Predator 90 Parts Manual

PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04
E2004 Polaris Sales Inc.

PREDATOR 90
Model #A05KA09CA
Model #A05KA09CB
This pageleftblankintentionally.
TABLE OF CONTENTS
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB
Parts Manual
A
AIR CLEANER A7 . . . . . . . . . . . . . . . . . . . . . . .
AXLE, REAR WHEEL B13 . . . . . . . . . . . . . . . . . .
B
BRAKE, FRONT B10 . . . . . . . . . . . . . . . . . . . . . .
BRAKE, REAR B11 . . . . . . . . . . . . . . . . . . . . . . .
BRAKELIGHT C2 . . . . . . . . . . . . . . . . . . . . . . . .
BUMPER B3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
CAB B5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR A8 . . . . . . . . . . . . . . . . . . . . . . .
CHAIN B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE A10 . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT A4 . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD A3 . . . . . . . . . . . . . . . . . . . . .
D
DECALS C5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE PULLEY A12 . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT A13 . . . . . . . . . . . . . . . . . . . . . . .
E
ELECTRICAL PARTS C4 . . . . . . . . . . . . . . . . . .
ENGINE BRACKET A14 . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE A9 . . . . . . . . . . . . . . . . . . . . . .
F
FAN COVER A5 . . . . . . . . . . . . . . . . . . . . . . . .
F
FOOTREST B4 . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME BODY B2 . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK B6 . . . . . . . . . . . . . . . . . . . . . . . . .
G
GENERATOR C3 . . . . . . . . . . . . . . . . . . . . . . . .
H
HANDLEBAR B12 . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT C2 . . . . . . . . . . . . . . . . . . . . . . . . .
O
OIL PUMP ASSEMBLY A6 . . . . . . . . . . . . . . . . .
OIL TANK B6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
S
SEAT B5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER A11 . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR C3 . . . . . . . . . . . . . . . . . . .
STEERING C1 . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION B7 . . . . . . . . . . . . . . . . . . . . . . .
SWING ARM B4 . . . . . . . . . . . . . . . . . . . . . . . .
T
TRANSMISSION 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.
A3
CYLINDER HEAD
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. PartNo. Qty. Description Ref. PartNo. Qty. Description
1 0450005 1 Plug, Spark
2 0450012 4 Nut, Flange
3 0452117 1 Head, Cylinder
4 0450004 1 Gasket, Cylinder Head
5 0450007 1 Cylinder
6 0450009 1 Gasket, Cylinder
7 0450011 4 Bolt, Stud
7/04
A4
CRANKSHAFT
3
12
2
4
1
5
10
8
11
9
7
9
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 0450802
0450651
0450704
1
1
1
Piston (Std)
Piston (.25 mm O/S)
Piston (.50 mm O/S)
11 0450877
0450025
0450705
2
2
2
Ring Set, Piston (Std)
Ring Set, Piston (.25 mm O/S)
Ring Set, Piston (.50 mm O/S)
12 0450015 1 Key, Semicycle
6/01
A5
FAN COVER
16
15
10
12
9
17
11
14
13
8
7
6
1
9
2
3
5
4
1 0451664 1 Cover, Fan Inlet
2 0451666 1 Strap
3 0451665 1 Duct, Cooling Fan
4 0452119 1 Filter, Cooling 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, Fan
11 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
7/04
A6
OIL PUMP ASSEMBLY
16
12
11
7
6
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, Oil 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, Phillips
16 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 CLEANER
17
16
2
1
3
4
8
14
6
15
10
9
5
7
11
12
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
9/02
A8
CARBURETOR
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
21
4
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, Needle
9 0450097 1 Jet, Main
10 0450976 1 Float, Carb
11 0450117 1 Pin, Float
12 0451032 1 Cable, Choke
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 Choke
25 0451056 1 Bracket, Manual Choke
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
7/04
A9
EXHAUST PIPE
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
15 0450128 1 Plate, Fixed, Exhaust
17 0450122 1 Gasket
7/04
A10
CRANKCASE
13
12
8
4
7
6
2
26
27
31
29
30
22
32
23
18
10
11
15
14
5
28
1
33
9
16
17
21
3
24
25
19
20
34
35
3
10
36
37
38
39
40
41
42
43
44
46
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, Upper
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
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 Bolt, Hex, Flange
37 0450162 1 Circlip, Internal
38 0452132 1 Bolt, Hex
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
7/04
A11
STARTER
10
12
13
14
9
16
18
17
19
20
1
2
3
4
11
6
5
7
8
15
21
17
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
6/01
A12
DRIVE PULLEY
25
22
23
21
24
20
1
6
5
15
13
2
12
16
4
3
7
8
9
11
10
29
27
26
30
14
31
32
33
34
35
36
2
26
28
17
18
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, Cam
28 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)
7/03
A13
DRIVE SHAFT
12
13
11
10
9
6
4
5
7
3
2
1
14
15
16
17
18
19
20
21
22
23
24
27
25
26
28
29
30
8
6
31
1 0450265 1 Nut, Lock
2 0452143 1 Sprocket, Drive
3 0450162 1 Circlip, Internal
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 Shift Drum
25 0452157 1 Fork, Shift
26 0452163 1 Roller, Drum Sensor
27 0452158 1 Shaft, Gear Shift
28 0452162 1 Spring, Drum Sensor
29 0452160 1 Spindle, Shift
30 0452161 1 E-Clip
31 0450264 1 Washer
7/04
A14
ENGINE BRACKET
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, Oil 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
7/04
B1
TRANSMISSION LEVER
1
2
3
4
5
6
7
8
9
10
11
13
14
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
7/04
B2
FRAME BODY
11
4
18
17
15
14
13
16
15
14
4
12
2
2
1
1
3
3
7
8
9
3
5
6
6
5
3
3
3
10
1 0450613 8 Grommet
2 0451112
0451113
1
1
Support, Footwell, LH
Support, Footwell, RH
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
7/04
B3
BUMPER
3
1
1
2
2
4
1 0450298 2 Bolt, Hex
3 0451154 1 Bumper, Front, Silver
4 0450150 2 Nut, Lock
7/04
B4
SWING ARM / FOOTREST
20
18
14
13
16
15
12
17
19
11
10
5
1
9
6
17
18
14
15
13
12
11
10
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, RH
6 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, Waterproof
16 0451155 1 Arm, Suspension, Silver, LH
18 0450288 4 Bushing
19 0450249 4 Nut, Flange
20 0451156 1 Arm, Suspension, Silver, RH
7/04
B5
CAB / SEAT
3
10
13
6
7
8
15
14
13
11
17
16
12
19
4
4
2
1
9
6
12
11
5
5
18
2 0451124 1 Cover, Front, Black Metallic
3 0452191-496
0452191-293
1
1
Cab, Front, Cosmic Sunburst (CA)
Cab, Front, Indy Red (CB)
4 0451123
0451122
1
1
Panel, Side, LH
Panel, Side, RH
6 0450340 4 Bolt, Hex
7 0451140 1 Strap, Battery
8 0451141 1 Strap, Tool Box
9 0450290 2 Rubber, Seat
10 0452192-496
0452192-293
1
1
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 0451125
0452213
1
1
Asm., Seat (CA)
Asm., Seat, Dale Jr. (CB)
19 9919505 1 Manual, Owners, 05 Sportsman 90,
Predator 50/90
7/04
B6
OIL TANK / FUEL TANK
12
9
15
14
19
17
8
16
1
2
20
4
10
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 Asm., Manual Fuel Cup
18 0451110 1 Hose
19 2520462 1 Filter, Fuel
20 0450340 2 Bolt, Hex
7/04
B7
SUSPENSION
1
6
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 0452193-446
0452193-293
2
2
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
7/04
B8
FRONT WHEEL
8
13
2
14
11
12
1
9
2
10
5
4
6
7
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 0451681
0451681-293
2
2
Drum, Brake, Front, Orange (CA)
Drum, Brake, Front, Indy Red (CB)
14 0450390 2 Spacer, Inner
7/04
B9
REAR WHEEL
3
2
1
4
5
7
8
9
6
1 0452194
0451682
2
2
Hub, Rear Wheel (CA)
Hub, Rear, Orange (CB)
2 0450386 2 Wheel, Rim
3 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
7/04
B10
FRONT BRAKE
9
8
4
6
3
2
7
5
1
3 2
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
7/02
B11
REAR BRAKE
22
8
7
6
20
9
10
17
3
5
4
1
2
21
19
18
23
26
28
25
14
12
15
11
27
16
13
25
24
12
14
15
7
6
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, Protective
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 Reflector, Rear
27 0451822 1 Washer, Black
28 0450447 1 Nut, Flange
7/04
B12
HANDLEBAR
10
1
23
22
27
9
32
24
25
5
13
6
26
1
28
31
20
18
4
21
11
19
19
2
3
30
29
14
8 7
17
15
16
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 0451137 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)
7/04
B13
REAR WHEEL AXLE
3
4
5
7
2
6
1
1 0450479 1 Tube, Spacer, LH
2 0450477 1 Axle, Rear
3 0450484
0450480
1
1
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
6/01
B14
CHAIN
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
7/03
C1
STEERING
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
7/03
C2
HEADLIGHT / BRAKELIGHT
8
3
1
7
2
4
1
2
7
5
6
6
1 0450880 2 Nut, Flange, Hex
3 0451691
0450995
1
1
Asm., Taillight
Bulb, Taillight
5 0451131 1 Asm., Headlight, LH
7 0451134 2 U-Nut
8 0451130 1 Asm., Headlight, RH
7/03
C3
GENERATOR/STARTING MOTOR
3
2
1
4 5
6
7
8
12
9
10
11
13
1 0450529 1 Nut, Flange
3 0450525 1 Flywheel
6 0451692 1 Asm., Starting 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
7/03
C4
ELECTRICAL PARTS
25
20
2
27
15
6
4
18
26
11
7
21
12
5
3
16
22
23
17
29
28
19
1
9
14
13
3
24
10 8
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
6 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 Battery
21 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
7/04
C5
DECALS
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, RH
2 7170896 3 Decal, POLARIS, Front/Rear, Black
3 7173013 1 Urocal, 50th Anniversary
4 7170295 1 Decal, Amber, RH
5 7172823
7172824
7172914
7172915
1
1
1
1
Decal, Fender, Front, LH (CA)
Decal, Fender, Front, RH (CA)
Decal, Fender, Front, Stripes, LH (CB)
Decal, Fender, Front, StripesRH (CB)
6 7171150
7171152
1
1
Decal, Headlight, Front, RH
Decal, Headlight, Side, RH
7 0451809 1 Decal, Youth, CE
8 7172677
7173040
1
1
Decal, Age Warning, 12 (CA)
Decal, Age Warning, 12 (CB)
9 7078465 1 Logo, Polaris Star
10 7172829
7172830
7172905
7172906
1
1
1
1
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
7171151
1
1
Decal, Headlight, Front, LH
Decal, Headlight, Side, LH
13 7172827
7172828
7172910
7172911
1
1
1
1
Decal, Front Cab, LH (CA)
Decal, Front Cab, RH (CA)
Decal, Front Cab, LH (CB)
Decal, Front Cab RH (CB)
14 7172819
7172820
7172909
1
1
2
Decal, PREDATOR, LH (CA)
Decal, PREDATOR, RH (CA)
Urocal, PREDATOR, Red (CB)
15 7172821
7172822
7172907
7172908
1
1
1
1
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 7172825
7172826
1
1
Decal, Rear Fender, Inside, LH (CA)
Decal, Rear Fender, Inside, RH (CA)
19 7172858
7175859
7172912
7172913
1
1
1
1
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
7/04
This pageleftblankintentionally.
PRINTED IN THE USA PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

Predator 90 Parts Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Predator 90 Parts Manual

Uploaded by

Copyright:

Available Formats

PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

E2004 Polaris Sales Inc.

You might also like