How to Build a Polaris Predator 500 Engine | 2003 - 2007 Full Build Step by Step

[@skeetlybeet2584]

A 45 min video from sabo….. The night couldn’t get any better!!

[@MichaelSabo]

Ahh shit, thank you for that Skeetly 👊

[@electric2018]

uMm aCtuAlLY iTs 44 mINutEs aNd 12 sEcONdS

[@TopherCrad]

​@MichaelSabo did you have to get a different throttle cable for that carb?

[@MichaelSabo]

Yall asked for it, here it is! Chapters and links below! Chapters 0:00 - Intro 1:32 - Disclaimer 2:38 - Differences in Crankshaft by Year 4:10 - Crankshaft Install 5:22 - Counter Balancer Install 6:13 - Transmission Install 7:17 - Shift Forks and Drum Install 9:27 - Oil Screen Install 9:50 - Assembling Case Halves 11:52 - Oil Pump Install 13:02 - Shift Mechanism/Shift Shaft 14:32 - Rear Cam Chain Slider Install 14:42 - Clutch Basket/Inner Hub Install 15:41 - Timing Chain Gear/Primary Drive Gear 17:03 - Starter Install 17:32 - Prepping Flywheel and Crank 20:54 - Flywheel Install/Starter Gears 22:06 - Stator Cover Install 23:22 - Neutral Switch Install 23:52 - Showing The Big Bore Kit 25:03 - Piston Install 26:19 - Cylinder and Head Install 29:47 - Camshaft Explanation 30:46 - Installing The Cams 33:47 - Timing Chain Tensioner Install 34:36 - Cam Cap Install 35:13 - Intake Boot Install 36:00 - Clutch Pack Install 37:33 - Clutch Push Rod/Actuator 39:15 - Clutch Cover Install 40:42 - Oil Filter Cover 41:11 - Water Pump Cover 41:38 - Oil One-Way Check Valve 42:10 - Engine Showcasing and Performance 43:24 - Closing/Sponsor Thank you Parts/Tools 39mm Carb - amzn.to/3wMB9Ux Air Filter - amzn.to/2TJixX1 Outerwear - amzn.to/3g5JYSi Service Manual - bit.ly/35CYImG Mapp Gas - amzn.to/3j03D9g Torch - amzn.to/2Uq3iCN Assembly Lube - bit.ly/3qecHJt Anti-Seize - bit.ly/2SP14vZ Crankshaft Install Tool - bit.ly/3j0mKjx Blue Loctite - bit.ly/3h3CArh Red Loctite - bit.ly/2SO2hDV Small Impact Driver - amzn.to/3zIh5Vm T-Handle Hex Wrenches - bit.ly/3gPaSOM Clutch Holding Tool - bit.ly/3cXqlej Large Torque Wrench - bit.ly/3zKjwa2 Large Impact Driver - amzn.to/3zImLi8 Timing Chain - amzn.to/3zKWHmC Dielectric Grease - bit.ly/3xDnPCa Valve Grinding Compound (For Flywheel) - amzn.to/3xOWZXR Assembly Grease - bit.ly/35FHiGk Big Bore Kit - bit.ly/2TTRUig Dead Blow Hammer - amzn.to/3xxEQxt Standard Bore Top End Gaskets - bit.ly/3wJnyx7 Kibble White Studs - Available Soon! Stage 1 Cams - bit.ly/2TKQM0a Valve Shim Kit - bit.ly/2TNQ0j8 Feeler Gauge - bit.ly/3iVAOuB Wrinkle Black Heat Paint - amzn.to/3xCKvlK Clutch Kit - bit.ly/3cWKkK2 Engine Oil - bit.ly/3xEROt5 2005-2007 Complete Gasket Kit - bit.ly/3zGCxKj Gasket Spray - amzn.to/3qe9iKy Engine Complete Seal Kit - amzn.to/3gNn2ro Engine Oil Filter - bit.ly/3xAabj1

[@hennessyremy4970]

Your a goat!!!!

[@arnou.1120]

The link for the service manual doesn’t work - can’t find the manual on that web site (searched for „Predator“).

[@leehuntley189]

Dude the grease on gaskets works but just for shits n giggles try original chapstick! Especially on carb gaskets! Since I've used it I've not had to buy another gasket I've chapsticked! Sounds dumb but works like a charm and holds them a tad better and not as messy as grease

[@immelting9834]

Your the f'in man bro . Thanks for posting this .

[@Moto67hub]

hello, I need spare parts for this motor, please tell me where to find them, get in touch with me, I'm from Russia

[@christopheravery5808]

I finally got a chance to watch this. It’s actually quite different from other motors I’ve seen, I’m glad you put this out there for everyone. I wish more people did in depth motor builds.

[@MichaelSabo]

Yes, a strange design from what I've seen as well

[@Luuminor_O]

It feels satisfying to watch you repair it. A few days ago I bought a 2007 Predator 500 with the only problem that it was binding oil with coolant. If you come down nearby, I would not hesitate to give you the engine so that you can repair it completely.

[@turcanusilviu5783]

What was the problem for the oil in the coolant ? I have same problem . Tnx

[@Sodder84]

Man it must feel so good knowing your engine is so well built. Just picked up a 2003 Predator. Very happy you recently did a build!!! Thanks for the content.

[@iifunnyyfn481]

i just dont understand how you dont have more subs than you do now. ive been here for like 2-2.5 years now, and ive watched you grow drastically. keep it up man

[@ls2005019227]

Best motor build/assembly video that I've ever seen! Thanks for taking us along! I don't have a predator; probably won't ever have a predator.....but have thoroughly enjoyed watching you go through this one. Your editing/organization is top notch, and I enjoyed this build video, more than any video of riding/ripping (although seeing the results is also part of the fun). Thanks!

[@MichaelSabo]

Thank you for the awesome feedback Robert; I appreciate you watching my video and following the build!

[@BillyPinto33]

Love the overall quality of the video. Definitely improving!

[@MichaelSabo]

I appreciate that feedback Billy 👊

[@backyardmec2348]

Thanks Micheal i just finished doing clutches timing chain nd timing my engine again on my 04 predator 500 im very happy and thankful for your vids you even helped me build my banshee last year 💪🏼

[@llacy01]

Just picked up an 04 Predator 500. your videos have given me more help on the bike than anything else! I know its been a while but keep it up!

[@Dabiiii__]

This is by farrrr my favorite build I’ve always wanted one of these 500s!

[@ni_wink84]

I’ve said it before I’ll say it again, your attention to details is amazing!

[@MichaelSabo]

Always appreciated Nick 🤘

[@XxXsupertrampXxX]

Thank yo man, this is going to help me alot, probably the only video of your ill be needing but you've earned my subscription with this super well made informative video, your the man.

[@arnou.1120]

Thank you, thank you, thank you. A comprehensive motor rebuild tutorial at last!

[@MichaelSabo]

You're welcome man, I hope it helps some people out!

[@arnou.1120]

BTW there is a service manual freely available on the web for the FUJI HEAVY „EW50“, which should be our motor. What does the identification plate on your motor say?

[@trentfinnessey5770]

Oh boy! I just got a predator 500 and my brother got a raptor 660! Both quads have a white brothers slip on. Can’t wait to see which ones faster!! 💪💪

[@MichaelSabo]

Congrats on the new quad man!

[@petemartin2824]

Thanks for the video. I'm in the process of building my 03 for the second time. Had to split the cases a few years after getting it (bought it new) due to the weak shift forks that came in the 03. For anyone with an 03, if you split the cases make sure you get shift forks from an 04. They have an "A" following the number stamped on the fork (M83A) while the 03 forks do not have the "A". They are substantially stronger. The main fork was the culprit. I have a 558 big bore kit with a sleeved cylinder that HPD inc used to sell back in the day, but fortunately the sleeve stayed put. I also have a set of stage 2 hot cams that I have never tried. The 558 kit gave me a nice boost in power. I am now going with the kit from BPRacing. I have a predator breakdown and rebuild video that I bought in the early 2000's that a guy shot with a VCR type recorder and then transferred to disc.your video is so much easier to watch. Thanks again.

[@koryburdette7478]

doubt yall will ever read this, but i really appreciate the video, i have one myself and i can hardly find any videos or info on them...i really appreciate it, now maybe i can fix mine

[@AllThingsCycle]

this content is absolute gold, Mike. Please keep up the phenomenal work brudda

[@MichaelSabo]

Glad you enjoy it man; thank you for the feedback and for watching 👊

[@azzionsmith7187]

That was a pretty in-depth build great vid i got a 05 predator I gotta rebuild soon. Now I can’t wait to tackle it

[@MichaelSabo]

Thank you man, I hope my video can help!

[@cranedaddy678]

Dude perfect timing, I just bought a 06 Predator this weekend. (It runs fine though)

[@MichaelSabo]

Hopefully it stays running fine man but if it doesn't you have this video 😂

[@cranedaddy678]

@@MichaelSabo That's why you're the man!

[@ivanbosyuk4175]

Very good and informative video, I remember when I did mine and couldn't find any info anywhere online so I just went in blind and thanks God everything went well

[@hectorochoa6265]

i used to have one of these with a yoshimura exhaust and it was insanely loud. you should really look into purchasing one you wont regret it

[@pasturedriftkings7174]

This is definitely a good video of step by step cuz I want to get another Polaris Predator

[@raiderhater2185]

Dropped 3rd in my 04 preddy this weekend at ocotillo wells so i might as well go through everything while I got it split. So great video and will be hunting a ton of parts soon.

[@gutierrezsergio15]

Glad you decided to make the build video

[@MichaelSabo]

sergio_G thank you for watching! 🤘

[@JohnnyScoular]

It’s always enjoyable learning about the different atv engines 🙂

[@MichaelSabo]

Glad you enjoyed it man!

[@jorgesoto8680]

Thats was priceless with the crank install 🤣 Love it mike keep it up brother

[@MichaelSabo]

😂 lol, glad you like the video man; thank you for watching 🤘

[@TNTMOTO]

OMG i laughed so hard when you installed the crank in the wrong position to have the rod clear. Awesome that you left that in. I built a motor a while ago and totally forgot to put the dowels in when i put the engine together. Got the whole motor together and then saw i still had them sitting on the bench. I swore for quite awhile before i started laughing at myself. Then proceeded to disassemble and reassemble everything.

[@mayitas107]

This is the best video so far for my rebuild 2005 polaris predator 450cc, I don't have any compression on the cylinder and I'm about to do smoke leak test first to see were is going 😮‍💨

[@bruceschlick4009]

My dude I can't believe you just called yourself a junior engine builder. Ok I know that this vid is a year old so I'm kinda late. But in my eyes you are a master mechanic.

[@aalkurdi]

Ur both lucky and hard working, way to go sir

[@justinhill5370]

I gotta replace the transmission in my 05 right now an watching this whole video has will help me so much thankyou

[@careysoutherland8291]

always enjoy your engine builds. keep the content coming

[@noghost4197]

Thank you very much for this video. I managed to do my first ever engine fix of anykind with this vid. I had to change my cranksaft, needlebearing broke.

[@commentpulling]

Yet another great video!! Keep them coming. 👍🏻

[@MichaelSabo]

Thank you commentpulling!

[@bubbacarnes7252]

At long last!! Great video as always 👍 thanks big Mike!😆

[@MichaelSabo]

I appreciate you watching Bubba 👊🤘

[@normanmonroe3758]

nice detailed video, i am currently rebuilding my top end and this video helped me. my predator is an '03

[@cycletechperformance9581]

I cant believe I just watched you put those cam caps on with a impact gun and then just tighten them without a torque wrench! Those fasteners are one of the most important on the whole motor to be properly torqued. On top of that you put assembly oil on the cam chain tensioner but not on the valve buckets and cam cap "plain bearing surfaces/Cams! Dude you are better then this. As a engine builder that builds these motors daily I felt I had to say something. Im here in PA also and maybe I should come over and make sure you are feeling ok! Lol

[@shurawi172]

Probably quite a few in this field with this engine, so figured I would ask. I have an SMC 500 Wildcat with this engine that has a nasty, kinda high pitch, "kling" sound when turning the starter. As soon as it starts the sound is gone. Changed the starter and it did make it sound a bit less nasty, but not much, so there is something more that is at play here. If anyone has an idea, feel free to share :) Great video to save for future renovations as my third gear is not sounding very nice anymore either. Still works great though but I guess a tooth is gone or something. Thanks for the video!

[@htxrancher3138]

Hey Michael I just wanna say i have been a subscriber since 15 or 20k and I enjoy your content👏👏👍🏻👍🏻

[@toddtaylor7635]

Thanks you just saved me from a mistake that I almost made.

[@davidthorburn9327]

Yes keep the engine builds coming!!!!!!!!!

[@MichaelSabo]

Thank you for watching Dave!

[@nado37]

I never really liked the predators but you build a beautiful clean looking engine!

[@owenstewart1160]

I want to learn more about these kinds of engines but I don’t have one I could get my hands on. If you don’t mind, could you go over what a few of the parts in the engine do and how it works such as the shift star. These types of videos you make are very good and you can actually understand what you are doing so thank you very much for making great content.

[@MichaelSabo]

Glad you enjoy the videos man! This was more of an assembly how to more than an actual explanation of how the components work but I might make a video explaining the shift star and how it works on a future build since you asked! 👊

[@Angorski7]

Hello, I want to congratulate you on a nice video and the work you put into making it! Thanks to your video I was able to fix my Predator myself! I really enjoy following your channel, keep up the good work!

[@isaachart4136]

Great video man! Such an awesome quad!

[@MichaelSabo]

Thank you Isaac Hart!

[@PedroTravi21]

I would love to see a YFZ 450 (carburator model) build from Michael. Nice quality of the video, and so entertaining!! I´m learning a lot. Thanks!!

[@MartellAVP]

This video was awesome! This is great for newbies wanting to dive into an engine. I plan on doing just that in the future. Thanks for doing these man! We appreciate it!

[@Donaldsrepair]

Love your vids man keep up the good work and the build videos

[@jacobreaves62]

Mike these engine builds like this are great. You should get a 04 or 05 trx 450r and do a build on that next. Can’t wait for quad wars series 2.

[@Suzieash82]

Hey Michael, i am rebuilding a predator myself, mine has a issue with the trans being stuck in gear. so i am splitting the case to see what the issue is, i have watched this video multiple times and i must say you are by far the most in depth build up guy i have seen. Keep it up dude. I also noticed something, on the video of you tearing this down you pulled the stator side off the case and disassembled the trans from that side and removed the springs in the shift fork shafts from that side. But when you put the engine back together in this video you assembled the trans with the sator side facing down and put the springs in the shift fork shafts from the other side. I just was wondering if the shaft is hollow or if it doesn't matter where the springs go or is there springs on both sides. also noticed a case bolt that was missing on yours that goes by where the oil scavenger pump is. 12:10 is the minuet mark. right by the shift drum just under where the shift paw bracket bolts. Just curious cause i haven't gotten my case split yet cause I'm waiting on my tool for it.

[@yzreek]

I recommend when your putting in them side piston clips you put a cloth down there so therefor you don’t drop the small clip into the bottom end then have to fish it out or even open it back up again.

[@jimmyschrage146]

Big fan of the show keep up the good work man. Learning a lot from you. You and stupid fast John together make some damn good KZbin TV lol especially anything 400EX

[@mikewiley1007]

Another excellent Sabo build 🤙🏽

[@StonedAF101]

This is good content man, Thank you for sharing all these amazing builds. You definitively deserve a like and sub, thus I've given you both. Cheers from Canada!

[@LSDdreams808]

This dude can build any thing an make it super bad ass

[@predatorpwr]

I love that you did something on the predator

[@rickfeith6372]

When you dropped the crank in and the rod was still in the case....and then the interference fit showed it's teeth. Damn bro. I felt your pain for a second.

[@djimenez1877]

What a great video love that you left the mistakes in 😂 so helpful

[@wouldyouglowme4235]

I remember hearing that the cam sprocket can actually slip whenever it gets hot enough so whenever you get back in the head weld the sprocket on the cam it will save you

[@wouldyouglowme4235]

@Quading Channel yea I heard about those on the hot cams but from what people have said is that they run better with the stock cams

[@MichaelSabo]

I see what you're saying; that's a good idea man

[@wouldyouglowme4235]

@@MichaelSabo I did it to mine to make sure so you should probably do it to yours too if you got the time

[@timothybuzardsr3610]

So stock cams are more reliable than aftermarket cams ?

[@demond7036]

Awesome viedo man details help out so much.keep it up dude 🤘🤘

[@mitchlec8916]

Excellent video my man!!

[@lypheEddie]

Why you got to tease us with trail clips, bro?! 😄 🤣 great video, can't wait to see all your riding footage

[@aaroncarter4458]

What throttle cable did you use for that fcr and did you use an adapter/ different boot to mount it?

[@stopibeastin]

Man you said it on point with the process of these engine love watch you build these things this engine is just extra special because I’ve owned the 2003 predator 500 im thinking bout buying yz 450f next year what you think? I heard there almost pushing 60 hp? It like 58 and half. Oh by the way I had a square wood drift key good luck brother!!

[@MichaelSabo]

Thank you for the kind words man! I say go for the YZ man; they do make great power out of the box and they're great bikes pretty much any year at least in my experience.

[@wyofitter9533]

great video, quick question on the flywheel removal....... i am replacing just the flywheel on my 03 predator. can i get some advice on how to keep it from turning when i try to remove the nut ? thanks

[@MattSmith-vl8zp]

I love the fact that you mess up and show it!

[@johnsmith-oh2xo]

Hey mike it's 03-04 and 05-07 i have an 06 troy lee edition nice build man love your video's.....

[@MichaelSabo]

Thank you for the love bro! 👊

[@syzygy3239]

Webcams 590 cams are what I ended up with and they are very good from 4000 on up. The difficulty is they are expensive because you have to install new guides, and springs to clear the lift.

[@MichaelSabo]

Hell yea man, I would have loved to have run Web but the lead time was crazy on them too

[@ericjones90googlepixel8pro]

I want you to show how you hook up the carburetor like where the lines go. You got it looking really good

[@F5Tornado44]

Hey Mike, another good way of preventing gaskets from sticking to the cases is to dust them with talcum powder. Works better than grease, in my opinion. Grease can sometimes cause a gasket to push in or out, especially when the gasket surfaces are really narrow. Awesome job on the build....well, accept for the minor brain fart in the beginning with the rod. LOL. Try out those other cams too. They may end up being a great combination with your other mods and porting.

[@MichaelSabo]

Interesting; I've never heard of the talcum powder method but it makes sense; sounds messy though 😂 I might be trying out the cams to see how they perform 🤘

[@F5Tornado44]

@@MichaelSabo Actually, it's not very messy at all. You only need to dust the gasket, not the cases. And you can dust the gasket just like you coated the gasket with the Spray-A-Gasket. Put the gasket on some paper towels and coat the gasket with talc. You can use a solder acid/flux brush to brush the talc even, then flip and repeat. Give it a try. It's a lot less cleanup than grease squishing out.

[@robertstephenson7156]

Hey Michael Sabo, great video. I do have a question, I just installed the 560 kit so I had to remove the clutch and all that. I put it back together and I went to put it in 1st and now the shifter feels like it's not hooked up, any ideas?

[@normanminer6165]

Hey Mike did you notice how similar this engine is to a 450! When I rebuilt my first predator engine I noticed how it was practically identical to a 450 but with 50cc bigger. And a 60 to 70+ pound heavier chassis. That's the one thing I hated the most with the predator 500 it weighted so much when compared to a actual 450. And stock for stock a can am DS 450 and a predator 500 run real good together.

[@jetskihoarder]

Great video. But I gotta say kinda was looking forward to seeing the process of truing the crankshaft I though you had mentioned in a previous video that it would be in this video. I've got some crankshafts I was willing to attempt to rebuild myself. So I was naturally interested. But even though I have no interest in own a polaris predator. This was still entertaining. I'm not mad......... just disappointed. :) just so the internet knows that was a joke I know alot of people forgot what jokes are. But seriously if you recorded the crankshaft content maybe think about sharing it with your people. Thanks

[@elviaestrada4494]

What compression numbers should a stock bike like that one have?

[@scooterohhh3059]

another great vid man. good job.

[@awsomedude515]

Awesome video! I just got an 06 outlaw from a trade that's been sitting for 4 years. Super excited to build it back up. Any recommendations on where I should start just to get it running? Thanks!!

[@ethansheesha7709]

I enjoy how you put the rod in wrong hahaha I did the same thing, on a 2 stroke..... i took it apart and it wasn't bent so I put it back in (the right way) and it runs to this day

[@scott7895]

Awesome video man. My carb looks a little different I have a 05 and I’m wondering where the electric connector from carb you ordered will go on my bike?

[@jonmelvin5682]

Great video Mike.

[@TruckinBeagle]

Talk about satisfying! I want to ride something I built like that!

[@707flores22]

Fantastic. I need to to tear mine down. Have more confidence now 4 th gear pops put any idea what would cause that

[@jimmadonna1436]

I like your garage, shop and or work area.

[@MichaelSabo]

Thank you Jim Madonna, my pop has contributed a ton to making that possible!

[@jimmadonna1436]

@@MichaelSabo your Dad seems to be very supportive of you and what you want to do. I bet that support goes a long way, in the growth of the channel.

[@boggsie5817]

"I can't fucking believe this." HA. I'm so glad you kept that part in

[@thatsright2456]

Good stuff appreciate the detail

[@davidtax6884]

Keep them coming.

[@davidwalls9954]

Thanks for this post, picked up a 400$ predator myself and I’ve used your video already. Any advice on how to make sure the decompression Valve on the exhaust cam is working correctly?

[@mikelbraun1903]

It need to be work smooth. I've got this on mine that the decompression will open the valve at 12 O'clock cam Rotation. Noises like a bad connecting rod bearing 🙈

[@KGInstalls]

Question. Should the oil pump gear have play in it or does it sit pretty snug after the C clip is installed? Hard to tell from the video.

[@connersnow298]

I like how you put the links of everything

[@roadgliderider1]

Just incredible bro.

[@MichaelSabo]

Thank you bro! 🤘

[@Dararum9419]

Very good job!!👍👏

[@ononewheel7]

Great vid! What mic are you using?

[@MichaelSabo]

I think it's called Kimafun, here's the link - amzn.to/2VeEATV

[@ononewheel7]

@@MichaelSabo thanks 🤘

[@ajaadish]

Awsome video👌 i have some issues with a Dinli/Masai 450cc but i been told the engine is basically the same as used in predator (Subaru/Fuji). Maybe stupid question😅 but is the stator a wet type? running in oil? I have start issues, and i see oil thru the inspection nuts on stator cover.

[@rmechanic9233]

Fantastic video man, I just recently picked up a 2005 Predator project myself and wound up here doing research. One question I have that you might be able to help with. Where did you find a connecting rod? OEM is discontinued and I can't find a replacement kit to save my life. This was supposed to be my daughter and I's winter project and I really don't want to have to tell her all the work we've put into it was for nothing. Thanks!

[@justinsweatt9147]

Hell yeah bro! I love odd balls

[@leesbikelife2231]

2005 Polaris Predator, spitting from overflow upon starting. I even removed the thermostat. I'm leaning towards headgasket. It doesnt smoke or anything. Runs really good. We just bought it. Any ideas before we tear down? It should not bubble upon starting. I even removed the thermostat, still the same. Even if I drain the antifreeze down, it still pushes antifreeze out. And if you hit the throttle it's worse.

[@channinbell8070]

Never heard it called spleen lol ive always heard it called splines but anywho nice job great video!

[@ynqbshim3819]

Yesss sir I applaud 👏 🙌 you mike keep it up

[@TheTechGuider]

surprised you didnt keep this beast longer

[@deontetanniehill3225]

Man I got my 04 Predator last July 2nd it has been setting up five plus years so the original owner said that it was the regulator so after going through it and replacing almost you know their entire fuel system and all that stuff end up in the bathroom so that's the only thing I've done to it than every modification to it besides inside the motor that's going to be this fall. I haven't had one problem with this 04 predator especially all the problems that everybody else say that they have with theirs I have not had any of those issues so I just want to say great job. could have been a better time. what's funny is that and it's amazing at the same time that these predators respond to mods like I never seen a ATV ever responded to airbox mod or exhaust. Keep the videos coming great job dude I appreciate it.. oh yeah I forgot to say that what size jet you running in the fcr carb? So do you think that big bore is worth the money? And where did you get those shocks from the Ressies?