500 rebuild
 

Hi, I was thinking about rebuilding my 03 predator 500 as it is knocking. I was wondering which parts I would need to buy to rebuild it.
Cheers :thanks:

Get one of these and read through it before you even lay a wrench on it.2003 Polaris Predator 500 Service Manual PDF Download

Hi thanks for your reply. Iv got clymer and a freind who is an expert at building engines who is going to do it for me. What parts ae most likley to go and what parts should i replace while we are in it?

The thing about engines is that you don't know what you'll need until you tear it down. Knocking can be from piston slap(worn piston /rings) lower rod bearing wear or even crank shaft bearings. Your Clymer should show you what to inspect for the most part.You may be able to get by with a new top end or you may have to completely strip the engine down and rebuild it. The most important thing to check is the rod when you pull the head and cylinder off.If it has any up and down play at the crank shaft,the lower part of the engine will have to be torn down. ebay has good prices on top end gasket kits as well as complete gasket kits if the engine has to be split. Plus for the most part Wiseco pistons are the best replacement pistons.http://www.ebay.com/itm/Tusk-Top-End-Head-Gasket-Kit-POLARIS-PREDATOR-500-2003-2007-NEW-/290881162287?pt=Motors_ATV_Parts_Accessories&hash=item43b9de4c2f&vxp=mtr http://www.ebay.com/itm/POLARIS-PREDATOR-500-Complete-Engine-Gasket-Kit-Set-2003-2004-03-04-ATV-/121564577127?pt=Motors_ATV_Parts_Accessories&hash=item1c4dd03d67&vxp=mtr http://www.ebay.com/itm/Polaris-Predator-500-2003-2007-Wiseco-Piston-Kit-4807M09920-High-Compression-/261729008444?pt=Motors_ATV_Parts_Accessories&hash=item3cf043bb3c&vxp=mtr

I was told when I bought my 05 that when the shop checked it over the cam bearing was a bit warn but not to worry about it. So that would be another thing to check as well as your wear limits on the cam itself. I think these engines are pretty noisy regardless, even when in pristine condition.

Good luck with your rebuild, and OPT, it's good to know that you don't always have to go with OEM for quality parts. :)Thanks.

Hey, Iv just installed a namura piston kit and it has fixed the problem :nod: I am just wondering how long it takes to run it in? Cheers

Break in period is normally a couple hrs or so of low to mid range throttle. No wide open throttle during this period. Cooling off between this period of time helps on ring seating also.Allows for contraction and expansion of cylinder,piston and rings.