500 rebuild
#2
Get one of these and read through it before you even lay a wrench on it.2003 Polaris Predator 500 Service Manual PDF Download
#3
#4
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
#5
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.
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.
#7
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