Polaris Predator Parts Manual

5/16/2018 Polaris Predator Parts Manual - slidepdf.com

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PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

E 2004 Polaris Sales Inc.

PREDATOR 90

Model #A05KA09CAModel #A05KA09CB



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TABLE OF CONTENTS

PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

Parts Manual

A AIR 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. . . . . . . . . . . . . . . . . . . . . . . .

H

HANDLEBAR 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. . . . . . . . . . . . . . . .

W

WHEEL, 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.


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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, Flange

3 0452117 1 Head, Cylinder

4 0450004 1 Gasket, Cylinder Head

5 0450007 1 Cylinder6 0450009 1 Gasket, Cylinder

7 0450011 4 Bolt, Stud

7/



CRANKSHAFTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

3

12

2

4

1

5

10

8

11

9

79

2

6




1 0450018 1 Seal, Oil

2 0450016 2 Bearing, Ball, Radial

3 0450649 1 Crankshaft

4 0450017 1 Seal, Oil

5 0450650 1 Collar, Crank, LH

6 0450653 1 Washer, Plain

7 0450029 1 Bearing, Needle

8 0450023 1 Pin, Piston

9 0450027 2 Clip, Piston Pin

10 045080204506510450704

111

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

11 04508770450025

0450705

22

2

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

Ring Set, Piston (.50 mm O/S)12 0450015 1 Key, Semicycle

6/



FAN COVERPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1615

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 Strap

3 0451665 1 Duct, Cooling Fan

4 0452119 1 Fil ter, Cool ing Fan

5 0451667 1 Gasket, Fan Inlet


7 0450040 1 Screw, Tapping

8 0450039 2 Bolt, Socket

9 0450034 5 Washer

10 0451712 1 Cover, Fan11 0450036 3 Damper, Air Shroud

12 0450033 3 Bolt , Socket, Hex

13 0450038 1 Deflector

14 0450037 1 Fan

15 0450031 2 Grommet, Cylinder

16 0450030 1 Shroud, Air, Cylinder


7/



OIL PUMP ASSEMBLYPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

16

1211

76

17

5

14

9

8

10

15

3

4

1

13

2

1

9

10

13




1 0450060 2 Circlip, External

2 0450655 1 Washer, Wave

3 0450058 1 Gear, Drive, Oil Pump

4 0450059 1 Pin, Dowel


6 0450050 1 Gear, Worm, Oi l Pump

7 0450048 1 O-Ring

8 0450055 1 Tube, Oil

9 0450054 2 Clip

10 0450056 2 Clip

11 0450046 1 Washer

12 0450884 1 Bolt, Phillips

13 0450061 2 Spring, Protective, Oil Pipe

14 0450053 1 Tube, Oil

15 0450057 2 Bolt, Pan, Phil lips

16 0450846 1 A sm., Oil Pump(Incl. 5,6,7,8,9,10,11,12,13,14,17)

17 0450051 1 Pin, Shaft

6/



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 Face

2 0450065 1 Manifold, Intake

3 0450067 1 Clamp, Hose

4 0450068 1 Clip

5 0451077 1 Elbow, Air Cleaner

6 0450071 1 Cover, Air Cleaner


8 0451080 1 Cleaner, Air (Incl. 5,6,7,9,10,13,14,15)

9 0451081 1 Seal

10 0450073 1 Element, Air Cleaner



13 0450079 2 Grommet

14 0450070 1 Case, Air Cleaner

15 0451138 1 Tube, Inlet, Air Cleaner

16 0450064 1 Gasket

17 0450063 1 Asm., Reed Valve

9/



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

214

3

27

12




1 0450119 1 Nut, Cable Adjust

2 0450082 1 Gasket

3 0451014 1 Plug, Oil

4 0451013 1 Pipe, Oil

5 0450102 1 Screw Set, Air Adjust

6 0450113 1 Screw Set, Throttle

7 0451024 1 Jet, Pilot

8 0452197 1 Nozzle, Needle9 0450097 1 Jet, Main

10 0450976 1 Float, Carb

11 0450117 1 Pin, Float

12 0451032 1 Cable, Choke

13 0450086 6 Bol t, Pan, Phillips

14 0450098 1 Tube, Overflow

15 0450104 1 Plug, Drain


17 0451669 1 Valve Set, Needle

18 0451054 1 Seal, Float Chamber

19 0451668 1 Asm., Carburetor (Incl. All Less 12)

20 0450923 1 Nozzle, Choke

21 0451055 1 Valve, Choke

22 0451057 1 Spring, Choke Return

23 0451028 1 O-Ring

24 0451058 1 Base, Manual Choke25 0451056 1 Bracket, Manual Choke

26 0450106 2 Bolt, Pan, Phil lips

27 0451060 1 Support, Cable

28 0451059 1 Cover, Cable Support

29 0451051 1 Slide, Carburetor

30 0452196 1 Needle Set

31 0451050 1 Spring, Carb Slide

32 0450087 2 Washer, Spring

7/



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




2 0450126 2 Gasket

3 0450657 1 Protector, Pipe, Exhaust



6 0452121 1 Pipe, Exhaust

7 0450282 1 Nut, Hex, Washer Face

8 0452198 1 Gasket


10 0452122 2 Gasket, Exhaust Bracket

11 0452123 1 Bolt, Hex


13 0450323 1 Bolt, Hex

14 0450298 1 Bolt, Hex, Washer Face

15 0450128 1 Plate, Fixed, Exhaust


17 0450122 1 Gasket

7/



CRANKCASEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

13

12

8

4

7

6

2

26

27

31

29

30

22

32

23

18

1011

15

14

5

28

1

33

916

1721

3

24 25

19

20

34

35


3

10

3637

3839

4041

42

43

4446

47

45

8



1 0450166 1 Protector A

2 0450164 1 Filter

3 0450142 2 Pin, Dowel

4 0450141 1 Gasket, Crankcase

5 0451671 1 Cover, Clutch

6 0450148 8 Bolt, Hex

7 0450157 1 Bracket, Oil Seal

8 0450158 2 Bolt, Hex

9 0450159 1 Gasket, Generator

10 0450138 8 Bolt

11 0450170 1 Plug, Rubber

12 0450135 1 Crankcase, RH

13 0450137 2 Pin, Dowel

14 0452127 1 Breather, Crankcase, Upper15 0450254 2 Bearing, Needle

16 0452130 1 Shaft , Primary Drive

17 0450199 1 Bearing

18 0450298 2 Bolt, Hex

19 0450684 1 Bolt, Hex

20 0452131 1 Mount, Engine, Rear

21 0450132 1 Bushing, Rubber

22 0450041 1 Washer


24 0450200 1 Seal, Oil

25 0452139 1 B earing, Needle


27 0452125 1 Breather, Crankcase, Lower

28 0452124 1 Crankcase, LH

29 0452134 1 Ball, Steel

30 0452135 1 Spring, Detent

31 0452136 1 Washer, Flat

32 0452137 1 Bolt, Hex

33 0452126 1 Bolt, Hex

34 0452129 1 O-Ring

35 0452128 1 Sensor, Gear Position

36 0452138 2 Bol t, Hex, Flange

37 0450162 1 Circlip, Internal

38 0452132 1 Bolt, Hex39 0452133 1 Washer, Flat

40 0450167 2 Bolt

41 0450168 2 Grommet

42 0451672 1 Guard, Clutch Cover

43 0450150 3 Nut, Hex, Flange

44 0450152 1 Protector B

45 0450151 1 Bolt, Hex

46 0450160 1 Bracket, Carburator Tube

47 0450147 1 Shaft, Pin

7/



STARTERPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1012

13

14

9

16

18

17

19

20

1

2

34

11

6

5

7

8

15

2117 20




1 0450183 1 Asm., Kick Shaft

2 0450184 1 Spring, Reset, Starter Shaft

3 0450185 1 Bushing

4 0450186 1 Washer

5 0450883 1 Bolt, Hex

6 0450569 1 Asm., Kick Crank

7 0450190 1 Asm., Kick Pinion

8 0450191 1 Clip, Spring

9 0450176 1 Clutch Set, Starter, Electric

10 0450171 1 Wheel, Starter



13 0450173 1 Boss, Gear


15 0450192 1 Washer

16 0450178 1 Asm., Idle Gear

17 0450180 2 Washer

18 0450682 1 Pin, Shaft

19 0450181 1 Plate, Idle Gear


21 0450193 1 Washer, Wave

6/



DRIVE PULLEYPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

25

2223

21

24

20

1

6

5

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, Oil

3 0450219 1 Seat, Spring, Secondary

4 0450217 1 Spring, Compression

5 0450206 3 Spring, Weight, Clutch

6 0450204 1 Carrier, Clutch

7 0450221 1 Nut

8 0450223 1 Cover, Clutch

9 0450224 1 Nut, Hex

10 0450226 1 O-Ring

11 0450225 1 Bearing

12 0450213 2 Ring, Oil

13 0450210 1 Wheel, Slot, Sliding, Secondary

14 0450239 1 V-Belt

15 0450208 1 Wheel, Slot, Fixed, Secondary

16 0450215 2 Pin, Guide

17 0451016 1 Bearing, Ball

18 0451017 1 Circlip


20 0450200 1 Seal, Oil


22 0450041 1 Washer


24 0450199 1 Bearing

25 0450195 1 Asm., Primary Drive

26 0450234 3 Slider

27 0450232 1 Plate, Cam28 0450229 6 Roller, Weight

29 0450228 1 Wheel, Slot, Sliding, Primary

30 0450236 1 Bushing

31 0450241 1 Sheave, Fixed, Primary

32 0450243 1 Washer, Claw

33 0450245 1 Clutch, One-Way


35 0450249 1 Nut, Flange

36 0450251 1 Asm., Sliding(Incl. 26,27,28,29,30,31,32)

7/



DRIVE SHAFTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

12 13

11

10 9

6

4 5

7

3

21


14

1516

1718 19

20 21

22

2324

272526

28

2930

8

6

31



1 0450265 1 Nut, Lock

2 0452143 1 S procket, Drive

3 0450162 1 Circlip, Internal

4 0 450261 1 Bearing, Ball

5 0452140 1 Cover, Transmission

6 0450142 2 Pin, Dowel

7 0450259 1 Seal, Oil

8 0452142 1 Gear, Final

9 0452141 1 Shaft, Final


11 0452144 1 Shaft, Counter

12 0452146 1 Gear, Counter

13 0452156 1 Bearing

14 0452155 1 Shaft, Main Transmission

15 0452154 1 Bushing, Reverse Gear

16 0452153 1 Gear, Reverse



19 0452151 1 Ratchet, Shift

20 0452150 1 Bushing, Spur Gear

21 0452149 1 Gear, Spur


23 0452147 1 Collar, Shaft

24 0452159 1 Asm., Gear Shif t Drum

25 0452157 1 Fork, Shift

26 0452163 1 Roller, Drum Sensor

27 0452158 1 Shaft, Gear Shif t

28 0452162 1 Spring, Drum Sensor

29 0452160 1 Spindle, Shift

30 0452161 1 E-Clip

31 0450264 1 Washer

7/



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, Hex

2 0450286 2 Washer

3 0450284 2 Bushing, Rubber, Front

4 0450283 1 Tube, Fixed, Front


6 0452165 1 Bracket, Oi l Tank

7 0451151 1 Asm., Engine, 90cc


9 0450192 1 Washer

10 0450268 1 Nut, Flange, Hex

11 0451107 1 Bolt, Hex

12 0451108 1 Collar

7/


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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 Cover

2 0451813 1 Plug, Oil

3 0450154 1 O-Ring

4 0452176 8 Bolt, Hex, Flange

5 0450701 2 Bolt, Hex, Washer

6 0452175 1 Seal, Oil

7 0452167 1 Lever, Transmission

8 0452168 1 Knob, Transmission Lever

9 0450967 1 Cover, Transmission Lever Knob

10 0450309 1 Bolt, Hex

11 0452170 1 Gate, Shift

12 0452171 1 Mount, Shift Lever

13 0450189 1 Bolt, Hex

14 0450192 2 Washer

15 0452173 1 Spring, Transmission Lever

16 0452174 1 Pin, Transmission Lever

17 0450719 1 Pin, Cotter

7/



FRAME BODYPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

11

4

18

17

1514

13

16

15

14

4

12

2

21

1

3

3

7

8

9

3

5

66

5

3

3

3


10



1 0450613 8 Grommet

2 0451112

0451113

1

1

Support, Footwell, LH

Support, Footwell, RH3 0452030 16 Bolt, Hex, Washer Face

4 0450299 2 Plate, Engine Bracket

5 0450800 2 Rubber

6 0451114 2 Bracket, Rear Cab Support

7 0450993 1 Flag


9 0450845 1 Nut, Hex

10 0450180 1 Washer

11 0452178 1 Frame, Main

12 0450265 1 Nut, Lock

13 0450304 1 Sleeve, Rubber

14 0450303 2 Cover, Swing Arm Seal

15 0450302 2 Seat, Grease Contain

16 0450305 1 Bolt, Hex

17 0450301 1 Tube, Spacer

18 0452179 1 Arm, Swing

7/



BUMPERPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

3

1

1

2

2

4




1 0450298 2 Bolt, Hex


3 0451154 1 Bumper, Front, Silver

4 0450150 2 Nut, Lock

7/



SWING ARM / FOOTRESTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

20

18

14

13

16 15

12

17

19

1110

5

1

9

6

1718

14

15

13

12

1110

7

4

2

3

8




1 0450701 3 Bolt, Hex

2 0450611 1 Shield, Heat

3 0450298 2 Bolt, Hex

4 0451119 1 Bracket, Heat Shield

5 0451117 1 Footwell, RH6 0452216 8 Bolt, Hex

7 0451118 1 Footwell, LH


9 0450808 8 Nut, Lock

10 0450321 2 Cap, Rubber

11 0450320 2 Valve, Grease

12 0450317 2 Rubber, Dustproof



15 0450316 2 Cover, Waterproof16 0451155 1 Arm, Suspension, Silver, LH


18 0450288 4 Bushing

19 0450249 4 Nut, Flange

20 0451156 1 Arm, Suspension, Silver, RH

7/



CAB / SEATPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

3

10

13

6

7 8

15

1413

11

17

1612

19

4

4

2

1

9

6

1211

5

5


18




2 0451124 1 Cover, Front, Black Metallic

3 0452191-4960452191-293

11

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

4 04511230451122

11

Panel, Side, LHPanel, Side, RH


6 0450340 4 Bolt, Hex

7 0451140 1 Strap, Battery

8 0451141 1 S trap, Tool Box

9 0450290 2 Rubber, Seat

10 0452192-4960452192-293

11

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

11 0450741 8 Nut, Lock


13 0450622 8 Bolt, Phillips

14 0450346 1 Rubber, Battery

15 0450345 1 Pad, Protector

16 04511250452213

11

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



19 9919505 1 Manual, Owner’s, ’05 Sportsman 90,Predator 50/90

7/



OIL TANK / FUEL TANK PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

12

9

15

14

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 Tank

2 0450903 1 Cap, Oil Tank

3 0451035 1 Bolt, Hex

4 0451126 1 Bracket, Fuel Tank

5 0450041 1 Washer

6 0450826-035 1 Tube, Oil, Side

7 0450363-430 1 Hose

8 0450054 7 Clip

9 0451098 1 Cap, Fuel Tank

10 0450375 1 Film, Breather

11 0450827 1 Boot, Tank Neck

12 0450358 1 Tank, Fuel

13 0450632 2 Mat, Rubber, Fuel Tank

14 0450361 2 Clip

15 0451110 3 Line, Fuel

16 0450701 1 Bolt, Hex

17 0450366 1 A sm., Manual Fuel Cup

18 0451110 1 Hose

19 2520462 1 Filter, Fuel

20 0450340 2 Bolt, Hex

7/



SUSPENSIONPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

16

5

5

1

6

6

6

5

5

4

2

4

2

8

10

9

7

11


3

3



1 0450868 2 Bolt, Hex

2 0450714 2 Tube, Inner, Suspension, Front

3 0451675 2 Collar, Adjustment, Spring, Front

4 0452193-4460452193-293

22

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

5 0450380 3 Bolt, Hex

6 0450249 4 Nut, Flange

7 0450929 1 Retainer, Spring

8 0452181-446

0452181-293

1

1

Spring, Suspension, Rear (CA)

Spring, Suspension, Rear (CB)9 0450894 1 Collar, Adjustment

10 0451072 1 Shock, Rear

11 0451135 1 Bolt, Hex

7/



FRONT WHEELPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

8

13

214

1112

1

9

2

10

5

4

67

3




1 0450393 2 Bearing

2 0450389 4 Seal, Oil

3 0450386 2 Wheel, Rim

4 0450394 2 Nut, Lock

5 0450395 2 Pin, Cotter

6 0450829 2 Cap, Rubber

7 0450397 2 Washer

8 0450870 2 Tire (19x7-8)

9 0450398 8 Bolt, Carriage

10 0450401 2 Valve, Rim

11 0450391 2 Spacer, Outer

12 0450392 2 Bearing

13 04516810451681-293

22

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

14 0450390 2 Spacer, Inner

7/



REAR WHEELPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

32

1

4

5

7

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, Rubber

6 0450409 2 Nut, Lock

7 0450412 2 Washer

8 0450398 8 Bolt, Carriage

9 0450401 2 Valve, Rim

7/



FRONT BRAKEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

9

8

4

6

32

7

5

1

32

7

5

1




1 0450985 2 Cable, Front Brake

2 0450422 2 Asm., Shoe, Front Brake

3 0450421 2 Shaft, Cam, Front Brake

4 0450912 1 Plate, Front Brake, RH

5 0450425 2 Bolt, Hex

6 0450913 1 Arm, Front Brake, RH

7 0450424 2 Spring, Return, Front

8 0450911 1 Arm, Front Brake, LH

9 0450910 1 Plate, Front Brake, LH

7/



REAR BRAKEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

22

8

76

20

9

10

17

3

54

1

2

21

19

18

23

26

28

25

1412

15

11

27

16

13

25 24

12

14

15

76




1 0450438 1 Cable, Rear Brake

2 0450268 2 Bolt, Hex

3 0450435 1 Spring, Cable, Rear Brake

4 0450437 1 Thru-Shaft, Rear Brake

5 0451079 1 Nut, Adjust, Brake

6 0450430 2 Seal, Oil

7 0450429 2 Bearing

8 0450428 1 Tube, Spacer

9 0450432 1 Arm, Rear Brake

10 0450433 1 Bolt, Hex

11 0450453 1 Spring, Arm, Rear Brake

12 0450451 2 Bolt, Hex

13 0450881 1 Nut, Lock

14 0450529 2 Nut, Flange

15 0450452 2 Bolt, Hex

16 0450854 1 Shaft, Fixed, Rear Brake

17 0450434 1 Shoe, Rear Brake

18 0450442 1 Rubber, Protect ive

19 0450441 1 Drum, Rear Brake

20 0450431 1 Shaft, Cam, Rear Brake

21 0450440 1 Plate, Rear Brake

22 0451683 1 Housing, Rear Axle, Silver

23 0450751 1 Cover, Rear

24 7171069 1 Decal, Drive Chain

25 0450340 2 Bolt, Hex

26 0450446 1 Ref lector, Rear

27 0451822 1 Washer, Black

28 0450447 1 Nut, Flange

7/



HANDLEBARPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

101

23

22

27

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, Hand

2 7080891 1 Wristband

3 0450550 1 Switch, Safety

4 0450806 1 Bolt , Brake Lever, RH

5 0452195 1 Cover, Handlebar

6 0 451137 2 Bolt, Philips

7 0451129 1 Bracket, Instrument Panel

8 0450701 2 Bolt, Washer Face

9 0450148 4 Bolt, Hex

10 0451161 1 Handlebar, Silver

11 0450807 1 Bolt, Brake Lever, LH

12 0452203 1 Hose, Breather

13 0451684 1 Asm., Switch, LH

14 0451037 1 Asm., Manual Choke (Incl. 15,16)

15 0451148 2 Bolt

16 0451149 1 Bolt

17 0450463 1 Asm., Lever LH (Incl. 18-21)

18 0450693 1 Lever, Brake, LH

19 0450808 2 Nut, Lock

20 0450692 1 Lock, Park Brake

21 0451090 1 Harness, Sensor Switch

22 0450460 1 Cover, Clamp, LH

23 0450459 2 Clamp, Saddle

24 0450279 2 Washer

25 0450276 2 Nut, Lock

26 0450471 1 Cable, Throttle

27 0450461 1 Cover, Clamp, RH

28 0452202 1 Arm, Throttle

29 0450994 1 Bracket, Brake Cable

30 0450309 1 Bolt

31 0450694 1 Lever, Brake, RH

32 0451099 1 Asm., Lever, RH (Incl. 28-31)

7/



REAR WHEEL AXLEPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

34

5

7

2

6

1




1 0450479 1 Tube, Spacer, LH

2 0450477 1 Axle, Rear

3 04504840450480

11

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

4 0450481 1 Hub, Sprocket

5 0450323 3 Bolt, Hex

6 0450478 1 Tube, Spacer, RH


6/



CHAINPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1

10

3

2

9

11


9

4

5

6

7

8



1 0450695 1 Asm., Drive Chain

2 0450489 2 Nut, Hex

3 0450856 1 Adjuster, Chain

4 0451685 1 Guard, Chain/Brake

5 0451687 1 Spring, Torsion

6 0451686 1 Asm., Chain Tensioner (Incl. 5-7)

7 0451688 1 Roller, Chain Tensioner

8 0451689 1 Bolt

9 0450325 3 Bolt, Hex

10 0450298 1 Bolt

11 0450972 1 Link, Master, Drive Chain

7/


http://slidepdf.com/reader/full/polaris-predator-parts-manual 30/36C1

STEERINGPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

2

10

11

12

13

14

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 Shaft

2 0450915 1 Shaft, Steering

3 0451690 2 Asm., Tie Rod

4 0450395 2 Pin, Cotter

5 0450502 2 Nut, Lock

6 0450507 2 Pin, Cotter

7 0450916 1 Knuckle, LH

8 0450276 4 Nut, Lock

9 0450719 5 Pin, Cotter

10 0450491 1 Seal, Oil

11 0450161 1 Circlip


13 0450389 1 Seal, Oil

14 0450390 1 Spacer

15 0450878 1 Nut, Lock

16 0450917 1 Knuckle, RH

17 0450268 2 Nut, Flange

18 0450499 1 Sleeve, Steering Shaft

7/



HEADLIGHT / BRAKELIGHTPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

8

31

7

2

4

12

7

56

6




1 0450880 2 Nut, Flange, Hex


3 04516910450995

11

Asm., TaillightBulb, Taillight


5 0451131 1 Asm., Headl ight, LH


7 0451134 2 U-Nut

8 0451130 1 Asm., Headl ight, RH

7/



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, Flange


3 0450525 1 Flywheel

4 0450033 2 Bolt, Socket, Hex


6 0451692 1 Asm., Start ing Motor(Incl. 7,8,9,10,12)

7 0450535 1 Brush Set

8 0450537 1 Ring, Oil

9 0450541 2 Bolt Set

10 0450857 1 Cord


12 0450539 1 Ring, Oil

13 0451692 1 Asm., Stator

7/



ELECTRICAL PARTSPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

25

202

27

15

6

4

18

26

11

7

21

12

5

3

16

2223

17

2928

19

1

9

14

13


324

108



1 0450886 1 Clip, Main Switch

2 0450549 1 Asm., Main Switch (Incl. 1)

3 0450701 2 Bolt , Washer Face, Hex

4 0450554 1 Asm., Resistor

5 0450057 2 Bol t, Pan, Phillips6 0452061 1 Regulator, Voltage

7 0450558 1 Asm., Oil Level Gauge

8 0452190 1 Indicator, Neutral

9 0451693 1 Switch, Safety

10 0452189 1 Indicator, Reverse

11 0451710 1 Lamp, Warning, Low Oil

12 0450309 1 Bolt, Hex

13 0451020 2 Screw, Fixing

14 0451019 1 Jumper

15 0452187 1 Asm., CDI Unit

16 0450563 1 Bag, Tool

17 0450842 1 Fuse

18 0450555 1 Asm., Starter Relay

19 0450888 2 Bolt and Nut, Battery

20 0451043 1 Battery21 0450559 3 Strap

22 0450721 1 Strap

23 0450742 1 Strap

24 0451695 1 Horn

25 0452186 1 Harness, Main Wire

26 0450556 2 Bolt, Hex

27 0450753 1 Asm., Ignition Coil (Incl. 29)

28 0451018 1 Washer, Star

29 0451162 1 Cap, Spark Plug

7/



DECALSPREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

9

24

17

2

13

23

15

22

20

14

5

19

16

4

21

1

2

2

RH

LH

18

10

8


11

7

3

6

12



1 7170300 1 Decal, Reflector, Red, RH2 7170896 3 Decal, “POLARIS”, Front/Rear, Black

3 7173013 1 Urocal, 50th Anniversary

4 7170295 1 Decal, Amber, RH

5 7172823717282471729147172915

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, CE

8 71726777173040

11

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

9 7078465 1 Logo, Polaris Star

10 7172829717283071729057172906

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 71711497171151

11

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, LH

17 7172566 1 Decal, Passenger Warning

18 71728257172826

11

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

19 71728587175859

71729127172913

11

11

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 90

21 7170296 1 Decal, Reflector, Red, LH

22 7172678 1 Decal, General Warning, CPSC

23 7172679 1 Decal, Youth Warning, Clutch Cover

24 7079287 1 Decal, Youth Carb/Filter Information

7/



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

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Polaris Predator Parts Manual

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