Harness, Main
Nut, Ignition Switch
Switch Ignition
Key, Blank NOTE: Your key can be duplicated only by obtaining a key blank
from Polaris and having it cut by mating
it with your existing key.
Nut, Nylok
Washer
Screw
Asm., Taillight
Screw
Wire, Taillight, LED
Mount, Taillight
Washer
Nut
Clip, Routing
Clip, Rosebud (Small)
Clip, Rosebud (Large)
Ref. Part No.
Qty. Description
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
16
1
1
1
2
2
1
2
1
1
3
1
8
1
1
1
1
1
1
7080138
7080761
7080492
4010678
2202213
7515199
4011169
7081123
5410608
4010884
5810317
4010654
7518196
4011087
4010093
3089266
3088052
4011170
4010926
Cable Tie
Cable Tie
Cable Tie
Battery
Kit, Battery Bolt
Screw
Cable, Ground, 6 Inch
Hook, Battery Strap
Strap, Rubber
Cable, Battery/Solenoid, Red, 7 Inch
Pad
Rectifier, Regulator
Screw
Switch, Magnetic
Cable, Solenoid/Starter
Asm., Coil, Ignition
Asm., CDI System
Cable, Ground, 13.75 Inch
Cable, Ground, 10 Inch
7/04
B14
FRONT SHOCK
PREDATOR 500 A05GJ50AA
19
1
20
18
17
2
16
15
3
4
E 2004 Polaris Sales Inc.
14
13
5
6
12
11
21
22
21
7
8
24
30
29
9
10
23
25
26
27
20
28
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
7043086
1500569
1500108
1500180
1500568
1500015
1500624
1500570
1500493
1500013
1500497
1500002
1500016
1500574
1500275
1500011
15 1500006
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Shock, IFP, Front (AA)
Asm., Cap, Body
O-Ring
O-Ring
Body
Plate, Back-Up
Piston
Asm., Bearing
Shaft
Asm., Eyelet
Sleeve
Bearing, External, Piston
Nut, Lock
Ring, Preload, Jam Nut
Asm., Floating Piston (Incl. 3)
Piston, Floating
Bearing, External, IFP
Ref. Part No.
16 1500161
1500022
17 1500019
18 1500014
19 1500566
20 1500103
21 1500573
22 1500572
23 1500567
24 1500074
25 1500544
26 1500020
27 1500266
28 1500268
29 1500496
30 1500488
Qty. Description
1
1
1
1
1
4
2
1
1
1
1
1
1
1
1
1
Screw w/O-Ring
O-Ring
Screw
Asm., Valve, Air
Sleeve
Bushing
Ring, Retaining
Guide, Spring
Bumper, Bottom Out
Bumper
Spacer
O-Ring
U-Cup
Wiper
O-Ring
Bearing
7/04
C1
FRONT SHOCK
PREDATOR 500 TROY LEE A05GJ50AB
24
1
23
22
21
2
20
3
19
13
4
18
16
5
6
7
17
15
14
13
12
11
8
E 2004 Polaris Sales Inc.
10
9
24
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
7043098
1500566
1500634
1500587
1500586
1500016
1500624
1500579
1500632
1500497
1500013
1500257
1500256
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
Shock, Piggy Back, Alum. (AB)
Sleeve
Body
Ring, Preload, Jam Nut
Ring, Preload, Jam Nut
Nut, Lock
Piston
O-Ring
Shaft
Sleeve
Asm., Eyelet
Wiper
U-Cup
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
1500228
1500074
1500635
1500014
1500019
1500589
1500236
1500633
1500515
1500208
1500617
1500627
1500103
Qty. Description
2
1
1
1
1
1
1
1
1
1
1
1
4
O-Ring
Bumper
Plate, Back-Up
Asm., Air Valve
Screw
Asm., Reservoir End Cap
Ring, Retaining
Reservoir
Piston, Floating
O-Ring
Cartridge, Single Adj.
Piston, Concentric Adj.
Bushing
7/04
C2
REAR SHOCK
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
15
16
17
14
13
1
18
19
20
21
10
2
3
4
5
6
12 11
9
36
35
7
22
23
34
8
33 32
26
25
24
31
E 2004 Polaris Sales Inc.
27
28
30
29
15
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
7043087
7043089
1500617
1500208
1500515
1500614
1500228
1500236
1500589
1500014
1500019
1500161
1500623
1500533
1500618
1500616
1500107
1500523
1500524
1500595
1500510
1500625
1500626
1500576
Qty. Description
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
Shock, Remote Reservoir, Steel (AA)
Shock, Remote Reservoir, Alum. (AB)
Asm., Cartridge, Single Adj.
O-Ring
Piston, Floating
Reservoir
O-Ring
Ring, Retaining
Asm., Reservoir, End Cap
Asm., Air Valve
Screw
Screw w/O-Ring
O-Ring
Hose
Housing, CD
Piston, Concentric Adj.
Fitting
Ring, Snap
Bearing
Asm., Body Cap
O-Ring
Body (AB)
Body (AA)
Ring, Preload, Jam Nut
Ref. Part No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
C3
1500575
7556312
1500516
1500630
1500631
1500579
1500256
1500613
1500577
1500597
1500637
1500638
1500639
1500640
1500641
1500642
1500619
1500612
1500257
1500578
1500228
1500298
1500615
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ring, Preload
Washer, Flat
Plate, Back-Up
Retainer, Spring
O-Ring
O-Ring
U-Cup
Rod
Bumper
Retainer, Spring
Spring
Ball
O-Ring
Retainer, RD Adjust
Knob
Screw
Eyelet
Shaft
Wiper
Asm., Bearing
O-Ring
Bumper, Top Out
Piston
7/04
REAR SHOCK RESERVOIR MOUNTING
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
1
2
4
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 ------2 7515319
Qty. Description
Ref. Part No.
1 Reservoir, Shock
2 Bolt
3 5132968
4 7542324
Qty. Description
2 Clamp, Reservoir
2 Nut, Nylok
7/02
C4
CRANKCASE
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
18
16
E 2004 Polaris Sales Inc.
7
8
6
20
15
9
11
5
19
2
4
3
1
17
12
13
21
14
16
3
10
2
25
1
13
27
22
24
26
23
28
2
32
29
31
30
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 3087930
2 3086838
3 3089580
3089679
4 3085525
5 3087934
6 3089585
7 3088138
8 3089439
9 3089586
10 3087935
11 3084834
12 3087929
13 3089581
14 3087928
3089680
15 3084862
16 3087926
Qty. Description
2
6
1
1
1
1
2
1
1
2
1
1
1
2
1
1
1
2
Collar
Pin, Dowel
Asm., Crankcase (Incl. all less 6-9,23)(AA)
Asm., Crankcase (Incl. all less 6-9,23)(AB)
Breather, Pipe, Air
Bearing, Ball
Plate, Stopper B
Plate, Stopper
Bolt, Socket Head
Bolt
Bearing, Ball
Bearing, Ball
Bearing, Ball
Bearing, Ball
Bearing, Ball (AA)
Bearing, Ball (AB)
Plug, Blind
Seal, Oil
Ref. Part No.
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
3087925
3086510
3089493
3087927
3087266
3089492
3089582
3089584
3089440
3089583
3087938
3087937
3082956
3089438
3084837
3086195
Qty. Description
1
1
8
1
2
7
2
1
1
1
1
1
1
1
1
1
Bearing, Release
Seal, Oil
Bolt, Flange
Seal, Oil
Knock, Pipe
Bolt, Flange
Bearing, Ball
Bearing, Needle
Bearing, Needle
Asm., Shaft, Water Pump (Incl. 27,28)
O-Ring
Bearing, Ball
Gasket
Plug
Asm., Seal, Mechanical
Pin, Stopper
8/04
C5
CYLINDER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
3
E 2004 Polaris Sales Inc.
5
4
6
7
9
8
10
14
13
12 11
24
23
15
16
10
25
22
17
18
19
20
21
26
27
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3087954
3087951
3087949
3085024
3089492
3087945
------3087275
3089441
3087947
3087944
3083798
3081330
3087956
3081497
Qty. Description
4
4
1
3
8
1
1
2
1
2
4
1
2
1
1
Bolt
Mount, Rubber
Cover, Head
Ball, Steel
Bolt, Flange
Support, Cam (Incl. 7)(AA)
Support, Cam (Incl. 7)(AB)
Pipe, Knock
O-Ring, Head Cover
Seal, Intake Valve
Valve, Guide
Pipe, Pulse
Bolt, Socket Head
Asm., Band Adapter (Incl. 14)
Screw, Pan Head
Ref. Part No.
15 3087955
16 3087953
17 3089587
18
19
20
21
22
23
24
25
26
27
3087957
3085326
3080530
3087199
3087266
3087946
3087952
3087948
3087941
3089519
Qty. Description
1 Asm., Adapter
2 Bolt, Flange
1 Asm., Cylinder Head
(Incl. 4-5,7,9-11,19,23)
2 Asm., Gasket, Exhaust
4 Stud
4 Washer, Spring
4 Nut
2 Knock, Pipe
2 Seal, Valve
4 Asm., Bolt and Washer
1 Asm., Gasket, Head
1 Asm., Cylinder
1 Gasket, Cylinder
8/04
C6
INTAKE and EXHAUST
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
E 2004 Polaris Sales Inc.
3
4
26 27
6
28
5
25
7
8
1
29
24
9
10
11
14
23
12
21
22
13
6
7
9
15
16
10
17
20
14
18
19
C7
8
5
INTAKE and EXHAUST
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
3087980
3087977
------------3087987
3087988
3087989
3087990
3087991
3087992
3087993
3087994
3087995
3087996
3087997
3087998
3087999
3088000
3088001
3088002
3088003
3088004
3088005
3088006
3088007
3088008
3088009
3088010
3088011
3088012
3088013
3088014
3088015
3088016
Qty. Description
2
1
1
1
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
Stopper, Bearing
Asm.,Camshaft, Intake (Incl. 3,4)
Bearing, Ball
Sprocket, Cam
Lifter, Valve
Pad, Adjusting, 1.450
Pad, Adjusting, 1.500
Pad, Adjusting, 1.550
Pad, Adjusting, 1.600
Pad, Adjusting, 1.625
Pad, Adjusting, 1.650
Pad, Adjusting, 1.675
Pad, Adjusting, 1.700
Pad, Adjusting, 1.725
Pad, Adjusting, 1.750
Pad, Adjusting, 1.775
Pad, Adjusting, 1.800
Pad, Adjusting, 1.825
Pad, Adjusting, 1.850
Pad, Adjusting, 1.875
Pad, Adjusting, 1.900
Pad, Adjusting, 1.925
Pad, Adjusting, 1.950
Pad, Adjusting, 1.975
Pad, Adjusting, 2.000
Pad, Adjusting, 2.025
Pad, Adjusting, 2.050
Pad, Adjusting, 2.075
Pad, Adjusting, 2.100
Pad, Adjusting, 2.125
Pad, Adjusting, 2.150
Pad, Adjusting, 2.200
Pad, Adjusting, 2.250
Pad, Adjusting, 2.300
Ref. Part No.
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
3084908
3087985
3087984
3087983
3087981
3089600
3088024
3087986
3084874
3085359
3088023
3088021
3088022
3087982
3089599
3088017
3088019
3087978
3088146
-------------------------
Qty. Description
8
4
4
4
2
1
1
4
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
Collet, Valve
Retainer, Spring
Spring, Valve, Inner
Spring, Valve, Outer
Valve, Intake
Asm., Lever
Bolt, Pivot
Seat, Valve Spring
Bolt, Flange
Bolt, Flange
Gasket, Aluminium
Asm., Tensioner
Gasket, Tensioner
Valve, Exhaust
Guide, Chain, 1
Chain, Timing
Guide, Chain, 2
Asm., Camshaft, Exhaust (Incl. 25,27,28)
Spring, Decompression
Bearing
Spacer
Cam, Decompression
Pin
8/04
C8
CARBURETOR
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
60
1
E 2004 Polaris Sales Inc.
2
3
53
54
4
56
5
50 49
51
55
52
59
6
7
58
57
8
46
47
48
9
11
14
13
10
12
39
16
22
18
20
23
24
21
33
32
25
26
27
19
42 13
38
37 36
35
34
15
17
41
40
31
30
28
29
C9
43
44
45
CARBURETOR
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
3131485
3131478
3131479
3131480
3131477
3131481
3131482
3131483
3131484
3130928
3131502
3130927
3130515
3130932
3131476
3130543
3130929
3130930
3131512
3131500
3131475
3131503
3130010
3131501
3131511
3130043
3131494
3131493
3131509
3130521
3131492
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
2
2
1
1
1
1
1
1
4
1
1
Cover, Diaphragm
Spring
Diaphragm
Valve, Piston
Holder
Spring
Washer
Washer
Jet, Needle
O-Ring
Case
Spring
Seal
Ring
Valve, Throttle, 105
Guide, Cable
O-Ring
Cover
Screw
A-Shaft, Throttle
Screw
Bolt
Spring
O-Ring
Screw, Adjust
Pin
O-Ring
Body, Float
Screw
Screw
A-Float
Ref. Part No.
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
3140172
3131490
3131491
3131496
3140053
3131575
3131057
3130924
3131023
3131488
3131574
------3130518
3130519
3130593
3130539
3130538
3131499
3131506
3131505
3131507
3131508
3131510
3130619
3131497
3131498
3130915
3130868
3140049
3130821
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
Jet, Main, 150
Ring
Holder, Jet
Jet, Needle
O-Ring
Valve, Needle
Screw
Screw
Jet, Pilot, 45
Jet, 42.5
Asm., Carburetor (Incl. All)
Packing
E-Ring
Cap
Asm., Plunger (AA)
Asm., Plunger (AB)
Spring
Holder, Guide
Screw
Cover
Spring
Asm., Diaphragm
Filter
Jet, Air
Jet, Main, 110
Jet, 120
Ring
E-Ring
O-Ring
Screw
8/04
C10
WATER PUMP
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
4
3
1
2
E 2004 Polaris Sales Inc.
5
6
7
9
8
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
3085352
3088028
3088029
3084877
3084942
3089601
Qty. Description
1
1
1
2
1
1
Asm., Switch, Thermostat
Asm., Thermostat
Cover, Thermostat
Bolt, Flange
Washer, Seal
Impeller
Ref. Part No.
7 3089714
8 3089602
3089681
9 3088030
10 3084874
Qty. Description
1
1
1
1
6
Gasket, Water Pump
Asm., Case, Water Pump (AA)
Asm., Case, Water Pump (AB)
Gasket, Copper
Bolt, Flange
9/04
C11
OIL PUMP
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
1
5
11
10
12
13
2
3
9
4
5
6
7
8
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
3088034
3088153
3088152
3089604
3088148
5 3084955
6 3089608
Qty. Description
1
1
1
1
1
2
1
Unit, Oil Strainer
Rotor, Scav, Outer
Rotor, Scav, Inner
Asm., Oil Pump (Incl. 2-6,9,11-13)
Case 1, Oil Pump
Pin, Dowel
Shaft, Oil Pump
Ref. Part No.
7
8
9
10
11
12
13
3089713
3088033
3084954
3088035
3089605
3089606
3089607
Qty. Description
1
1
2
3
1
1
1
Gear, Oil Pump
Ring, Snap
Pin, Dowel
Bolt, Flange
Case 2, Oil Pump
Rotor, Feed, Inner
Rotor, Feed, Outer
9/04
C12
OIL FILTER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
1
2
3
1
2
1
2
4
5
9
11
10
8
6
12
13
14
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
7
3086815
3088044
3089610
3087155
3084874
3088046
3088157
3088037
3089682
3089683
Qty.
3
6
1
1
2
1
1
1
1
1
Description
Ref. Part No.
Bolt, Banjo
Gasket
Asm., Oil Delivery Pipe
Plug
Bolt, Flange
Bolt, Flange
Asm., Filter Cover (Incl. 4,7)(AA)
Cover, Filter (AA)
Asm., Filter Cover (Incl. 4,7)(AB)
Cover, Filter (AB)
8
9
10
11
12
13
14
C13
3088038
3088036
3088042
3088039
3088040
3089450
3088041
Qty.
1
1
1
1
1
1
1
Description
O-Ring, Filter Cover
Asm., Filter, Oil
Spring, Filter
Asm., Valve, One Way
Spring, Valve, One Way
Gasket, Aluminum
Plug, One Way
8/04
MAGNETO
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
2
1
3
11
10
4
6
5
7
8
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
3088053
3088054
7080138
8360052
3089612
------3088055
Qty. Description
Ref. Part No.
Qty. Description
1
1
2
1
1
1
1
7
8
9
10
11
1
8
1
1
1
Asm., Coil, Ignition
Cap, Spark Plug
Cable Tie
Tubing, Convoluted
Asm., Stator
Asm., Magneto (Incl. 5)
Asm., Flywheel
3088048
3089439
3088049
3089613
3088051
Asm., Clutch, One Way
Bolt, Socket Head
Gear, Starter
Asm., CDI System
Plug, Spark (DCPR8E)
8/04
C14
CRANKSHAFT and PISTON
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
4
2
E 2004 Polaris Sales Inc.
4
3
20
5
18
17
16
15
19
6
14
13
7
12
11
10
8
9
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 3089444
2 3089596
3 3087971
------4 3085534
5 3087963
6 3089591
7 3087967
8 3087968
9 3089595
10 3089594
Qty. Description
1
1
1
1
2
1
1
1
1
1
1
Set, Piston Ring, Standard
Set, Piston, Standard (Incl. 4)
Pin, Piston (AA)
Pin, Piston (AB)
Clip
Bearing, Large End
Asm., Pin, Crank
Nut
Washer
Gear, Primary Drive
Sprocket, Crank
Ref. Part No.
11 3089593
12 3089590
13 3089588
3089589
14 3089597
15 3087976
16 3087974
17 3087975
18 3089598
19 3240168
20 3089592
Qty. Description
1
1
1
1
1
1
1
1
1
1
1
Gear, Balancer, Drive
Crankshaft 2
Asm., Crankshaft (Incl. 5,6,11-13,20)
Crankshaft 1
Asm., Shaft, Balancer
Bearing, Needle
Nut, Flange
Washer
Spacer
Key, Woodruff
Rod, Connecting
8/04
D1
MAGNETO COVER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
5
2
3
7
4
6
1
8
9
10
11
E 2004 Polaris Sales Inc.
12
13
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
3088065
3088067
3088066
3088068
3088057
3089684
6 3088061
7 3088059
3089686
Qty.
1
1
1
1
1
1
1
1
1
Description
Ref. Part No.
Qty.
Gear 1, Reduction
Gear 2, Reduction
Shaft 1
Shaft 2
Asm., Cover, Magneto (AA)
Asm., Cover, Magneto (AB)
O-Ring
Plug 2, Magneto Cover (AA)
Plug 2, Magneto Cover (AB)
8 3088058
3089685
9 3088060
10 3088064
11 3085698
12 3088062
13 3089451
1
1
1
11
2
3
1
Description
Plug 1, Magneto Cover (AA)
Plug 1, Magneto Cover (AB)
O-Ring
Bolt, Flange
Asm., Screw and Washer
Bolt, Socket Head
Gasket, Magneto Cover
8/04
D2
STARTING MOTOR
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
4
E 2004 Polaris Sales Inc.
3
5
2
1
6
7
10
6
9
8
5
11
8
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
6
3084874
3088167
3088169
3083649
3084408
3084982
Qty. Description
2
1
1
1
3
1
Bolt, Flange
Asm., Bracket, Rear
Brush Set, Carbon
Nut, Flange
O-Ring
Washer Set
Ref. Part No.
7 3085353
8 3084405
9 3088069
3085033
10 3240114
11 3084983
Qty. Description
1
2
1
1
1
2
Asm., Armature
Ring, Rubber
Asm., Starting Motor (Incl. 2-11)
Asm., Front Bracket (Incl. 10)
O-Ring
Asm., Set Bolt (Incl. 5)
8/04
D3
FUEL PUMP
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
E 2004 Polaris Sales Inc.
2
1
2
4
3
5
4
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1 3084591
2 3085356
3 3084999
Qty.
Description
Ref. Part No.
4 Asm., Screw and Washer
2 Asm., Screw and Washer
1 Asm., Screw and Washer
4 3088170
5 3088070
Qty.
Description
1 Gasket Set, Diaphragm
1 Asm., Fuel Pump (Incl. All)
8/04
D4
CLUTCH
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
11 12
E 2004 Polaris Sales Inc.
10
8
3
1
6
5
4
9
15
17
16
7
13 14
19
2
1
21
22
25
26
27
23
14
24
28
31 32
30
29
20
14
34
33
35
37 38
36
36
39
42
41
43
40
45
44
46
50
68
52
69
66
64
63
67
65
63
57 56
58
60
62
61
60
59
53
55 54
D5
51
47
49
48
18
CLUTCH
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
Qty.
1 3088096
2 3088104
3089706
3 3089631
3089701
4 3089635
3089705
5 3088093
6 3088091
7 3089636
8 3089665
9 3088191
10 3089668
11 3089667
12 3089666
13 3089652
3089711
14 3089637
15 3089672
16 3089670
17 3088135
18 3089671
19 3088033
20 3089669
21 3088106
3089712
22 3089629
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
3089630
3089699
1
1
3089700
3089634
3089704
3089632
3089702
3089653
3088092
3088095
3089633
3089703
3089622
3089623
3089688
3089689
3088094
3089698
3088106
3089694
3089626
3089692
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
23
24
25
26
27
28
29
30
31
32
Description
Ref. Part No.
Qty.
Washer
Collar (AA)
Collar (AB)
Gear, 1st Driven (AA)
Gear, 1st Driven (AB)
Gear, 5th Driven (AA)
Gear, 5th Driven (AB)
Clip
Washer, Spline
Collar
Shaft, Reverse (Incl. 9,10,11,12)
Pin, Dowel
Collar
Gear, Reverse Idle
Washer
Gear, Reverse, Driven (AA)
Gear, Reverse, Driven (AB)
Washer
Washer
Spring, Reverse Arm
Bolt, Flange
Lever, Reverse Arm
Ring, Snap
Arm, Reverse
Collar (AA)
Collar (AB)
Asm., Counter Shaft
(Incl. 1-7,14,23,24,28)(AA)
Shaft, Counter (AA)
Asm., Counter Shaft
(Incl. 1-7,14,23,24,28)(AB)
Shaft, Counter (AB)
Gear, 4th Driven (AA)
Gear, 4th Driven (AB)
Gear, 2nd Driven (AA)
Gear, 2nd Driven (AB)
Collar
Washer
Washer, Lock
Gear, 3rd Driven (AA)
Gear, 3rd Driven (AB)
Asm., Main Shaft (Incl. 14,31-38)(AA)
Shaft, Main (AA)
Asm., Main Shaft (Incl. 14,31-38)(AB)
Shaft, Main (AB)
Washer (AA)
Washer (AB)
Collar (AA)
Collar (AB)
Gear, 5th Drive (AA)
Gear, 5th Drive (AB)
33 3088091
3089695
34 3088093
3089697
35 3089624
3089690
36 3089628
3089696
37 3089627
3089693
38 3089625
3089691
39 3089651
3089710
40 3089650
41 3089645
42 3089644
3089709
43 3089662
44 3089646
45 3089643
3089708
46 3088115
47 3083783
48 3089647
49 3088123
50 3088116
51 3089638
3089707
52 3088191
53 3089641
54 3089640
55 3088117
56 3089639
57 3089642
58 3089660
59 3089661
60 3089659
61 3089654
62 3089655
63 3089658
64 3089656
65 3089657
66 3089649
67 3089664
68 3089663
69 3089648
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
Description
Washer, Spline (AA)
Washer, Spline (AB)
Clip (AA)
Clip (AB)
Gear, 2nd, 3rd Drive (AA)
Gear, 2nd, 3rd Drive (AB)
Washer (AA)
Washer (AB)
Collar (AA)
Collar (AB)
Gear, 4th Drive (AA)
Gear, 4th Drive (AB)
Gear, Reverse, Drive (AA)
Gear, Reverse, Drive (AB)
Shaft, Fork
Fork, Shift, Right
Fork, Shift, Left (AA)
Fork, Shift, Left (AB)
Spring, Forkshaft
Shaft, Fork
Fork, Shift, Main (AA)
Fork, Shift, Main (AB)
Point, Neutral
Asm., Screw and Washer
Asm., Switch, Position (Incl. 49)
O-Ring
Spring, Point
Asm., Drum, Shift (Incl. 52)(AA)
Asm., Drum, Shift (Incl. 52)(AB)
Pin, Dowel
Spring, Stopper
Asm., Arm, Stopper
Bolt, Stopper
Cam, Shift
Pin, Shifter
Plate, Guide
Bolt, Flange
Spring, Plunger
Shifter, Drum
Collar, Shifter
Plunger, Pawl
Pawl, Ratcher A
Pawl, Ratcher B
Spring, Return
Washer
Ring, Snap
Asm., Shaft, Shift
8/04
D6
CLUTCH
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
3
2
1
4
E 2004 Polaris Sales Inc.
5
6
8
7
13
11
14
12
15
10
9
19
20
17
16
26
18
25
21
22
23
24
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
3089616
1
2
3
4
5
6
7
8
9
10
11
12
13
3089621
3088079
3088078
3084877
3089619
3089617
3088186
3088180
3088081
3089620
3086285
3086286
3088184
Qty.
Description
1 Asm., Clutch, Multi
(Incl. 6-8,13-18,25,26)
1 Plate, Release
1 Spring, Release
1 Asm., Shaft, Release
1 Bolt, Flange
1 Collar, Distance
1 Asm., Clutch, Outer
1 Washer, Thrust
1 Asm., Center, Clutch
1 Pusher
1 Rod, Push
1 Nut, Lock
1 Washer, Lock
7 Plate, Clutch
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
3088185
3089618
3088177
3088176
3088175
3089615
3089614
3089687
3085850
3084874
3088072
3088073
3088178
3088179
Qty.
1
7
6
6
6
1
1
1
1
11
1
1
1
1
Description
Disk B, Clutch Friction
Disk A, Clutch Friction
Spring, Clutch
Washer, Clutch Spring
Bolt
Gasket, Clutch Cover
Asm., Cover, Clutch (Incl. 21,23,24)(AA)
Asm., Cover, Clutch (Incl. 21,23,24)(AB)
Asm., Pipe
Bolt, Flange
Seal, Oil, Crank
Ring, Snap, Inner
Disk, Clutch Pressure
Bearing, Ball
8/04
D7
CHAIN COVER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
5
E 2004 Polaris Sales Inc.
4
2
3
6
1
6
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
3089675
3089676
3088135
3089674
Qty. Description
1
1
2
1
Ref. Part No.
Sprocket, 14T
Plate, Fixing
Bolt, Flange
Plate, Drive Chain
5 3089673
6 3084874
7 3089677
Qty. Description
1 Asm., Cover, Drive Chain
3 Bolt, Flange
1 Asm., Pedal, Shift
8/04
D8
TOOL KIT
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
11
1
2
3
10
4
5
9
6
8
7
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No.
1
2
3
4
5
3088136
2870725
2874748
-------------------
Qty. Description
1
1
1
1
1
1
Kit, Tool (Incl. 3-7)
Gauge, Tire Pressure
Screwdriver, Straight Blade
Wrench, Open
Wrench, Plug
Screwdriver, Star End
Ref. Part No.
6
7
8
9
10
11
------------2871095-067
2873647
2682572
9919510
Qty. Description
1
1
1
1
1
1
Puller, Spark Plug (Wrench Handle)
Bag, Plastic
Wrench, Spanner
Wrench, Torx
Pouch, Tool Kit
Owner’s Manual, ‘05 Predator
7/04
D9
PRINTED IN THE USA
PARTS MANUAL PN 9919511 and MICROFICHE PN 9919512 7/04