PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

PREDATOR 90
Model #A05KA09CA
Model #A05KA09CB

E 2004 Polaris Sales Inc.

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TABLE OF CONTENTS
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

Parts Manual

A

F

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

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

B
BRAKE, FRONT . . . . . . . . . . . . . . . . . . . . . .
BRAKE, REAR . . . . . . . . . . . . . . . . . . . . . . .
BRAKELIGHT . . . . . . . . . . . . . . . . . . . . . . . .
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . .

B10
B11
C2
B3

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . C3

H
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B12
HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . C2

C
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . .

G

B5
A8
B14
A10
A4
A3

D
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
DRIVE PULLEY . . . . . . . . . . . . . . . . . . . . . . A12
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . A13

E
ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . C4
ENGINE BRACKET . . . . . . . . . . . . . . . . . . . A14
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . A9

F
FAN COVER . . . . . . . . . . . . . . . . . . . . . . . . A5

O
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . A6
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

S
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . .
SWING ARM . . . . . . . . . . . . . . . . . . . . . . . .

B5
A11
C3
C1
B7
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.

Description 1 Cylinder 1 Gasket. Plug. Cylinder Gasket. Cylinder Head 5 0450007 6 0450009 7 0450011 Qty. Cylinder 4 Bolt. Part No. Spark Nut. 1 2 3 4 0450005 0450012 0452117 0450004 Qty. Stud 7/04 A3 . Part No. Electronic records are the most current. 6 5 4 3 2 1 Part numbers may change after the making of the microfiche or paper copies. Ref. 1 4 1 1 Description Ref. Flange Head.CYLINDER HEAD PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 7 E 2004 Polaris Sales Inc.

50 mm O/S) Ring Set. Plain Bearing. Oil Bearing. Ref.CRANKSHAFT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 E 2004 Polaris Sales Inc.50 mm O/S) Key. 1 2 3 4 5 6 7 8 0450018 0450016 0450649 0450017 0450650 0450653 0450029 0450023 Qty. 3 12 9 2 11 4 8 10 9 5 6 7 Part numbers may change after the making of the microfiche or paper copies. Seal. 1 2 1 1 1 1 1 1 Description Ref. Piston (Std) Ring Set. Piston (. Crank. Semicycle 6/01 A4 .25 mm O/S) Piston (. Piston Pin Piston (Std) Piston (. Electronic records are the most current. Piston 9 0450027 10 0450802 0450651 0450704 11 0450877 0450025 0450705 12 0450015 2 1 1 1 2 2 2 1 Description Clip. Radial Crankshaft Seal. Needle Pin. LH Washer. Ball. Part No. Oil Collar. Qty. Piston (. Part No.25 mm O/S) Ring Set.

5 6 7 8 9 13 10 11 12 17 9 14 15 16 Part numbers may change after the making of the microfiche or paper copies. Socket Washer 10 11 12 13 14 15 16 17 0451712 0450036 0450033 0450038 0450037 0450031 0450030 0450035 Qty. Cooling Fan Filter. Hex Deflector Fan Grommet. Air.FAN COVER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 4 3 2 1 E 2004 Polaris Sales Inc. 1 1 1 1 1 1 1 2 5 Description Ref. 1 3 3 1 1 2 1 1 Description Cover. Plain Screw. Fan Inlet Strap Duct. Cylinder Screw. Cylinder Shroud. Ref. Air Shroud Bolt. 1 2 3 4 5 6 7 8 9 0451664 0451666 0451665 0452119 0451667 0450041 0450040 0450039 0450034 Qty. Tapping 7/04 A5 . Cooling Fan Gasket. Part No. Part No. Fan Damper. Socket. Fan Inlet Washer. Tapping Bolt. Electronic records are the most current. Cover.

Part No. External Washer. Oil Pump O-Ring Tube.6.17) 1 Pin.7. Worm.OIL PUMP ASSEMBLY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 3 1 4 E 2004 Polaris Sales Inc.13. Oil Bolt. Electronic records are the most current. Wave Gear.14. Part No. 2 1 1 1 1 1 1 1 2 Description Ref.12. Drive. 10 8 12 13 6 7 9 10 5 17 11 16 9 14 13 15 Part numbers may change after the making of the microfiche or paper copies. Oil Pipe Tube.11. Oil Pump Pin. 1 2 3 4 5 6 7 8 9 0450060 0450655 0450058 0450059 0450052 0450050 0450048 0450055 0450054 Qty. Oil Clip 10 11 12 13 14 15 16 0450056 0450046 0450884 0450061 0450053 0450057 0450846 17 0450051 Qty. Pan. Oil Pump (Incl. Protective. Shaft 6/01 A6 . Phillips Spring.9.8. Description 2 1 1 2 1 2 1 Clip Washer Bolt.10. Dowel Circlip. Phillips Asm. External Gear. Circlip. 5.. Ref.

15) Seal 10 11 12 13 14 15 16 17 0450073 0450039 0450034 0450079 0450070 0451138 0450064 0450063 Qty. Air Cleaner Bolt. Washer Face Manifold. 5. 1 2 3 4 5 6 7 8 9 0450066 0450065 0450067 0450068 0451077 0450071 0450076 0451080 0451081 Qty. Air Cleaner Tube.9. Part No. 1 2 2 2 1 1 1 1 Description Element. Bolt. Ref. Air Cleaner Screw.13. Air Cleaner Cover. Air (Incl.10. Air Cleaner Gasket Asm. Reed Valve 9/02 A7 .. Socket Washer. Electronic records are the most current.14.6.AIR CLEANER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 3 E 2004 Polaris Sales Inc. Tapping Cleaner. 17 16 15 4 14 13 12 11 10 9 5 6 7 8 Part numbers may change after the making of the microfiche or paper copies.7. Hex. Hose Clip Elbow. 4 1 1 1 1 1 3 1 1 Description Ref. Part No. Plain Grommet Case. Inlet. Intake Clamp.

Float Cable.CARBURETOR PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 13 32 2 1 28 26 27 31 25 30 24 23 22 21 29 3 4 5 20 6 19 18 7 E 2004 Polaris Sales Inc. Ref. Overflow Plug. Nut. Cable Cover. Electronic records are the most current. Manual Choke Bolt. Manual Choke Bracket. Phillips Tube. Carb Slide Washer. Carb Pin. Phillips 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0451669 0451054 0451668 0450923 0451055 0451057 0451028 0451058 0451056 0450106 0451060 0451059 0451051 0452196 0451050 0450087 Qty. Main Float. Drain Bolt. Choke Valve.. 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 Description Valve Set. Air Adjust Screw Set. Oil Pipe. Cable Adjust Gasket Plug. Spring 7/04 A8 . Float Chamber Asm. Cable Support Slide. All Less 12) Nozzle. 8 17 9 10 11 16 12 15 13 14 Part numbers may change after the making of the microfiche or paper copies. Carburetor Needle Set Spring. Choke Return O-Ring Base. Oil Screw Set. Choke Spring. Choke Bolt. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0450119 0450082 0451014 0451013 0450102 0450113 0451024 0452197 0450097 0450976 0450117 0451032 0450086 0450098 0450104 0450108 Qty. Part No. Pan. Pan. Pan. Needle Seal. Needle Jet. Part No. 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 Description Ref. Phillips Support. Throttle Jet. Carburetor (Incl. Pilot Nozzle.

1 2 3 4 5 6 7 8 9 0450658 0450126 0450657 0450684 0450279 0452121 0450282 0452198 0450325 Qty. Exhaust Bolt. Hex. Hex Washer. Exhaust Bolt. Part No. Washer Face Gasket 7/04 A9 . 3 4 5 7 6 8 17 9 10 11 15 12 16 13 14 Part numbers may change after the making of the microfiche or paper copies. Hex. Pan. Phillips Gasket Protector. 2 2 1 1 1 1 1 1 1 Description Ref. Hex. Exhaust Bracket Bolt. 2 1 1 1 1 1 2 1 Description Gasket. Bolt. Part No. Fixed. Washer Face Gasket Bolt. Washer Face 10 11 12 13 14 15 16 17 0452122 0452123 0451702 0450323 0450298 0450128 0450123 0450122 Qty. Washer Face Washer.EXHAUST PIPE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 1 2 2 E 2004 Polaris Sales Inc. Hex. Hex Bolt. Hex. Plain Pipe. Spring Bolt. Exhaust Nut. Ref. Washer Face Plate. Pipe. Electronic records are the most current.

1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 3 1 1 1 1 Description Bearing. Part No. Dowel Gasket. Rubber Washer Circlip. Carburator Tube Shaft. Detent Washer. Clutch Cover Nut. Needle Bushing. Steel Spring. Primary Drive Bearing Bolt. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 0450166 0450164 0450142 0450141 0451671 0450148 0450157 0450158 0450159 0450138 0450170 0450135 0450137 0452127 0450254 0452130 0450199 0450298 0450684 0452131 0450132 0450041 0450198 0450200 Qty. Flat Bolt. Crankcase. Gear Position Bolt. Clutch Bolt. Flat Bolt Grommet Guard. Internal Bolt. Hex. Needle Shaft. Lower Crankcase. Upper Bearing. RH Pin. Flange Circlip. 1 1 2 1 1 8 1 2 1 8 1 1 2 1 2 1 1 2 1 1 1 1 1 1 Description Protector A Filter Pin. Ref. Hex Bracket. Crankcase Cover. Hex Mount. Rear Bushing. Rubber Breather. Flange Protector B Bolt. Dowel Breather. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 A10 0452139 0451139 0452125 0452124 0452134 0452135 0452136 0452137 0452126 0452129 0452128 0452138 0450162 0452132 0452133 0450167 0450168 0451672 0450150 0450152 0450151 0450160 0450147 Qty. Oil Seal Bolt. Hex Bracket. Hex Washer. 16 11 18 17 12 8 8 7 3 1 2 5 4 3 15 13 6 20 21 22 23 24 25 26 27 28 14 29 33 34 45 10 47 46 30 31 32 39 38 44 43 37 35 36 42 41 40 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current. Hex Bolt. External Seal. Part No. LH Ball. Engine. Hex.CRANKCASE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 19 9 10 E 2004 Polaris Sales Inc. Generator Bolt Plug. Hex O-Ring Sensor. Rubber Crankcase. Oil Ref. Crankcase. Hex Bolt. Pin 7/04 . Hex Gasket.

1 2 3 4 5 6 7 8 9 10 11 0450183 0450184 0450185 0450186 0450883 0450569 0450190 0450191 0450176 0450171 0450187 Qty. Needle Boss. 1 1 1 1 1 2 1 1 2 1 Description Bearing. Ref. Kick Crank Asm. Wave 6/01 A11 . Idle Gear Washer Pin.. 15 16 17 18 19 20 21 20 17 Part numbers may change after the making of the microfiche or paper copies. Plain Washer Asm. Kick Shaft Spring. Idle Gear Bolt.. Starter Circlip. Gear Washer.. 1 1 1 1 1 1 1 1 1 1 1 Description Asm. Hex Asm. Reset. Socket.STARTER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 6 2 3 5 4 14 11 13 12 10 9 8 7 E 2004 Polaris Sales Inc. Spring Clutch Set. Shaft Plate. Starter. Kick Pinion Clip. Electric Wheel. Part No.. Hex Washer. External Ref. Part No. Electronic records are the most current. 12 13 14 15 16 17 18 19 20 21 0450172 0450173 0450174 0450192 0450178 0450180 0450682 0450181 0450805 0450193 Qty. Starter Shaft Bushing Washer Bolt.

External Washer Bolt. Clutch 1 Nut. Secondary 2 Pin. Ref. Oil 1 Seat. Clutch 1 Nut 1 Cover. Spring Nut. 2. Fixed..27. Part No. Hex Bearing Asm. One-Way Washer.29. Spring. 26.. Fixed. Secondary Sheave (Incl.DRIVE PULLEY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB E 2004 Polaris Sales Inc. Weight. Flange Asm. 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 0451015 0450200 0450198 0450041 0450158 0450199 0450195 0450234 0450232 0450229 0450228 0450236 0450241 0450243 0450245 0450247 0450249 0450251 Qty. Slot.3. 2 1 3 4 5 6 7 25 24 23 8 9 22 10 21 20 11 19 18 17 16 15 2 14 26 13 27 26 12 28 29 33 30 35 36 31 32 34 Part numbers may change after the making of the microfiche or paper copies. Guide 1 Bearing.13. Hex 1 O-Ring 1 Bearing 2 Ring.15. Sliding. Primary Washer. Needle Seal.28. Sliding (Incl. Oil 1 Wheel.7. Ball 1 Circlip Ref. Clutch 1 Carrier.8. Socket.6.16) 2 Seal. Secondary 1 Spring. Compression 3 Spring. Secondary 1 V-Belt 1 Wheel. 1 1 1 1 1 1 1 3 1 6 1 1 1 1 1 1 1 1 Description Bearing. Slot.31.4. Part No.5. Slot. Description 1 Asm.12. 1 0450202 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0450211 0450219 0450217 0450206 0450204 0450221 0450223 0450224 0450226 0450225 0450213 0450210 0450239 0450208 0450215 0451016 0451017 Qty. Primary Bushing Sheave. Weight Wheel.30. Sliding.. Primary Drive Slider Plate. Electronic records are the most current.32) 7/03 A12 . Claw Clutch. Oil Circlip. Cam Roller.

Flat Circlip. Ball Shaft. External Ratchet. Spur Washer.. Reverse Gear Gear. Ref. Lock Sprocket. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 Description Nut. Drum Sensor Shaft. Reverse Ref. Dowel Seal. Flat Collar. Oil Gear. Ball Cover. Part No. Shift Bushing. Gear Shift Spring. Drum Sensor Spindle. Spur Gear Gear. Electronic records are the most current. Final Bearing. Final Shaft. Counter Bearing Shaft. Shift Roller. Counter Gear. Shift E-Clip Washer 7/04 A13 . Transmission Pin. Part No. Drive Circlip. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0452152 0450060 0452151 0452150 0452149 0452148 0452147 0452159 0452157 0452163 0452158 0452162 0452160 0452161 0450264 Qty. 6 5 7 8 10 9 11 12 13 14 15 6 30 16 17 29 28 27 26 18 19 20 25 21 22 23 24 Part numbers may change after the making of the microfiche or paper copies. Internal Bearing. Shaft Asm. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Washer. Gear Shift Drum Fork.DRIVE SHAFT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 3 4 31 E 2004 Polaris Sales Inc. Main Transmission Bushing. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0450265 0452143 0450162 0450261 0452140 0450142 0450259 0452142 0452141 0450254 0452144 0452146 0452156 0452155 0452154 0452153 Qty.

2 2 2 1 1 1 Description Nut. Engine. Part No. 7 8 9 10 11 12 0451151 0450684 0450192 0450268 0451107 0451108 Qty.ENGINE BRACKET PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 E 2004 Polaris Sales Inc. Flange. Front Tube. Front Bushing. 1 2 1 1 1 1 Description Asm. 90cc Bolt.. Rubber Bracket. Hex Collar 7/04 A14 . Washer Face Washer Nut. 1 2 3 4 5 6 0450271 0450286 0450284 0450283 0450132 0452165 Qty. Rubber. Fixed. 2 3 4 3 6 5 7 8 9 10 12 11 Part numbers may change after the making of the microfiche or paper copies. Hex Washer Bushing. Electronic records are the most current. Hex. Ref. Part No. Oil Tank Ref. Hex Bolt.

Transmission Lever Cover. 1 2 3 4 5 6 7 8 9 0452169 0451813 0450154 0452176 0450701 0452175 0452167 0452168 0450967 Qty. Electronic records are the most current. Transmission Cover Plug. 9 2 3 8 10 4 5 7 4 11 5 6 12 14 4 17 16 14 13 15 Part numbers may change after the making of the microfiche or paper copies. Part No. Hex Washer Spring. Gasket. Transmission Lever Pin. Description 1 1 1 1 2 1 1 1 Bolt. Transmission Knob. Transmission Lever Knob 10 11 12 13 14 15 16 17 0450309 0452170 0452171 0450189 0450192 0452173 0452174 0450719 Qty. Washer Seal. Transmission Lever Pin. Hex. Flange Bolt. Description 1 1 1 8 2 1 1 1 1 Ref. Shift Lever Bolt.TRANSMISSION LEVER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 E 2004 Polaris Sales Inc. Cotter 7/04 B1 . Hex. Oil Lever. Part No. Oil O-Ring Bolt. Shift Mount. Ref. Hex Gate.

Rear Cab Support Flag Washer. Grommet Support. LH Support. Footwell. Swing 7/04 B2 . 1 1 1 1 2 2 1 1 1 Description Washer Frame. 8 1 1 16 2 2 2 1 1 1 Description Ref.FRAME BODY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB E 2004 Polaris Sales Inc. Rubber Cover. Washer Face Plate. Part No. Part No. Lock Sleeve. Electronic records are the most current. Main Nut. Ref. Swing Arm Seal Seat. Engine Bracket Rubber Bracket. Hex Tube. 1 0450613 2 0451112 0451113 3 0452030 4 0450299 5 0450800 6 0451114 7 0450993 8 0450844 9 0450845 Qty. RH Bolt. Hex. Spring Nut. Hex 10 11 12 13 14 15 16 17 18 0450180 0452178 0450265 0450304 0450303 0450302 0450305 0450301 0452179 Qty. 7 1 2 3 8 9 5 4 6 3 5 6 3 3 4 11 12 3 10 13 14 15 18 1 15 14 17 2 16 3 Part numbers may change after the making of the microfiche or paper copies. Grease Contain Bolt. Footwell. Spacer Arm.

2 Bolt. Washer Face 3 0451154 4 0450150 Qty. Front. Hex. Ref. Hex 2 Bolt. Part No.BUMPER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 3 E 2004 Polaris Sales Inc. Electronic records are the most current. Part No. Description 1 Bumper. Description Ref. 1 0450298 2 0450309 Qty. 2 4 2 1 1 Part numbers may change after the making of the microfiche or paper copies. Silver 2 Nut. Lock 7/04 B3 .

LH Washer. Grease Rubber. Heat Shield Footwell. Suspension. 1 2 3 4 5 6 7 8 9 10 0450701 0450611 0450298 0451119 0451117 0452216 0451118 0450879 0450808 0450321 Qty. 3 1 2 1 1 8 1 8 8 2 Description Ref. LH Bolt. Grease Contain Seat. Plain Nut. Silver. Suspension. Hex. Hex Shield. 7 15 10 14 11 8 20 9 17 18 13 19 12 16 15 14 18 17 10 11 13 12 Part numbers may change after the making of the microfiche or paper copies. Washer Face Bushing Nut. Lock Cap. Flange Arm. Electronic records are the most current. Waterproof Arm. Heat Bolt. Rubber 11 12 13 14 15 16 17 18 19 20 0450320 0450317 0450314 0450313 0450316 0451155 0450820 0450288 0450249 0451156 Qty. 2 2 2 2 2 1 4 4 4 1 Description Valve. Grease Contain Cover. Ref. RH 7/04 B4 . Hex Footwell. Hex Bracket. RH Bolt. Part No. Part No. Silver. Bolt. Dustproof Seat.SWING ARM / FOOTREST PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 3 4 5 6 E 2004 Polaris Sales Inc.

2 1 1 1 1 1 4 4 1 1 2 1 1 Description Ref. Tapping Manual. (CB) Bolt.CAB / SEAT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 8 7 E 2004 Polaris Sales Inc. Battery Strap. RH Screw. Screw. Part No. 5 9 6 6 10 4 3 12 2 13 1 17 13 11 18 5 4 12 11 14 15 16 19 Part numbers may change after the making of the microfiche or paper copies. Tapping Cover. LH Panel. Hex. Plain Bolt. Black Metallic Cab. Seat. Part No. Side. Protector Asm. Electronic records are the most current.. Battery Pad. Rear. Dale Jr. Phillips Rubber. Hex Strap. Indy Red (CB) Panel. 1 0451132 2 0451124 3 0452191-496 0452191-293 4 0451123 0451122 5 0450676 6 0450340 7 0451140 8 0451141 9 0450290 10 0452192-496 0452192-293 Qty. Ref. Lock Washer. Seat (CA) Asm. Predator 50/90 7/04 B5 .. Rear. Side. Owner’s. ’05 Sportsman 90. Front. Front. Cosmic Sunburst (CA) Cab. Tapping Bolt. Front. Seat Cab. Indy Red (CB) 11 12 13 14 15 16 0450741 0450710 0450622 0450346 0450345 0451125 0452213 17 0450824 18 0451674 19 9919505 Qty. Cosmic Sunburst (CA) Cab. Washer Face Screw. Tool Box Rubber. 8 8 8 1 1 1 1 2 2 1 Description Nut.

Breather 11 12 13 14 15 16 17 18 19 20 0450827 0450358 0450632 0450361 0451110 0450701 0450366 0451110 2520462 0450340 Qty. 17 18 Part numbers may change after the making of the microfiche or paper copies. Tank Neck Tank. 1 2 3 4 5 6 7 8 9 10 0450927 0450903 0451035 0451126 0450041 0450826-035 0450363-430 0450054 0451098 0450375 Qty.. Part No. Oil Tank Cap. Fuel Bolt. Fuel Tank Washer Tube. Side Hose Clip Cap. Manual Fuel Cup Hose Filter. Rubber. Hex Bracket. 1 1 1 1 1 1 1 7 1 1 Description Ref. Fuel Tank Film. Hex 7/04 B6 . Hex Asm. Ref. Fuel Mat. Part No. 1 1 2 2 3 1 1 1 1 2 Description Boot. Fuel Tank Clip Line. Oil. Oil Tank Bolt.. Asm. Electronic records are the most current.OIL TANK / FUEL TANK PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 5 3 2 6 9 4 7 10 8 11 12 1 13 20 14 15 20 14 8 15 8 15 8 19 8 16 E 2004 Polaris Sales Inc. Fuel Bolt.

Suspension. Front (CA) Spring. 2 2 2 2 2 3 4 Description Ref. Spring Spring. 9 6 5 8 6 4 3 5 2 10 4 1 3 11 2 6 6 1 5 Part numbers may change after the making of the microfiche or paper copies. Adjustment. Adjustment Shock. Rear (CA) Spring. Suspension. Ref. Suspension. Bolt. Front Collar. 1 1 1 1 1 1 Description Retainer. Flange 7 0450929 8 0452181-446 0452181-293 9 0450894 10 0451072 11 0451135 Qty. Spring. Suspension. Front Spring.SUSPENSION PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 7 E 2004 Polaris Sales Inc. Hex 7/04 B7 . Hex Nut. Rear (CB) Collar. Part No. Electronic records are the most current. Rear Bolt. Front (CB) Bolt. Inner. Hex Tube. Part No. Suspension. 1 2 3 4 0450868 0450714 0451675 0452193-446 0452193-293 5 0450380 6 0450249 Qty.

Rim Nut. Front.FRONT WHEEL PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 3 2 2 14 13 12 11 4 5 9 7 10 6 8 E 2004 Polaris Sales Inc. Orange (CA) Drum. Indy Red (CB) Spacer. Rubber Washer Tire (19x7-8) 9 10 11 12 13 0450398 0450401 0450391 0450392 0451681 0451681-293 14 0450390 Qty. Ref. 2 4 2 2 2 2 2 2 Description Ref. 8 2 2 2 2 2 2 Description Bolt. Rim Spacer. Part numbers may change after the making of the microfiche or paper copies. 1 2 3 4 5 6 7 8 0450393 0450389 0450386 0450394 0450395 0450829 0450397 0450870 Qty. Bearing Seal. Brake. Front. Lock Pin. Electronic records are the most current. Part No. Part No. Oil Wheel. Brake. Outer Bearing Drum. Inner 7/04 B8 . Carriage Valve. Cotter Cap.

Part No. Rubber Nut. Cotter 5 6 7 8 9 0450829 0450409 0450412 0450398 0450401 Qty. Orange (CB) Wheel. Rear. Electronic records are the most current.5-8) Pin. 2 2 2 2 2 Description Ref.REAR WHEEL PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 3 4 9 8 7 E 2004 Polaris Sales Inc. Ref. 1 0452194 0451682 2 0450386 3 0451127 4 0450395 Qty. Rear Wheel (CA) Hub. 2 2 2 8 2 Description Cap. Part No. 6 5 Part numbers may change after the making of the microfiche or paper copies. Rim Tire (18x9. Lock Washer Bolt. Hub. Carriage Valve. Rim 7/04 B9 .

Hex 6 7 8 9 0450913 0450424 0450911 0450910 Qty. Front Brake Shaft. Ref. Front Brake. Front Brake Asm. Front Brake. Front Brake. Cam. RH Spring. Electronic records are the most current.FRONT BRAKE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB E 2004 Polaris Sales Inc. Cable.. 1 1 7 7 8 2 3 6 4 5 5 3 9 2 Part numbers may change after the making of the microfiche or paper copies. Part No. LH Plate. Return. Front Arm. 1 2 3 4 5 0450985 0450422 0450421 0450912 0450425 Qty. Front Brake Plate. Shoe. RH Bolt. 1 2 1 1 Description Arm. 2 2 2 1 2 Description Ref. Front Brake. LH 7/02 B10 . Part No.

20 6 11 10 7 15 9 8 21 14 12 7 22 6 28 27 26 25 24 23 25 Part numbers may change after the making of the microfiche or paper copies. Hex Spring. Arm. Part No. Rear Brake Shaft. Rear Brake Nut. Ref. 1 2 1 1 1 2 2 1 1 1 1 2 1 2 Description Cable. Oil Bearing Tube. Cam. Spacer Arm. Rear Decal. Rear Brake Thru-Shaft. Fixed. Rear Brake Plate. Hex Reflector. Cable. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 0450452 0450854 0450434 0450442 0450441 0450431 0450440 0451683 0450751 7171069 0450340 0450446 0451822 0450447 Qty. Rear Axle. Black Nut. Flange 7/04 B11 . Part No. Hex Nut. Rear Brake Housing. Rear Brake Bolt. Flange Ref. Hex Spring.REAR BRAKE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 19 2 3 4 5 18 17 16 15 14 13 12 E 2004 Polaris Sales Inc. Rear Brake Rubber. Hex Shaft. 2 1 1 1 1 1 1 1 1 1 2 1 1 1 Description Bolt. Electronic records are the most current. Brake Seal. Rear Brake Bolt. Rear Washer. Adjust. Lock Nut. Rear Brake Shoe. Rear Brake Bolt. Silver Cover. Drive Chain Bolt. Protective Drum. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0450438 0450268 0450435 0450437 0451079 0450430 0450429 0450428 0450432 0450433 0450453 0450451 0450881 0450529 Qty.

Brake. RH Arm. Switch. Handlebar Bolt. Electronic records are the most current. Hex Handlebar. 15. Park Brake Harness. Brake Cable Bolt Lever. Brake Lever. Brake Lever.16) Bolt Bolt Ref. Philips Bracket. Instrument Panel Bolt. Silver Bolt.. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0451097 7080891 0450550 0450806 0452195 0451137 0451129 0450701 0450148 0451161 0450807 0452203 0451684 0451037 0451148 0451149 Qty. Throttle Bracket. 18-21) Lever. 28-31) 7/04 B12 . RH Asm.HANDLEBAR PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 6 5 2 1 4 3 7 8 E 2004 Polaris Sales Inc. Part No. 2 1 1 1 1 2 1 2 4 1 1 1 1 1 2 1 Description Grip. LH Nut. 1 1 2 1 1 1 2 2 2 1 1 1 1 1 1 1 Description Asm. Sensor Switch Cover. Lock Cable. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0450463 0450693 0450808 0450692 0451090 0450460 0450459 0450279 0450276 0450471 0450461 0452202 0450994 0450309 0450694 0451099 Qty. Clamp. Brake. Ref. LH Asm. Breather Asm. Part No. Lever. RH Cover. Lock Lock. 9 31 30 29 32 12 11 19 13 10 28 27 14 15 22 1 15 16 23 21 24 26 19 20 25 18 17 Part numbers may change after the making of the microfiche or paper copies. Safety Bolt. RH (Incl. LH Hose. Saddle Washer Nut. Throttle Cover. Clamp. Washer Face Bolt. Manual Choke (Incl.. LH Clamp. Hand Wristband Switch. Lever LH (Incl...

1 1 1 1 Description Ref. Spring 6/01 B13 . RH Washer.4. Spacer. 1 3 1 3 Description Hub. Rear Asm.REAR WHEEL AXLE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 6 3 4 5 E 2004 Polaris Sales Inc. LH Axle. Electronic records are the most current. Part No. 1 0450479 2 0450477 3 0450484 0450480 Qty. Ref. 7 2 1 Part numbers may change after the making of the microfiche or paper copies. Sprocket Bolt. Final 4 5 6 7 0450481 0450323 0450478 0450483 Qty. Part No. Hex Tube. 3. Final Drive Sprocket (Incl. Drive.5.7) Sprocket.. Spacer. Tube.

Hex Bolt Link. Drive Chain Nut. Master. Chain Tensioner Bolt Bolt. Ref. Part No. 1 2 3 4 5 6 0450695 0450489 0450856 0451685 0451687 0451686 Qty. 1 1 3 1 1 Description Roller. Chain Guard. Hex Adjuster. 7 8 9 10 11 0451688 0451689 0450325 0450298 0450972 Qty.. Drive Chain 7/03 B14 . Part No.CHAIN PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 E 2004 Polaris Sales Inc. 1 2 1 1 1 1 Description Asm. Electronic records are the most current. 5-7) Ref. Chain Tensioner (Incl. Torsion Asm. Chain/Brake Spring. 11 2 3 4 9 5 6 10 7 9 8 Part numbers may change after the making of the microfiche or paper copies..

Lock Pin. Part No.STEERING PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 18 1 E 2004 Polaris Sales Inc. Bracket. Ball Seal. 17 5 6 4 2 3 4 3 6 16 5 9 8 9 8 9 10 7 11 12 8 9 13 14 9 15 Part numbers may change after the making of the microfiche or paper copies. Oil Circlip Bearing. Lock Knuckle.. Steering Shaft 7/03 C1 . Cotter Nut. Steering Asm. Oil Spacer Nut. Electronic records are the most current. Tie Rod Pin. Lock Pin. RH Nut. Ref. Upper. Steering Shaft Shaft. Cotter Knuckle. Flange Sleeve. 2 1 2 2 2 2 1 4 5 Description Ref. 1 2 3 4 5 6 7 8 9 0450505 0450915 0451690 0450395 0450502 0450507 0450916 0450276 0450719 Qty. Cotter 10 11 12 13 14 15 16 17 18 0450491 0450161 0450493 0450389 0450390 0450878 0450917 0450268 0450499 Qty. 1 1 1 1 1 1 1 2 1 Description Seal. Part No. LH Nut.

RH 7/03 C2 .. Tapping U-Nut Asm. Part No. 4 8 5 6 6 7 7 Part numbers may change after the making of the microfiche or paper copies. LH Screw. Ref. Headlight.. Part No. Taillight Bulb. Flange. Headlight. Plain Asm.. 1 0450880 2 0450041 3 0451691 0450995 4 0451133 Qty. Tapping 5 6 7 8 0451131 0451132 0451134 0451130 Qty.HEADLIGHT / BRAKELIGHT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 2 1 3 2 1 E 2004 Polaris Sales Inc. Taillight Screw. Electronic records are the most current. 2 2 1 1 2 Description Ref. Nut. Hex Washer. 1 2 2 1 Description Asm.

GENERATOR/STARTING MOTOR PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB E 2004 Polaris Sales Inc. Plain Flywheel Bolt. Flange Washer. 1 2 3 13 5 4 9 6 8 7 10 12 11 Part numbers may change after the making of the microfiche or paper copies. Hex Washer.10. 1 2 3 4 5 6 0450529 0450545 0450525 0450033 0450034 0451692 Qty.. Part No. Plain Asm. 1 1 1 2 2 1 Description Ref.8. Socket. Part No.9. Oil Bolt Set Cord Bolt. Nut. Oil Asm. Stator 7/03 C3 . Socket Ring. 7.12) 7 8 9 10 11 12 13 0450535 0450537 0450541 0450857 0450039 0450539 0451692 Qty. 1 1 2 1 2 1 1 Description Brush Set Ring.. Ref. Starting Motor (Incl. Electronic records are the most current.

Main Switch Asm. CDI Unit 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0450563 0450842 0450555 0450888 0451043 0450559 0450721 0450742 0451695 0452186 0450556 0450753 0451018 0451162 Qty. Fixing Jumper Asm. Clip. Reverse Lamp. Spark Plug 7/04 C4 . 29) Washer. Tool Fuse Asm. Pan. Part No. Part numbers may change after the making of the microfiche or paper copies. 1) Bolt. Safety Indicator. Star Cap.... Starter Relay Bolt and Nut. Main Switch (Incl. Part No. Neutral Switch. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 0450886 0450549 0450701 0450554 0450057 0452061 0450558 0452190 0451693 0452189 0451710 0450309 0451020 0451019 0452187 Qty.. Battery Battery Strap Strap Strap Horn Harness. Phillips Regulator. Ignition Coil (Incl. Low Oil Bolt. Electronic records are the most current. Main Wire Bolt. Hex Screw.ELECTRICAL PARTS PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 10 8 13 12 9 16 14 15 7 11 5 3 17 6 18 19 4 20 2 25 1 29 28 27 3 24 26 21 22 23 E 2004 Polaris Sales Inc. 1 1 1 2 1 3 1 1 1 1 2 1 1 1 Description Bag.. Voltage Asm. Washer Face. Hex Asm. 1 1 2 1 2 1 1 1 1 1 1 1 2 1 1 Description Ref. Oil Level Gauge Indicator. Resistor Bolt.. Warning. Hex Asm. Ref.

50th Anniversary Decal. Tank Side. LH Decal. Side. LH (CA) Decal. RH Decal. Red. Front Cab RH (CB) Description Decal. RH Decal. Stripes. Front Cover. Fender. LH (CA) Decal. Tire Pressure 90 Decal. Youth Warning. 1 2 3 4 5 6 7 8 9 10 11 12 13 7170300 7170896 7173013 7170295 7172823 7172824 7172914 7172915 7171150 7171152 0451809 7172677 7173040 7078465 7172829 7172830 7172905 7172906 7172904 7171149 7171151 7172827 7172828 7172910 7172911 Qty. Front Cover. RH (CA) Decal. 14 7172819 7172820 7172909 15 7172821 7172822 7172907 7172908 16 7170286 17 7172566 18 7172825 7172826 19 7172858 7175859 7172912 7172913 20 7172682 21 7170296 22 7172678 23 7172679 24 7079287 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Decal. RH (CB) Decal. Front Cab. General Warning. Reflector. LH (CB) Decal. LH (CB) Decal. RH (CB) Decal. Tank Side. Reflector. Headlight. Headlight. Passenger Warning Decal. RH (CA) Decal. “PREDATOR”. Fender. Clutch Cover Decal. Red (CB) Decal. CPSC Decal. RH (CA) Decal. Electronic records are the most current. LH (CB) Decal. “POLARIS”. Fender. Red. Stripes. Front. Inside. LH Decal. LH (CA) Decal. LH (CA) Decal. Stripes. Side. Rear. Ref. Rear Fender. 15 16 17 18 19 20 21 22 10 9 24 2 23 LH Part numbers may change after the making of the microfiche or paper copies. Stripes. Stripes. LH (CB) Decal. RH (CA) Decal. Front. Fender. 12 (CA) Decal. Fender. Outside. Front. Headlight. LH Decal. Age Warning. Polaris Star Decal. Age Warning. Outside. Amber.DECALS PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 4 2 5 6 3 1 RH 8 12 7 2 14 13 11 E 2004 Polaris Sales Inc. Amber. Fender. 12 (CB) Logo. Fender. Inside. “PREDATOR”. Black Urocal. Tank Side. Youth Carb/Filter Information 7/04 C5 . Rear. Front. LH (CA) Decal. LH Decal. Headlight. Part No. RH (CB) Decal. Qty. Front Cab. Tank Side. Rear. Front. Rear Fender. Fender. RH (CA) Decal. LH (CB) Decal. Rear. StripesRH (CB) Decal. CE Decal. Front Cab. Front. LH (CA) Decal. 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Ref. RH Decal. Youth. RH Decal. Red (CB) Decal. Front Cover. RH (CA) Decal. Front Cover. Front/Rear. RH (CA) Urocal. “PREDATOR”. Part No. Front Cover. LH (CA) Decal.

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

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