PREDATOR 90 Model #A05KA09CA Model #A05KA09CBpi54.com/corp/manuals/Parts/9919525.pdf · PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04 E 2004 Polaris Sales Inc. PREDATOR 90

PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

E 2004 Polaris Sales Inc.

PREDATOR 90Model #A05KA09CAModel #A05KA09CB

This page left blank intentionally.

TABLE OF CONTENTSPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

Parts Manual

AAIR CLEANER A7. . . . . . . . . . . . . . . . . . . . . . .AXLE, REAR WHEEL B13. . . . . . . . . . . . . . . . . .

BBRAKE, FRONT B10. . . . . . . . . . . . . . . . . . . . . .BRAKE, REAR B11. . . . . . . . . . . . . . . . . . . . . . .BRAKELIGHT C2. . . . . . . . . . . . . . . . . . . . . . . .BUMPER B3. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCAB B5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR A8. . . . . . . . . . . . . . . . . . . . . . .CHAIN B14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRANKCASE A10. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT A4. . . . . . . . . . . . . . . . . . . . . . .CYLINDER HEAD A3. . . . . . . . . . . . . . . . . . . . .

DDECALS C5. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE PULLEY A12. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT A13. . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL PARTS C4. . . . . . . . . . . . . . . . . .ENGINE BRACKET A14. . . . . . . . . . . . . . . . . . .EXHAUST PIPE A9. . . . . . . . . . . . . . . . . . . . . .

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

FFOOTREST B4. . . . . . . . . . . . . . . . . . . . . . . . .FRAME BODY B2. . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B6. . . . . . . . . . . . . . . . . . . . . . . . .

GGENERATOR C3. . . . . . . . . . . . . . . . . . . . . . . .

HHANDLEBAR B12. . . . . . . . . . . . . . . . . . . . . . . .HEADLIGHT C2. . . . . . . . . . . . . . . . . . . . . . . . .

OOIL PUMP ASSEMBLY A6. . . . . . . . . . . . . . . . .OIL TANK B6. . . . . . . . . . . . . . . . . . . . . . . . . . .

SSEAT B5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTER A11. . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR C3. . . . . . . . . . . . . . . . . . .STEERING C1. . . . . . . . . . . . . . . . . . . . . . . . . .SUSPENSION B7. . . . . . . . . . . . . . . . . . . . . . .SWING ARM B4. . . . . . . . . . . . . . . . . . . . . . . .

TTRANSMISSION LEVER B1. . . . . . . . . . . . . . . .

WWHEEL, FRONT B8. . . . . . . . . . . . . . . . . . . . . .WHEEL, REAR B9. . . . . . . . . . . . . . . . . . . . . . .

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 A05KA09CA and PREDATOR 90 A05KA09CB

3

4

1

5

6

7

2


Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

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

1 0450005 1 Plug, Spark2 0450012 4 Nut, Flange3 0452117 1 Head, Cylinder4 0450004 1 Gasket, Cylinder Head

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

7/04

A4

CRANKSHAFTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 A05KA09CA and PREDATOR 90 A05KA09CB

16 15

10

12

9

17

11

14

138

76

1

9

E 2004 Polaris Sales Inc.2

3

5

4



1 0451664 1 Cover, Fan Inlet2 0451666 1 Strap3 0451665 1 Duct, Cooling Fan4 0452119 1 Filter, Cooling Fan5 0451667 1 Gasket, Fan Inlet6 0450041 1 Washer, Plain7 0450040 1 Screw, Tapping8 0450039 2 Bolt, Socket9 0450034 5 Washer

10 0451712 1 Cover, Fan11 0450036 3 Damper, Air Shroud12 0450033 3 Bolt, Socket, Hex13 0450038 1 Deflector14 0450037 1 Fan15 0450031 2 Grommet, Cylinder16 0450030 1 Shroud, Air, Cylinder17 0450035 1 Screw, Tapping

7/04

A6

OIL PUMP ASSEMBLYPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 A05KA09CA and PREDATOR 90 A05KA09CB

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 A05KA09CA and PREDATOR 90 A05KA09CB

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 0452197 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 0452196 1 Needle Set31 0451050 1 Spring, Carb Slide32 0450087 2 Washer, Spring

7/04

A9

EXHAUST PIPEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

6

17

16

4

3

2

1

14

8

2

1

7

9

5


15

10

12

13

11



1 0450658 2 Bolt, Pan, Phillips2 0450126 2 Gasket3 0450657 1 Protector, Pipe, Exhaust4 0450684 1 Bolt, Hex, Washer Face5 0450279 1 Washer, Plain6 0452121 1 Pipe, Exhaust7 0450282 1 Nut, Hex, Washer Face8 0452198 1 Gasket9 0450325 1 Bolt, Hex, Washer Face

10 0452122 2 Gasket, Exhaust Bracket11 0452123 1 Bolt, Hex12 0451702 1 Washer, Spring13 0450323 1 Bolt, Hex14 0450298 1 Bolt, Hex, Washer Face15 0450128 1 Plate, Fixed, Exhaust16 0450123 2 Bolt, Hex, Washer Face17 0450122 1 Gasket

7/04

A10

CRANKCASEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

13

12

8

4

7

6

2

2627

31

29

30

22

32

23

18

1011

15

14

528

1

33

916

1721

3

24 25

19

20

34

35


3

10

3637

3839

4041

42

434446

47

45

8



1 0450166 1 Protector A2 0450164 1 Filter3 0450142 2 Pin, Dowel4 0450141 1 Gasket, Crankcase5 0451671 1 Cover, Clutch6 0450148 8 Bolt, Hex7 0450157 1 Bracket, Oil Seal8 0450158 2 Bolt, Hex9 0450159 1 Gasket, Generator10 0450138 8 Bolt11 0450170 1 Plug, Rubber12 0450135 1 Crankcase, RH13 0450137 2 Pin, Dowel14 0452127 1 Breather, Crankcase, Upper15 0450254 2 Bearing, Needle16 0452130 1 Shaft, Primary Drive17 0450199 1 Bearing18 0450298 2 Bolt, Hex19 0450684 1 Bolt, Hex20 0452131 1 Mount, Engine, Rear21 0450132 1 Bushing, Rubber22 0450041 1 Washer23 0450198 1 Circlip, External24 0450200 1 Seal, Oil

25 0452139 1 Bearing, Needle26 0451139 1 Bushing, Rubber27 0452125 1 Breather, Crankcase, Lower28 0452124 1 Crankcase, LH29 0452134 1 Ball, Steel30 0452135 1 Spring, Detent31 0452136 1 Washer, Flat32 0452137 1 Bolt, Hex33 0452126 1 Bolt, Hex34 0452129 1 O-Ring35 0452128 1 Sensor, Gear Position36 0452138 2 Bolt, Hex, Flange37 0450162 1 Circlip, Internal38 0452132 1 Bolt, Hex39 0452133 1 Washer, Flat40 0450167 2 Bolt41 0450168 2 Grommet42 0451672 1 Guard, Clutch Cover43 0450150 3 Nut, Hex, Flange44 0450152 1 Protector B45 0450151 1 Bolt, Hex46 0450160 1 Bracket, Carburator Tube47 0450147 1 Shaft, Pin

7/04

A11

STARTERPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 A05KA09CA and PREDATOR 90 A05KA09CB

25

2223

21

24

20

1

65

15

13

2

12

16

4

3

7 8

9

1110

29

27

26

30

14

31 32

33

34

3536

2

26

28

1718

19




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 A05KA09CA and PREDATOR 90 A05KA09CB

12 13

11

10 9

64

57

32

1


14

1516

1718 19

20 21

22

2324

272526

28

2930

8

6

31



1 0450265 1 Nut, Lock2 0452143 1 Sprocket, Drive3 0450162 1 Circlip, Internal4 0450261 1 Bearing, Ball5 0452140 1 Cover, Transmission6 0450142 2 Pin, Dowel7 0450259 1 Seal, Oil8 0452142 1 Gear, Final9 0452141 1 Shaft, Final10 0450254 1 Bearing, Ball11 0452144 1 Shaft, Counter12 0452146 1 Gear, Counter13 0452156 1 Bearing14 0452155 1 Shaft, Main Transmission15 0452154 1 Bushing, Reverse Gear16 0452153 1 Gear, Reverse

17 0452152 1 Washer, Flat18 0450060 1 Circlip, External19 0452151 1 Ratchet, Shift20 0452150 1 Bushing, Spur Gear21 0452149 1 Gear, Spur22 0452148 1 Washer, Flat23 0452147 1 Collar, Shaft24 0452159 1 Asm., Gear Shift Drum25 0452157 1 Fork, Shift26 0452163 1 Roller, Drum Sensor27 0452158 1 Shaft, Gear Shift28 0452162 1 Spring, Drum Sensor29 0452160 1 Spindle, Shift30 0452161 1 E-Clip31 0450264 1 Washer

7/04

A14

ENGINE BRACKETPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

9

10

1

12

4

3

11

2

6 5

3

7


8



1 0450271 2 Nut, Hex2 0450286 2 Washer3 0450284 2 Bushing, Rubber, Front4 0450283 1 Tube, Fixed, Front5 0450132 1 Bushing, Rubber6 0452165 1 Bracket, Oil Tank

7 0451151 1 Asm., Engine, 90cc8 0450684 2 Bolt, Hex, Washer Face9 0450192 1 Washer10 0450268 1 Nut, Flange, Hex11 0451107 1 Bolt, Hex12 0451108 1 Collar

7/04

B1

TRANSMISSION LEVERPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc.1

2

3 4

5

6

7

8

9

10

11

1314

15

16

17

4

4

5

14

12



1 0452169 1 Gasket, Transmission Cover2 0451813 1 Plug, Oil3 0450154 1 O-Ring4 0452176 8 Bolt, Hex, Flange5 0450701 2 Bolt, Hex, Washer6 0452175 1 Seal, Oil7 0452167 1 Lever, Transmission8 0452168 1 Knob, Transmission Lever9 0450967 1 Cover, Transmission Lever Knob

10 0450309 1 Bolt, Hex11 0452170 1 Gate, Shift12 0452171 1 Mount, Shift Lever13 0450189 1 Bolt, Hex14 0450192 2 Washer15 0452173 1 Spring, Transmission Lever16 0452174 1 Pin, Transmission Lever17 0450719 1 Pin, Cotter

7/04

B2

FRAME BODYPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 0452030 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 0452178 1 Frame, Main12 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 0452179 1 Arm, Swing

7/04

B3

BUMPERPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

3

1

1

2

2

4




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

3 0451154 1 Bumper, Front, Silver4 0450150 2 Nut, Lock

7/04

B4

SWING ARM / FOOTRESTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 0452216 8 Bolt, Hex7 0451118 1 Footwell, LH8 0450879 8 Washer, Plain9 0450808 8 Nut, Lock10 0450321 2 Cap, Rubber

11 0450320 2 Valve, Grease12 0450317 2 Rubber, Dustproof13 0450314 2 Seat, Grease Contain14 0450313 2 Seat, Grease Contain15 0450316 2 Cover, Waterproof16 0451155 1 Arm, Suspension, Silver, LH17 0450820 4 Bolt, Hex, Washer Face18 0450288 4 Bushing19 0450249 4 Nut, Flange20 0451156 1 Arm, Suspension, Silver, RH

7/04

B5

CAB / SEATPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 0452191-496

0452191-29311

Cab, Front, Cosmic Sunburst (CA)Cab, Front, Indy Red (CB)

4 04511230451122

11

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 0452192-496

0452192-29311

Cab, Rear, Cosmic Sunburst (CA)Cab, Rear, Indy Red (CB)

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

045221311

Asm., Seat (CA)Asm., Seat, Dale Jr. (CB)

17 0450824 2 Bolt, Hex, Washer Face18 0451674 2 Screw, Tapping19 9919505 1 Manual, Owner’s, ’05 Sportsman 90,

Predator 50/90

7/04

B6

OIL TANK / FUEL TANKPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 2520462 1 Filter, Fuel20 0450340 2 Bolt, Hex

7/04

B7

SUSPENSIONPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

16

5

5

1

6

6

6

5

5

4

24

2

8

10

9

7

11


3

3



1 0450868 2 Bolt, Hex2 0450714 2 Tube, Inner, Suspension, Front3 0451675 2 Collar, Adjustment, Spring, Front4 0452193-446

0452193-29322

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

5 0450380 3 Bolt, Hex6 0450249 4 Nut, Flange

7 0450929 1 Retainer, Spring8 0452181-446

0452181-29311

Spring, Suspension, Rear (CA)Spring, Suspension, Rear (CB)

9 0450894 1 Collar, Adjustment10 0451072 1 Shock, Rear11 0451135 1 Bolt, Hex

7/04

B8

FRONT WHEELPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 (19x7-8)

9 0450398 8 Bolt, Carriage10 0450401 2 Valve, Rim11 0450391 2 Spacer, Outer12 0450392 2 Bearing13 0451681

0451681-29322

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

14 0450390 2 Spacer, Inner

7/04

B9

REAR WHEELPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

32

1

4

57

89

6E 2004 Polaris Sales Inc.



1 04521940451682

22

Hub, Rear Wheel (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

7/04

B10

FRONT BRAKEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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

B11

REAR BRAKEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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 0451822 1 Washer, Black28 0450447 1 Nut, Flange

7/04

B12

HANDLEBARPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

10 1

23

2227

9

32

24

25

5

13

6

26

1

28

31

2018

4

21

11

19

19

2 3

3029

14

87

17

1516

15


12



1 0451097 2 Grip, Hand2 7080891 1 Wristband3 0450550 1 Switch, Safety4 0450806 1 Bolt, Brake Lever, RH5 0452195 1 Cover, Handlebar6 0451137 2 Bolt, Philips7 0451129 1 Bracket, Instrument Panel8 0450701 2 Bolt, Washer Face9 0450148 4 Bolt, Hex10 0451161 1 Handlebar, Silver11 0450807 1 Bolt, Brake Lever, LH12 0452203 1 Hose, Breather13 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 0452202 1 Arm, Throttle29 0450994 1 Bracket, Brake Cable30 0450309 1 Bolt31 0450694 1 Lever, Brake, RH32 0451099 1 Asm., Lever, RH (Incl. 28-31)

7/04

B13

REAR WHEEL AXLEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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

B14

CHAINPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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

C1

STEERINGPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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

C2

HEADLIGHT / BRAKELIGHTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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

C3

GENERATOR/STARTING MOTORPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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

C4

ELECTRICAL PARTSPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

25

202

27

15

6

4

18

26

117

21

12

5

3

16

2223

17

2928

19

1

914

13


324

108



1 0450886 1 Clip, Main Switch2 0450549 1 Asm., Main Switch (Incl. 1)3 0450701 2 Bolt, Washer Face, Hex4 0450554 1 Asm., Resistor5 0450057 2 Bolt, Pan, Phillips6 0452061 1 Regulator, Voltage7 0450558 1 Asm., Oil Level Gauge8 0452190 1 Indicator, Neutral9 0451693 1 Switch, Safety10 0452189 1 Indicator, Reverse11 0451710 1 Lamp, Warning, Low Oil12 0450309 1 Bolt, Hex13 0451020 2 Screw, Fixing14 0451019 1 Jumper15 0452187 1 Asm., CDI Unit

16 0450563 1 Bag, Tool17 0450842 1 Fuse18 0450555 1 Asm., Starter Relay19 0450888 2 Bolt and Nut, Battery20 0451043 1 Battery21 0450559 3 Strap22 0450721 1 Strap23 0450742 1 Strap24 0451695 1 Horn25 0452186 1 Harness, Main Wire26 0450556 2 Bolt, Hex27 0450753 1 Asm., Ignition Coil (Incl. 29)28 0451018 1 Washer, Star29 0451162 1 Cap, Spark Plug

7/04

C5

DECALSPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

9

24

17

2

13

23

15

22

20

14

5

1916

4

21

1

2

2

RH

LH

18

10

8


11

7

36

12



1 7170300 1 Decal, Reflector, Red, RH2 7170896 3 Decal, “POLARIS”, Front/Rear, Black3 7173013 1 Urocal, 50th Anniversary4 7170295 1 Decal, Amber, RH5 7172823

717282471729147172915

1111

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

6 71711507171152

11

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

7 0451809 1 Decal, Youth, CE8 7172677

717304011

Decal, Age Warning, 12 (CA)Decal, Age Warning, 12 (CB)

9 7078465 1 Logo, Polaris Star10 7172829

717283071729057172906

1111

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

11 7172904 1 Decal, Front Cover, Red (CB)12 7171149

717115111

Decal, Headlight, Front, LHDecal, Headlight, Side, LH

13 7172827717282871729107172911

1111

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

14 717281971728207172909

112

Decal, “PREDATOR”, LH (CA)Decal, “PREDATOR”, RH (CA)Urocal, “PREDATOR”, Red (CB)

15 7172821717282271729077172908

1111

Decal, Tank Side, LH (CA)Decal, Tank Side, RH (CA)Decal, Tank Side, LH (CB)Decal, Tank Side, RH (CB)

16 7170286 1 Decal, Amber, LH17 7172566 1 Decal, Passenger Warning18 7172825

717282611

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

19 7172858717585971729127172913

1111

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

20 7172682 1 Decal, Tire Pressure 9021 7170296 1 Decal, Reflector, Red, LH22 7172678 1 Decal, General Warning, CPSC23 7172679 1 Decal, Youth Warning, Clutch Cover24 7079287 1 Decal, Youth Carb/Filter Information

7/04

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PRINTED IN THE USA PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

Documents

PREDATOR 90 Model #A05KA09CA Model #A05KA09CBpi54.com/corp/manuals/Parts/9919525.pdf · PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04 E 2004 Polaris Sales Inc. PREDATOR 90