PREDATOR 90 Model #A04KA09CA Model #A04KA09CBpi54.com/corp/manuals/Parts/9919132.pdf · PREDATOR 90 Model #A04KA09CA Model #A04KA09CB E 2003 Polaris Sales Inc. PARTS MANUAL PN 9919132

PREDATOR 90Model #A04KA09CAModel #A04KA09CB

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9919132 and MICROFICHE PN 9919133 7/03

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TABLE OF CONTENTSPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

Parts Manual

AAIR CLEANER A7. . . . . . . . . . . . . . . . . . . . . . .AXLE, REAR WHEEL B12. . . . . . . . . . . . . . . . . .

BBRAKE, FRONT B9. . . . . . . . . . . . . . . . . . . . . .BRAKE, REAR B10. . . . . . . . . . . . . . . . . . . . . . .BRAKELIGHT C1. . . . . . . . . . . . . . . . . . . . . . . .BUMPER B2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCAB B4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR A8. . . . . . . . . . . . . . . . . . . . . . .CHAIN B13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRANKCASE A10. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT A4. . . . . . . . . . . . . . . . . . . . . . .CYLINDER HEAD A3. . . . . . . . . . . . . . . . . . . . .

DDECALS C4. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE PULLEY A12. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT A13. . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL PARTS C3. . . . . . . . . . . . . . . . . .ENGINE BRACKET A14. . . . . . . . . . . . . . . . . . .EXHAUST PIPE A9. . . . . . . . . . . . . . . . . . . . . .

FFAN COVER A5. . . . . . . . . . . . . . . . . . . . . . . .

FFOOTREST B3. . . . . . . . . . . . . . . . . . . . . . . . .FRAME BODY B1. . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B5. . . . . . . . . . . . . . . . . . . . . . . . .

GGENERATOR C2. . . . . . . . . . . . . . . . . . . . . . . .

HHANDLEBAR B11. . . . . . . . . . . . . . . . . . . . . . . .HEADLIGHT C1. . . . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP ASSEMBLY A6. . . . . . . . . . . . . . . . .OIL TANK B5. . . . . . . . . . . . . . . . . . . . . . . . . . .

SSEAT B4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTER A11. . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR C2. . . . . . . . . . . . . . . . . . .STEERING B14. . . . . . . . . . . . . . . . . . . . . . . . . .SUSPENSION B6. . . . . . . . . . . . . . . . . . . . . . .SWING ARM B3. . . . . . . . . . . . . . . . . . . . . . . .

WWHEEL, FRONT B7. . . . . . . . . . . . . . . . . . . . . .WHEEL, REAR B8. . . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

CYLINDER HEADPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

3

4

1

5

6

7

2


Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 0450005 1 Plug, Spark2 0450012 4 Nut, Flange3 0451091 1 Head, Cylinder4 0450004 1 Gasket, Cylinder Head

5 0450007 1 Cylinder6 0450009 1 Gasket, Cylinder7 0450011 4 Bolt, Stud

6/02

A4

CRANKSHAFTPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

3

12

2

4

1

5

10

811

9

79

2

6




1 0450018 1 Seal, Oil2 0450016 2 Bearing, Ball, Radial3 0450649 1 Crankshaft4 0450017 1 Seal, Oil5 0450650 1 Collar, Crank, LH6 0450653 1 Washer, Plain7 0450029 1 Bearing, Needle8 0450023 1 Pin, Piston

9 0450027 2 Clip, Piston Pin10 0450802

04506510450704

111

Piston (Std)Piston (.25 mm O/S)Piston (.50 mm O/S)

11 045087704500250450705

222

Ring Set, Piston (Std)Ring Set, Piston (.25 mm O/S)Ring Set, Piston (.50 mm O/S)

12 0450015 1 Key, Semicycle

6/01

A5

FAN COVERPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

15 14

9

11

8

16

10

13

127

54

1

8

E 2003 Polaris Sales Inc.2

3

6



1 0451664 1 Cover, Fan Inlet2 0451666 1 Strap3 0451665 1 Duct, Cooling Fan4 0450041 1 Washer, Plain5 0450040 1 Screw, Tapping6 0451667 1 Gasket, Fan Inlet7 0450039 2 Bolt, Socket8 0450034 5 Washer

9 0451712 1 Cover, Fan10 0450036 3 Damper, Air Shroud11 0450033 3 Bolt, Socket, Hex12 0450038 1 Deflector13 0450037 1 Fan14 0450031 2 Grommet, Cylinder15 0450030 1 Shroud, Air, Cylinder16 0450035 1 Screw, Tapping

7/03

A6

OIL PUMP ASSEMBLYPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

16

1211

76

17

5

14

9

810

15

3

4

1

13

2

1

910

13




1 0450060 2 Circlip, External2 0450655 1 Washer, Wave3 0450058 1 Gear, Drive, Oil Pump4 0450059 1 Pin, Dowel5 0450052 1 Circlip, External6 0450050 1 Gear, Worm, Oil Pump7 0450048 1 O-Ring8 0450055 1 Tube, Oil9 0450054 2 Clip

10 0450056 2 Clip11 0450046 1 Washer12 0450884 1 Bolt, Phillips13 0450061 2 Spring, Protective, Oil Pipe14 0450053 1 Tube, Oil15 0450057 2 Bolt, Pan, Phillips16 0450846 1 Asm., Oil Pump

(Incl. 5,6,7,8,9,10,11,12,13,14,17)17 0450051 1 Pin, Shaft

6/01

A7

AIR CLEANERPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

1716

2

1

3

4

8

14

6

15

109 5

7

1112

13




1 0450066 4 Bolt, Hex, Washer Face2 0450065 1 Manifold, Intake3 0450067 1 Clamp, Hose4 0450068 1 Clip5 0451077 1 Elbow, Air Cleaner6 0450071 1 Cover, Air Cleaner7 0450076 3 Screw, Tapping8 0451080 1 Cleaner, Air (Incl. 5,6,7,9,10,13,14,15)9 0451081 1 Seal

10 0450073 1 Element, Air Cleaner11 0450039 2 Bolt, Socket12 0450034 2 Washer, Plain13 0450079 2 Grommet14 0450070 1 Case, Air Cleaner15 0451138 1 Tube, Inlet, Air Cleaner16 0450064 1 Gasket17 0450063 1 Asm., Reed Valve

9/02

A8

CARBURETORPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

19

2 31

13

32

29

30

8

18

9

14

7

5

15

26

16

23

6

17

11

1

13

20

10

28

24

22

25

2143

27

12




1 0450119 1 Nut, Cable Adjust2 0450082 1 Gasket3 0451014 1 Plug, Oil4 0451013 1 Pipe, Oil5 0450102 1 Screw Set, Air Adjust6 0450113 1 Screw Set, Throttle7 0451024 1 Jet, Pilot8 0451053 1 Nozzle, Needle9 0450097 1 Jet, Main10 0450976 1 Float, Carb11 0450117 1 Pin, Float12 0451032 1 Cable, Choke13 0450086 6 Bolt, Pan, Phillips14 0450098 1 Tube, Overflow15 0450104 1 Plug, Drain16 0450108 1 Bolt, Pan, Phillips

17 0451669 1 Valve Set, Needle18 0451054 1 Seal, Float Chamber19 0451668 1 Asm., Carburetor (Incl. All Less 12)20 0450923 1 Nozzle, Choke21 0451055 1 Valve, Choke22 0451057 1 Spring, Choke Return23 0451028 1 O-Ring24 0451058 1 Base, Manual Choke25 0451056 1 Bracket, Manual Choke26 0450106 2 Bolt, Pan, Phillips27 0451060 1 Support, Cable28 0451059 1 Cover, Cable Support29 0451051 1 Slide, Carburetor30 0451052 1 Needle Set31 0451050 1 Spring, Carb Slide32 0450087 2 Washer, Spring

7/03

A9

EXHAUST PIPEPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

6 13

12

4

3

2

1

10

11

128

2

1

7

9

5




1 0450658 2 Bolt, Pan, Phillips2 0450126 2 Gasket3 0450657 1 Protector, Pipe, Exhaust4 0450684 1 Bolt, Hex, Washer Face5 0450279 1 Washer, Plain6 0451106 1 Pipe, Exhaust7 0450282 1 Nut, Hex, Washer Face

8 0450659 1 Gasket9 0450325 1 Bolt, Hex, Washer Face10 0450925 1 Plate, Fix, Exhaust Pipe11 0450298 1 Bolt, Hex, Washer Face12 0450123 2 Bolt, Hex, Washer Face13 0450122 1 Gasket

9/02

A10

CRANKCASEPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

12

117

4

65

2

2627

32

25

30 3122

33

23

18

17

9

10

1413

2829

1

34

8

1516

20

3

24

2525

25

2 18

1719

3536 21




1 0450159 1 Gasket, Generator2 0450138 8 Bolt, Socket3 0450170 1 Plug, Rubber4 0450135 1 Crankcase, RH5 0450137 2 Pin, Dowel6 0451670 1 Hose, Breather7 0450133 1 Head, Breather Hose8 0450161 1 Circlip, Internal9 0450153 1 Plug, Oil10 0450154 1 O-Ring11 0451139 1 Bushing, Rubber12 0451082 1 Crankcase, LH13 0450156 1 Washer14 0450298 1 Bolt, Hex15 0450162 1 Circlip, Internal16 0451672 1 Guard, Clutch Cover17 0450168 2 Grommet18 0450167 2 Bolt, Flat Head, Phillips

19 0450150 3 Nut, Flange, Hex20 0450152 1 Protector B21 0450151 1 Bolt, Socket, Hex22 0451671 1 Cover, Clutch23 0450148 8 Bolt, Socket, Hex24 0450674 1 Tube, Breather25 0450142 4 Pin, Dowel26 0450139 1 Cover, Mission27 0450140 1 Gasket, Cover, Mission28 0450157 1 Bracket, Oil Seal29 0450158 1 Bolt, Socket, Hex30 0450143 2 Bolt, Pan Head31 0450039 3 Bolt, Pan Head32 0450141 1 Gasket, Crankcase Cover, LH33 0450147 1 Shaft, Pin34 0450160 1 Bracket, Carburetor Tube35 0450164 1 Filter36 0450166 1 Protector A

7/03

A11

STARTERPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

1012

13

14

9

16

1817

1920

1

2

34

11

6

5

7

8

15

2117 20




1 0450183 1 Asm., Kick Shaft2 0450184 1 Spring, Reset, Starter Shaft3 0450185 1 Bushing4 0450186 1 Washer5 0450883 1 Bolt, Hex6 0450569 1 Asm., Kick Crank7 0450190 1 Asm., Kick Pinion8 0450191 1 Clip, Spring9 0450176 1 Clutch Set, Starter, Electric10 0450171 1 Wheel, Starter11 0450187 1 Circlip, External

12 0450172 1 Bearing, Needle13 0450173 1 Boss, Gear14 0450174 1 Washer, Plain15 0450192 1 Washer16 0450178 1 Asm., Idle Gear17 0450180 2 Washer18 0450682 1 Pin, Shaft19 0450181 1 Plate, Idle Gear20 0450805 2 Bolt, Socket, Hex21 0450193 1 Washer, Wave

6/01

A12

DRIVE PULLEYPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

25

2223

21

24

20

1

65

15

13

2

12

16

4

3

7 8

91110

29

27

26

30

14

31 32 3334 35

36

2

26

28

171819




1 0450202 1 Asm., Secondary Sheave(Incl. 2,3,4,5,6,7,8,12,13,15,16)

2 0450211 2 Seal, Oil3 0450219 1 Seat, Spring, Secondary4 0450217 1 Spring, Compression5 0450206 3 Spring, Weight, Clutch6 0450204 1 Carrier, Clutch7 0450221 1 Nut8 0450223 1 Cover, Clutch9 0450224 1 Nut, Hex10 0450226 1 O-Ring11 0450225 1 Bearing12 0450213 2 Ring, Oil13 0450210 1 Wheel, Slot, Sliding, Secondary14 0450239 1 V-Belt15 0450208 1 Wheel, Slot, Fixed, Secondary16 0450215 2 Pin, Guide17 0451016 1 Bearing, Ball18 0451017 1 Circlip

19 0451015 1 Bearing, Needle20 0450200 1 Seal, Oil21 0450198 1 Circlip, External22 0450041 1 Washer23 0450158 1 Bolt, Socket, Hex24 0450199 1 Bearing25 0450195 1 Asm., Primary Drive26 0450234 3 Slider27 0450232 1 Plate, Cam28 0450229 6 Roller, Weight29 0450228 1 Wheel, Slot, Sliding, Primary30 0450236 1 Bushing31 0450241 1 Sheave, Fixed, Primary32 0450243 1 Washer, Claw33 0450245 1 Clutch, One-Way34 0450247 1 Washer, Spring35 0450249 1 Nut, Flange36 0450251 1 Asm., Sliding

(Incl. 26,27,28,29,30,31,32)7/03

A13

DRIVE SHAFTPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

1112

10

9

8

6

4

5

7

321




1 0450265 1 Nut, Lock2 0450264 1 Washer3 0450263 1 Sprocket, Drive4 0450162 1 Circlip5 0450261 1 Bearing, Ball6 0450259 1 Seal, Oil

7 0450161 1 Circlip8 0450258 1 Bearing9 0450585 1 Asm., Drive Axle10 0450255 1 Washer11 0450253 1 Axle, Main12 0450254 1 Bearing, Ball

6/01

A14

ENGINE BRACKETPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

6

13

14

9

5

1

16

874

3

15

2

1110

3

21

812




1 0450271 2 Nut, Hex2 0450286 2 Washer3 0450284 2 Bushing, Rubber, Front4 0450283 1 Tube, Fixed, Front5 0450270 1 Bolt, Hex6 0450266 1 Shaft, Fixed7 0450709 1 O-Ring8 0450684 2 Bolt, Hex, Washer Face

9 0450269 1 Bracket, Engine10 0450132 1 Bushing, Rubber11 0450287 1 Plate, Fixed, Oil Tank12 0451151 1 Asm., Engine, 90cc13 0450192 1 Washer14 0450268 1 Nut, Flange, Hex15 0451107 1 Bolt, Hex16 0451108 1 Collar

1/03

B1

FRAME BODYPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

11

4

18

17

1514

13

16

1514

4

12

2

21

1

3

3

7

89

3

5

66

5

3

3

3


10



1 0450613 8 Grommet2 0451112

045111311

Support, Footwell, LHSupport, Footwell, RH

3 0450887 16 Bolt, Hex, Washer Face4 0450299 2 Plate, Engine Bracket5 0450800 2 Rubber6 0451114 2 Bracket, Rear Cab Support7 0450993 1 Flag8 0450844 1 Washer, Spring9 0450845 1 Nut, Hex

10 0450180 1 Washer11 0451152 1 Frame, Silver12 0450265 1 Nut, Lock13 0450304 1 Sleeve, Rubber14 0450303 2 Cover, Swing Arm Seal15 0450302 2 Seat, Grease Contain16 0450305 1 Bolt, Hex17 0450301 1 Tube, Spacer18 0451153 1 Subasm., Swing Arm, Silver

7/03

B2

BUMPERPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

3

1

1

2

2

4




1 0450298 2 Bolt, Hex2 0450309 2 Bolt, Hex, Washer Face

3 04511160451154

11

Bumper, Front (CA)Bumper, Front, Silver (CB)

4 0450150 2 Nut, Lock2/03

B3

SWING ARM / FOOTRESTPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

20

18

14

13

16 15

12

17

19

1110

5

1

9

6

1718

1415

1312

1110

7

4

2

3

8




1 0450701 3 Bolt, Hex2 0450611 1 Shield, Heat3 0450298 2 Bolt, Hex4 0451119 1 Bracket, Heat Shield5 0451117 1 Footwell, RH6 0450340 8 Bolt, Hex, Washer Face7 0451118 1 Footwell, LH8 0450879 8 Washer, Plain9 0450808 8 Nut, Lock10 0450321 2 Cap, Rubber11 0450320 2 Valve, Grease

12 0450317 2 Rubber, Dustproof13 0450314 2 Seat, Grease Contain14 0450313 2 Seat, Grease Contain15 0450316 2 Cover, Waterproof16 0451004

045115511

Arm, Suspension, Red, LH (CA)Arm, Suspension, Silver, LH (CB)

17 0450820 4 Bolt, Hex, Washer Face18 0450288 4 Bushing19 0450249 4 Nut, Flange20 0451003

045115611

Arm, Suspension, Red, RH (CA)Arm, Suspension, Silver, RH (CB)

2/03

B4

CAB / SEATPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

3

10

13

6

7 8

1514

13

11

17

1612

19

4

4

2

1

96

1211

5

5


18



1 0451132 2 Screw, Tapping2 0451124 1 Cover, Front, Black Metallic3 0451157 1 Cab, Front, Black4 0451123

045112211

Panel, Side, LHPanel, Side, RH

5 0450676 4 Screw, Tapping6 0450340 4 Bolt, Hex7 0451140 1 Strap, Battery8 0451141 1 Strap, Tool Box9 0450290 2 Rubber, Seat10 0451158 1 Cab, Rear, Black

11 0450741 8 Nut, Lock12 0450710 8 Washer, Plain13 0450622 8 Bolt, Phillips14 0450346 1 Rubber, Battery15 0450345 1 Pad, Protector16 0451125

04516761 Asm., Seat (CA)

Asm., Seat, Troy Lee (CB)17 0450824 2 Bolt, Hex, Washer Face18 0451674 2 Screw, Tapping19 9918778 1 Manual, Owner’s, ’04 Youth

7/03

B5

OIL TANK / FUEL TANKPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

12

9

1514

19

17

8

16

1

2

20

410

14

15

8

8

20

8

13

6

8

11

7

15

18

3

5




1 0450927 1 Asm., Oil Tank2 0450903 1 Cap, Oil Tank3 0451035 1 Bolt, Hex4 0451126 1 Bracket, Fuel Tank5 0450041 1 Washer6 0450826-035 1 Tube, Oil, Side7 0450363-430 1 Hose8 0450054 7 Clip9 0451098 1 Cap, Fuel Tank10 0450375 1 Film, Breather

11 0450827 1 Boot, Tank Neck12 0450358 1 Tank, Fuel13 0450632 2 Mat, Rubber, Fuel Tank14 0450361 2 Clip15 0451110 3 Line, Fuel16 0450701 1 Bolt, Hex17 0450366 1 Asm., Manual Fuel Cup18 0451110 1 Hose19 2530009 1 Asm., Fuel Filter20 0450340 2 Bolt, Hex

7/03

B6

SUSPENSIONPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

8

17

65

5

1

7

7

76

5

5

4

24

2

10

12

11

9

13


3

3



1 0450868 2 Bolt, Hex2 0450714 2 Tube, Inner, Suspension, Front3 0451675 2 Collar, Adjustment, Spring, Front4 0450971

045168022

Spring, Suspension, Front (CA)Spring, Front Shock (CB)

5 0450380 3 Bolt, Hex6 0450906

045167922

Suspension, Front (Incl. 2,4)(CA)Asm., Front Shock (Incl. 2,4)(CB)

7 0450249 4 Nut, Flange

8 04510700451677

11

Asm., Rear Shock (Incl. 9,10,11,12)(CA)Asm., Rear Shock (Incl. 9,10,11,12)(CB)

9 0450929 1 Retainer, Spring10 0450905

045167811

Spring, Suspension, Rear (CA)Spring, Shock, Rear (CB0

11 0450894 1 Collar, Adjustment12 0451072 1 Shock, Rear13 0451135 1 Bolt, Hex

7/03

B7

FRONT WHEELPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

8

13

2 14

1112

1

9

2

10

5

4

67

3




1 0450393 2 Bearing2 0450389 4 Seal, Oil3 0450386 2 Wheel, Rim4 0450394 2 Nut, Lock5 0450395 2 Pin, Cotter6 0450829 2 Cap, Rubber7 0450397 2 Washer8 0450870 2 Tire, 18x7-7

9 0450398 8 Bolt, Carriage10 0450401 2 Valve, Rim11 0450391 2 Spacer, Outer12 0450392 2 Bearing13 0451159

045168122

Drum, Brake, Front, Indy Red (CA)Drum, Brake, Front, Orange (CB)

14 0450390 2 Spacer, Inner

2/03

B8

REAR WHEELPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

32

1

4

57

89

6E 2003 Polaris Sales Inc.



1 04511600451682

22

Hub, Rear Wheel, Indy Red (CA)Hub, Rear, Orange (CB)

2 0450386 2 Wheel, Rim3 0451127 2 Tire (18x9.5-8)4 0450395 2 Pin, Cotter

5 0450829 2 Cap, Rubber6 0450409 2 Nut, Lock7 0450412 2 Washer8 0450398 8 Bolt, Carriage9 0450401 2 Valve, Rim

2/03

B9

FRONT BRAKEPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

9

8

4

6

3 2

7

5

1

32

7

5

1




1 0450985 2 Cable, Front Brake2 0450422 2 Asm., Shoe, Front Brake3 0450421 2 Shaft, Cam, Front Brake4 0450912 1 Plate, Front Brake, RH5 0450425 2 Bolt, Hex

6 0450913 1 Arm, Front Brake, RH7 0450424 2 Spring, Return, Front8 0450911 1 Arm, Front Brake, LH9 0450910 1 Plate, Front Brake, LH

7/02

B10

REAR BRAKEPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

22

8

76

209

10

17

35

4

1

2

21

19

18

23

26

28

25

1412

15

11

27

16

13

25 24

12

1415

76




1 0450438 1 Cable, Rear Brake2 0450268 2 Bolt, Hex3 0450435 1 Spring, Cable, Rear Brake4 0450437 1 Thru-Shaft, Rear Brake5 0451079 1 Nut, Adjust, Brake6 0450430 2 Seal, Oil7 0450429 2 Bearing8 0450428 1 Tube, Spacer9 0450432 1 Arm, Rear Brake10 0450433 1 Bolt, Hex11 0450453 1 Spring, Arm, Rear Brake12 0450451 2 Bolt, Hex13 0450881 1 Nut, Lock14 0450529 2 Nut, Flange

15 0450452 2 Bolt, Hex16 0450854 1 Shaft, Fixed, Rear Brake17 0450434 1 Shoe, Rear Brake18 0450442 1 Rubber, Protective19 0450441 1 Drum, Rear Brake20 0450431 1 Shaft, Cam, Rear Brake21 0450440 1 Plate, Rear Brake22 0451683 1 Housing, Rear Axle, Silver23 0450751 1 Cover, Rear24 7171069 1 Decal, Drive Chain25 0450340 2 Bolt, Hex26 0450446 1 Reflector, Rear27 0450643 1 Washer28 0450447 1 Nut, Flange

7/03

B11

HANDLEBARPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

11 1

23

2227

10

28

24

25

6

13

7

26

1

5

31

20 18

4

21

12

19

19

2 3

3029

14

98

17

1516

15




1 0451097 2 Grip, Hand2 7080891 1 Wristband3 0450550 1 Switch, Safety4 0450806 1 Bolt, Brake Lever, RH5 0451040 1 Arm, Throttle6 0451128 1 Cover, Handlebar7 0451137 2 Bolt, Philips8 0451129 1 Bracket, Instrument Panel9 0450701 2 Bolt, Washer Face10 0450148 4 Bolt, Hex11 0451161 1 Handlebar, Silver12 0450807 1 Bolt, Brake Lever, LH13 0451684 1 Asm., Switch, LH14 0451037 1 Asm., Manual Choke (Incl. 15,16)15 0451148 2 Bolt16 0451149 1 Bolt

17 0450463 1 Asm., Lever LH (Incl. 18-21)18 0450693 1 Lever, Brake, LH19 0450808 2 Nut, Lock20 0450692 1 Lock, Park Brake21 0451090 1 Harness, Sensor Switch22 0450460 1 Cover, Clamp, LH23 0450459 2 Clamp, Saddle24 0450279 2 Washer25 0450276 2 Nut, Lock26 0450471 1 Cable, Throttle27 0450461 1 Cover, Clamp, RH28 0451099 1 Asm., Lever, RH (Incl. 5,29-31)29 0450994 1 Bracket, Brake Cable30 0450309 1 Bolt31 0450694 1 Lever, Brake, RH

7/03

B12

REAR WHEEL AXLEPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

34

5

7

2

6

1




1 0450479 1 Tube, Spacer, LH2 0450477 1 Axle, Rear3 0450484

045048011

Asm., Final Drive Sprocket (Incl. 3,4,5,7)Sprocket, Drive, Final

4 0450481 1 Hub, Sprocket5 0450323 3 Bolt, Hex6 0450478 1 Tube, Spacer, RH7 0450483 3 Washer, Spring

6/01

B13

CHAINPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

1

10

3

2

9

11


9

4

5

6

7

8



1 0450695 1 Asm., Drive Chain2 0450489 2 Nut, Hex3 0450856 1 Adjuster, Chain4 0451685 1 Guard, Chain/Brake5 0451687 1 Spring, Torsion6 0451686 1 Asm., Chain Tensioner (Incl. 5-7)

7 0451688 1 Roller, Chain Tensioner8 0451689 1 Bolt9 0450325 3 Bolt, Hex10 0450298 1 Bolt11 0450972 1 Link, Master, Drive Chain

7/03

B14

STEERINGPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

2

101112

1314

15

17

18

7

16

5

3

1

8

6

1

6 5 8

8

9

9

9

9

9

4

4


3



1 0450505 2 Bracket, Upper, Steering Shaft2 0450915 1 Shaft, Steering3 0451690 2 Asm., Tie Rod4 0450395 2 Pin, Cotter5 0450502 2 Nut, Lock6 0450507 2 Pin, Cotter7 0450916 1 Knuckle, LH8 0450276 4 Nut, Lock9 0450719 5 Pin, Cotter

10 0450491 1 Seal, Oil11 0450161 1 Circlip12 0450493 1 Bearing, Ball13 0450389 1 Seal, Oil14 0450390 1 Spacer15 0450878 1 Nut, Lock16 0450917 1 Knuckle, RH17 0450268 2 Nut, Flange18 0450499 1 Sleeve, Steering Shaft

7/03

C1

HEADLIGHT / BRAKELIGHTPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

8

31

7

2

4

1 2

7

56

6




1 0450880 2 Nut, Flange, Hex2 0450041 2 Washer, Plain3 0451691

045099511

Asm., TaillightBulb, Taillight

4 0451133 2 Screw, Tapping

5 0451131 1 Asm., Headlight, LH6 0451132 2 Screw, Tapping7 0451134 2 U-Nut8 0451130 1 Asm., Headlight, RH

7/03

C2

GENERATOR / STARTING MOTORPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

3

21

4 5

6

7

8

12

9

10

11

13




1 0450529 1 Nut, Flange2 0450545 1 Washer, Plain3 0450525 1 Flywheel4 0450033 2 Bolt, Socket, Hex5 0450034 2 Washer, Plain6 0451692 1 Asm., Starting Motor

(Incl. 7,8,9,10,12)

7 0450535 1 Brush Set8 0450537 1 Ring, Oil9 0450541 2 Bolt Set10 0450857 1 Cord11 0450039 2 Bolt, Socket12 0450539 1 Ring, Oil13 0451692 1 Asm., Stator

7/03

C3

ELECTRICAL PARTSPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

23

183

25

13

7

5

16

24

9

1

19

10

6

4

14

2021

15

2726

17

2

8

12

11


422



1 0450558 1 Asm., Oil Level Gauge2 0450886 1 Clip, Main Switch3 0450549 1 Asm., Main Switch (Incl. 2)4 0450701 2 Bolt, Washer Face, Hex5 0450554 1 Asm., Resistor6 0450057 2 Bolt, Pan, Phillips7 0450553 1 Rectifier/Regulator8 0451693 1 Switch, Safety9 0451710 1 Lamp, Warning, Low Oil10 0450309 1 Bolt, Hex11 0451020 2 Screw, Fixing12 0451019 1 Jumper13 0451018 1 Asm., CDI Unit14 0450563 1 Bag, Tool

15 0450842 1 Fuse16 0450555 1 Asm., Starter Relay17 0450888 2 Bolt and Nut, Battery18 0451043 1 Battery19 0450559 3 Strap20 0450721 1 Strap21 0450742 1 Strap22 0451695 1 Horn23 0451694 1 Asm., Main Wire Harness24 0450556 2 Bolt, Hex25 0450753 1 Asm., Ignition Coil (Incl. 27)26 0451018 1 Washer, Star27 0451162 1 Cap, Spark Plug

7/03

C4

DECALSPREDATOR 90 A04KA09CA and PREDATOR 90 A04KA09CB

11

9

25

32

14

24

16

23

21

15

5

20

17

4

22

1

2

2

RH

LH

19

12

10


6

18

7

8

13



1 7170941 1 Decal, Reflector, Red, RH2 7171761 3 Decal, “POLARIS”, Front, Silver3 7077920 1 Decal, Passenger Warning4 7170939 1 Decal, Reflector, Amber, RH5 7171768

717176971720267172027

1111

Decal, Fender, Front, LH (CA)Decal, Fender, Front, RH (CA)Decal, Fender, Front, LH (CB)Decal, Fender, Front, RH (CB)

6 7171149717115071711517171152

1111

Decal, Headlight, Front, LHDecal, Headlight, Front, RHDecal, Headlight, Side, LHDecal, Headlight, Side, RH

7 7172038 1 Decal, Front Cover, Logo (CB)8 7172039

717204011

Decal, Front Cover, LH (CB)Decal, Front Cover, RH (CB)

9 7172041 8 Decal, “PREDATOR”, Rim, Orange (CB)10 7079091 1 Decal, Age Warning, 1211 7078465 1 Logo, Polaris Star12 7171762

717176371720367172037

1111

Decal, Front Cover, Silver, LH (CA)Decal, Front Cover, Silver, RH (CA)Decal, Front Cover, Silver, LH (CB)Decal, Front Cover, Silver, RH (CB)

13 7172067 1 Decal, Front Cover Stripes, Upper (CB)

14 71717647170176571720347172035

1111

Decal, Front Cab, LH (CA)Decal, Front Cab, RH (CA)Decal, Front Cab, LH (CB)Decal, Front Cab RH (CB)

15 7170921717092271720247172025

1111

Decal, “PREDATOR 90”, LH (CA)Decal, “PREDATOR 90”, RH (CA)Decal, “PREDATOR 90”, LH (CB)Decal, “PREDATOR 90”, RH (CB)

16 71717667171767

1 Decal, Tank Side, Stripes, LH (CA)Decal, Tank Side, Stripes, RH (CA)

17 7170938 1 Decal, Reflector, Amber, LH18 7172028

717202911

Decal, Rear Fender, Front, LH (CB)Decal, Rear Fender, Front, RH (CB)

19 71720327172033

11

Decal, Rear Fender, Inside, LH (CB)Decal, Rear Fender, Inside, RH (CB)

20 7171770717177171720307172031

1111

Decal, Fender, Rear, LH (CA)Decal, Fender, Rear, RH (CA)Decal, Outside Fender, Rear, LH (CB)Decal, Outside Fender, Rear, RH (CB)

21 7170109 1 Decal, Tire Pressure 9022 7170940 1 Decal, Reflector, Red, LH23 7079133 1 Decal, General Warning, CPSC24 7079288 1 Decal, Youth Warning, Clutch Cover25 7079287 1 Decal, Youth Carb/Filter Information

7/03

PRINTED IN THE USA PARTS MANUAL PN 9919132 and MICROFICHE PN 9919133 7/03

Documents

PREDATOR 90 Model #A04KA09CA Model #A04KA09CBpi54.com/corp/manuals/Parts/9919132.pdf · PREDATOR 90 Model #A04KA09CA Model #A04KA09CB E 2003 Polaris Sales Inc. PARTS MANUAL PN 9919132