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 FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . B4
AXLE, REAR WHEEL . . . . . . . . . . . . . . . . . . B13 FRAME BODY . . . . . . . . . . . . . . . . . . . . . . . B2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . B6

B G
BRAKE, FRONT . . . . . . . . . . . . . . . . . . . . . . B10
BRAKE, REAR . . . . . . . . . . . . . . . . . . . . . . . B11 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . C3
BRAKELIGHT . . . . . . . . . . . . . . . . . . . . . . . . C2
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
H
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . B12
C HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . C2
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A8
B14
O
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . A10 OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . A6
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . A4 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . A3

S
D SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . C5 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
DRIVE PULLEY . . . . . . . . . . . . . . . . . . . . . . A12 STARTING MOTOR . . . . . . . . . . . . . . . . . . . C3
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . A13 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . C1
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . B7
SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . B4

E
ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . C4 T
ENGINE BRACKET . . . . . . . . . . . . . . . . . . . A14 TRANSMISSION LEVER . . . . . . . . . . . . . . . . B1
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . A9

W
F WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . . B8
FAN COVER . . . . . . . . . . . . . . . . . . . . . . . . A5 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.
 CYLINDER HEAD
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc. 7

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, Spark 5 0450007 1 Cylinder
2 0450012 4 Nut, Flange 6 0450009 1 Gasket, Cylinder
3 0452117 1 Head, Cylinder 7 0450011 4 Bolt, Stud
4 0450004 1 Gasket, Cylinder Head
7/04

A3
 CRANKSHAFT
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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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 0450018 1 Seal, Oil 9 0450027 2 Clip, Piston Pin
2 0450016 2 Bearing, Ball, Radial 10 0450802 1 Piston (Std)
3 0450649 1 Crankshaft 0450651 1 Piston (.25 mm O/S)
0450704 1 Piston (.50 mm O/S)
4 0450017 1 Seal, Oil
11 0450877 2 Ring Set, Piston (Std)
5 0450650 1 Collar, Crank, LH 0450025 2 Ring Set, Piston (.25 mm O/S)
6 0450653 1 Washer, Plain 0450705 2 Ring Set, Piston (.50 mm O/S)
7 0450029 1 Bearing, Needle 12 0450015 1 Key, Semicycle
8 0450023 1 Pin, Piston
6/01

A4
 FAN COVER
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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2
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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 0451664 1 Cover, Fan Inlet 10 0451712 1 Cover, Fan
2 0451666 1 Strap 11 0450036 3 Damper, Air Shroud
3 0451665 1 Duct, Cooling Fan 12 0450033 3 Bolt, Socket, Hex
4 0452119 1 Filter, Cooling Fan 13 0450038 1 Deflector
5 0451667 1 Gasket, Fan Inlet 14 0450037 1 Fan
6 0450041 1 Washer, Plain 15 0450031 2 Grommet, Cylinder
7 0450040 1 Screw, Tapping 16 0450030 1 Shroud, Air, Cylinder
8 0450039 2 Bolt, Socket 17 0450035 1 Screw, Tapping
9 0450034 5 Washer
7/04

A5
 OIL PUMP ASSEMBLY
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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4

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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 0450060 2 Circlip, External 10 0450056 2 Clip
2 0450655 1 Washer, Wave 11 0450046 1 Washer
3 0450058 1 Gear, Drive, Oil Pump 12 0450884 1 Bolt, Phillips
4 0450059 1 Pin, Dowel 13 0450061 2 Spring, Protective, Oil Pipe
5 0450052 1 Circlip, External 14 0450053 1 Tube, Oil
6 0450050 1 Gear, Worm, Oil Pump 15 0450057 2 Bolt, Pan, Phillips
7 0450048 1 O-Ring 16 0450846 1 Asm., Oil Pump
8 0450055 1 Tube, Oil (Incl. 5,6,7,8,9,10,11,12,13,14,17)
9 0450054 2 Clip 17 0450051 1 Pin, Shaft
6/01

A6
 AIR CLEANER
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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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 0450066 4 Bolt, Hex, Washer Face 10 0450073 1 Element, Air Cleaner
2 0450065 1 Manifold, Intake 11 0450039 2 Bolt, Socket
3 0450067 1 Clamp, Hose 12 0450034 2 Washer, Plain
4 0450068 1 Clip 13 0450079 2 Grommet
5 0451077 1 Elbow, Air Cleaner 14 0450070 1 Case, Air Cleaner
6 0450071 1 Cover, Air Cleaner 15 0451138 1 Tube, Inlet, Air Cleaner
7 0450076 3 Screw, Tapping 16 0450064 1 Gasket
8 0451080 1 Cleaner, Air (Incl. 5,6,7,9,10,13,14,15) 17 0450063 1 Asm., Reed Valve
9 0451081 1 Seal
9/02

A7
 CARBURETOR
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB
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32 28
26
27
1 2 31

25
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23
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4 21
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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 0450119 1 Nut, Cable Adjust 17 0451669 1 Valve Set, Needle
2 0450082 1 Gasket 18 0451054 1 Seal, Float Chamber
3 0451014 1 Plug, Oil 19 0451668 1 Asm., Carburetor (Incl. All Less 12)
4 0451013 1 Pipe, Oil 20 0450923 1 Nozzle, Choke
5 0450102 1 Screw Set, Air Adjust 21 0451055 1 Valve, Choke
6 0450113 1 Screw Set, Throttle 22 0451057 1 Spring, Choke Return
7 0451024 1 Jet, Pilot 23 0451028 1 O-Ring
8 0452197 1 Nozzle, Needle 24 0451058 1 Base, Manual Choke
9 0450097 1 Jet, Main 25 0451056 1 Bracket, Manual Choke
10 0450976 1 Float, Carb 26 0450106 2 Bolt, Pan, Phillips
11 0450117 1 Pin, Float 27 0451060 1 Support, Cable
12 0451032 1 Cable, Choke 28 0451059 1 Cover, Cable Support
13 0450086 6 Bolt, Pan, Phillips 29 0451051 1 Slide, Carburetor
14 0450098 1 Tube, Overflow 30 0452196 1 Needle Set
15 0450104 1 Plug, Drain 31 0451050 1 Spring, Carb Slide
16 0450108 1 Bolt, Pan, Phillips 32 0450087 2 Washer, Spring
7/04

A8
 EXHAUST PIPE
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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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 0450658 2 Bolt, Pan, Phillips 10 0452122 2 Gasket, Exhaust Bracket
2 0450126 2 Gasket 11 0452123 1 Bolt, Hex
3 0450657 1 Protector, Pipe, Exhaust 12 0451702 1 Washer, Spring
4 0450684 1 Bolt, Hex, Washer Face 13 0450323 1 Bolt, Hex
5 0450279 1 Washer, Plain 14 0450298 1 Bolt, Hex, Washer Face
6 0452121 1 Pipe, Exhaust 15 0450128 1 Plate, Fixed, Exhaust
7 0450282 1 Nut, Hex, Washer Face 16 0450123 2 Bolt, Hex, Washer Face
8 0452198 1 Gasket 17 0450122 1 Gasket
9 0450325 1 Bolt, Hex, Washer Face
7/04

A9
 CRANKCASE
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB
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9
16 18 20
11
21
10 17
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8 22 23
7 24 25 26
3 15
1 13 27
5 6
4 28
2 3 14
29
30
31
33
45 34 32
10
47 39 38
44 35
46 36
43 37

42

41
40
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 0450166 1 Protector A 25 0452139 1 Bearing, Needle
2 0450164 1 Filter 26 0451139 1 Bushing, Rubber
3 0450142 2 Pin, Dowel 27 0452125 1 Breather, Crankcase, Lower
4 0450141 1 Gasket, Crankcase 28 0452124 1 Crankcase, LH
5 0451671 1 Cover, Clutch 29 0452134 1 Ball, Steel
6 0450148 8 Bolt, Hex 30 0452135 1 Spring, Detent
7 0450157 1 Bracket, Oil Seal 31 0452136 1 Washer, Flat
8 0450158 2 Bolt, Hex 32 0452137 1 Bolt, Hex
9 0450159 1 Gasket, Generator 33 0452126 1 Bolt, Hex
10 0450138 8 Bolt 34 0452129 1 O-Ring
11 0450170 1 Plug, Rubber 35 0452128 1 Sensor, Gear Position
12 0450135 1 Crankcase, RH 36 0452138 2 Bolt, Hex, Flange
13 0450137 2 Pin, Dowel 37 0450162 1 Circlip, Internal
14 0452127 1 Breather, Crankcase, Upper 38 0452132 1 Bolt, Hex
15 0450254 2 Bearing, Needle 39 0452133 1 Washer, Flat
16 0452130 1 Shaft, Primary Drive 40 0450167 2 Bolt
17 0450199 1 Bearing 41 0450168 2 Grommet
18 0450298 2 Bolt, Hex 42 0451672 1 Guard, Clutch Cover
19 0450684 1 Bolt, Hex 43 0450150 3 Nut, Hex, Flange
20 0452131 1 Mount, Engine, Rear 44 0450152 1 Protector B
21 0450132 1 Bushing, Rubber 45 0450151 1 Bolt, Hex
22 0450041 1 Washer 46 0450160 1 Bracket, Carburator Tube
23 0450198 1 Circlip, External 47 0450147 1 Shaft, Pin
24 0450200 1 Seal, Oil
7/04
A10
 STARTER
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB
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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 0450183 1 Asm., Kick Shaft 12 0450172 1 Bearing, Needle
2 0450184 1 Spring, Reset, Starter Shaft 13 0450173 1 Boss, Gear
3 0450185 1 Bushing 14 0450174 1 Washer, Plain
4 0450186 1 Washer 15 0450192 1 Washer
5 0450883 1 Bolt, Hex 16 0450178 1 Asm., Idle Gear
6 0450569 1 Asm., Kick Crank 17 0450180 2 Washer
7 0450190 1 Asm., Kick Pinion 18 0450682 1 Pin, Shaft
8 0450191 1 Clip, Spring 19 0450181 1 Plate, Idle Gear
9 0450176 1 Clutch Set, Starter, Electric 20 0450805 2 Bolt, Socket, Hex
10 0450171 1 Wheel, Starter 21 0450193 1 Washer, Wave
11 0450187 1 Circlip, External
6/01

A11
 DRIVE PULLEY
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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25
24 23 9
22 10
21 11
20
19
18 17 16

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2
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26
13
27

26
28 12

29
30 33
35
36
31 32
34

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 0450202 1 Asm., Secondary Sheave 19 0451015 1 Bearing, Needle
(Incl. 2,3,4,5,6,7,8,12,13,15,16) 20 0450200 1 Seal, Oil
2 0450211 2 Seal, Oil 21 0450198 1 Circlip, External
3 0450219 1 Seat, Spring, Secondary 22 0450041 1 Washer
4 0450217 1 Spring, Compression 23 0450158 1 Bolt, Socket, Hex
5 0450206 3 Spring, Weight, Clutch 24 0450199 1 Bearing
6 0450204 1 Carrier, Clutch 25 0450195 1 Asm., Primary Drive
7 0450221 1 Nut 26 0450234 3 Slider
8 0450223 1 Cover, Clutch 27 0450232 1 Plate, Cam
9 0450224 1 Nut, Hex 28 0450229 6 Roller, Weight
10 0450226 1 O-Ring 29 0450228 1 Wheel, Slot, Sliding, Primary
11 0450225 1 Bearing 30 0450236 1 Bushing
12 0450213 2 Ring, Oil 31 0450241 1 Sheave, Fixed, Primary
13 0450210 1 Wheel, Slot, Sliding, Secondary 32 0450243 1 Washer, Claw
14 0450239 1 V-Belt 33 0450245 1 Clutch, One-Way
15 0450208 1 Wheel, Slot, Fixed, Secondary 34 0450247 1 Washer, Spring
16 0450215 2 Pin, Guide 35 0450249 1 Nut, Flange
17 0451016 1 Bearing, Ball 36 0450251 1 Asm., Sliding
18 0451017 1 Circlip (Incl. 26,27,28,29,30,31,32)
7/03
A12
 DRIVE SHAFT
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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29 18 19
28 27 20 21
26 25
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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 0450265 1 Nut, Lock 17 0452152 1 Washer, Flat
2 0452143 1 Sprocket, Drive 18 0450060 1 Circlip, External
3 0450162 1 Circlip, Internal 19 0452151 1 Ratchet, Shift
4 0450261 1 Bearing, Ball 20 0452150 1 Bushing, Spur Gear
5 0452140 1 Cover, Transmission 21 0452149 1 Gear, Spur
6 0450142 2 Pin, Dowel 22 0452148 1 Washer, Flat
7 0450259 1 Seal, Oil 23 0452147 1 Collar, Shaft
8 0452142 1 Gear, Final 24 0452159 1 Asm., Gear Shift Drum
9 0452141 1 Shaft, Final 25 0452157 1 Fork, Shift
10 0450254 1 Bearing, Ball 26 0452163 1 Roller, Drum Sensor
11 0452144 1 Shaft, Counter 27 0452158 1 Shaft, Gear Shift
12 0452146 1 Gear, Counter 28 0452162 1 Spring, Drum Sensor
13 0452156 1 Bearing 29 0452160 1 Spindle, Shift
14 0452155 1 Shaft, Main Transmission 30 0452161 1 E-Clip
15 0452154 1 Bushing, Reverse Gear 31 0450264 1 Washer
16 0452153 1 Gear, Reverse
7/04
A13
 ENGINE BRACKET
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc.

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11

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 0450271 2 Nut, Hex 7 0451151 1 Asm., Engine, 90cc
2 0450286 2 Washer 8 0450684 2 Bolt, Hex, Washer Face
3 0450284 2 Bushing, Rubber, Front 9 0450192 1 Washer
4 0450283 1 Tube, Fixed, Front 10 0450268 1 Nut, Flange, Hex
5 0450132 1 Bushing, Rubber 11 0451107 1 Bolt, Hex
6 0452165 1 Bracket, Oil Tank 12 0451108 1 Collar
7/04

A14
 TRANSMISSION LEVER
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1
E 2004 Polaris Sales Inc.
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2 8
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3 4

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17 15
4 14
16

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 0452169 1 Gasket, Transmission Cover 10 0450309 1 Bolt, Hex
2 0451813 1 Plug, Oil 11 0452170 1 Gate, Shift
3 0450154 1 O-Ring 12 0452171 1 Mount, Shift Lever
4 0452176 8 Bolt, Hex, Flange 13 0450189 1 Bolt, Hex
5 0450701 2 Bolt, Hex, Washer 14 0450192 2 Washer
6 0452175 1 Seal, Oil 15 0452173 1 Spring, Transmission Lever
7 0452167 1 Lever, Transmission 16 0452174 1 Pin, Transmission Lever
8 0452168 1 Knob, Transmission Lever 17 0450719 1 Pin, Cotter
9 0450967 1 Cover, Transmission Lever Knob
7/04

B1
 FRAME BODY
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc.

1 2 3 8
9
4 5
6 5
3
6
3

3
4 10
11
3 12
13 14
15

1 18
15
14
2 17
16
3

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 0450613 8 Grommet 10 0450180 1 Washer
2 0451112 1 Support, Footwell, LH 11 0452178 1 Frame, Main
0451113 1 Support, Footwell, RH 12 0450265 1 Nut, Lock
3 0452030 16 Bolt, Hex, Washer Face 13 0450304 1 Sleeve, Rubber
4 0450299 2 Plate, Engine Bracket 14 0450303 2 Cover, Swing Arm Seal
5 0450800 2 Rubber 15 0450302 2 Seat, Grease Contain
6 0451114 2 Bracket, Rear Cab Support 16 0450305 1 Bolt, Hex
7 0450993 1 Flag 17 0450301 1 Tube, Spacer
8 0450844 1 Washer, Spring 18 0452179 1 Arm, Swing
9 0450845 1 Nut, Hex
7/04

B2
 BUMPER
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

3
E 2004 Polaris Sales Inc.

1 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 0450298 2 Bolt, Hex 3 0451154 1 Bumper, Front, Silver
2 0450309 2 Bolt, Hex, Washer Face 4 0450150 2 Nut, Lock
7/04

B3
 SWING ARM / FOOTREST
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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6
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15
14 8
11 20
10 9
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13 18
12 19 16 15
18 14
17
13
12
11
10

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 0450701 3 Bolt, Hex 11 0450320 2 Valve, Grease
2 0450611 1 Shield, Heat 12 0450317 2 Rubber, Dustproof
3 0450298 2 Bolt, Hex 13 0450314 2 Seat, Grease Contain
4 0451119 1 Bracket, Heat Shield 14 0450313 2 Seat, Grease Contain
5 0451117 1 Footwell, RH 15 0450316 2 Cover, Waterproof
6 0452216 8 Bolt, Hex 16 0451155 1 Arm, Suspension, Silver, LH
7 0451118 1 Footwell, LH 17 0450820 4 Bolt, Hex, Washer Face
8 0450879 8 Washer, Plain 18 0450288 4 Bushing
9 0450808 8 Nut, Lock 19 0450249 4 Nut, Flange
10 0450321 2 Cap, Rubber 20 0451156 1 Arm, Suspension, Silver, RH
7/04

B4
 CAB / SEAT
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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6
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10
4
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12
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13
1 14
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12 16
11
18

19

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 0451132 2 Screw, Tapping 11 0450741 8 Nut, Lock
2 0451124 1 Cover, Front, Black Metallic 12 0450710 8 Washer, Plain
3 0452191-496 1 Cab, Front, Cosmic Sunburst (CA) 13 0450622 8 Bolt, Phillips
0452191-293 1 Cab, Front, Indy Red (CB) 14 0450346 1 Rubber, Battery
4 0451123 1 Panel, Side, LH 15 0450345 1 Pad, Protector
0451122 1 Panel, Side, RH
16 0451125 1 Asm., Seat (CA)
5 0450676 4 Screw, Tapping 0452213 1 Asm., Seat, Dale Jr. (CB)
6 0450340 4 Bolt, Hex 17 0450824 2 Bolt, Hex, Washer Face
7 0451140 1 Strap, Battery 18 0451674 2 Screw, Tapping
8 0451141 1 Strap, Tool Box 19 9919505 1 Manual, Owner’s, ’05 Sportsman 90,
9 0450290 2 Rubber, Seat Predator 50/90
10 0452192-496 1 Cab, Rear, Cosmic Sunburst (CA)
0452192-293 1 Cab, Rear, Indy Red (CB)
7/04
B5
 OIL TANK / FUEL TANK
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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2 3 4
7 8 10
11

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20 15

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15

17
18

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 0450927 1 Asm., Oil Tank 11 0450827 1 Boot, Tank Neck
2 0450903 1 Cap, Oil Tank 12 0450358 1 Tank, Fuel
3 0451035 1 Bolt, Hex 13 0450632 2 Mat, Rubber, Fuel Tank
4 0451126 1 Bracket, Fuel Tank 14 0450361 2 Clip
5 0450041 1 Washer 15 0451110 3 Line, Fuel
6 0450826-035 1 Tube, Oil, Side 16 0450701 1 Bolt, Hex
7 0450363-430 1 Hose 17 0450366 1 Asm., Manual Fuel Cup
8 0450054 7 Clip 18 0451110 1 Hose
9 0451098 1 Cap, Fuel Tank 19 2520462 1 Filter, Fuel
10 0450375 1 Film, Breather 20 0450340 2 Bolt, Hex
7/04

B6
 SUSPENSION
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc. 8

5 6 9
6

4
3
5
2
4 10
1
3

2 11
6

5
6
1

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 0450868 2 Bolt, Hex 7 0450929 1 Retainer, Spring
2 0450714 2 Tube, Inner, Suspension, Front 8 0452181-446 1 Spring, Suspension, Rear (CA)
3 0451675 2 Collar, Adjustment, Spring, Front 0452181-293 1 Spring, Suspension, Rear (CB)
4 0452193-446 2 Spring, Suspension, Front (CA) 9 0450894 1 Collar, Adjustment
0452193-293 2 Spring, Suspension, Front (CB) 10 0451072 1 Shock, Rear
5 0450380 3 Bolt, Hex 11 0451135 1 Bolt, Hex
6 0450249 4 Nut, Flange
7/04

B7
 FRONT WHEEL
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1 3
2

2
14
12 11
13 4

9
10 7
6

E 2004 Polaris Sales Inc. 8

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 0450393 2 Bearing 9 0450398 8 Bolt, Carriage
2 0450389 4 Seal, Oil 10 0450401 2 Valve, Rim
3 0450386 2 Wheel, Rim 11 0450391 2 Spacer, Outer
4 0450394 2 Nut, Lock 12 0450392 2 Bearing
5 0450395 2 Pin, Cotter 13 0451681 2 Drum, Brake, Front, Orange (CA)
6 0450829 2 Cap, Rubber 0451681-293 2 Drum, Brake, Front, Indy Red (CB)
7 0450397 2 Washer 14 0450390 2 Spacer, Inner
8 0450870 2 Tire (19x7-8)
7/04

B8
 REAR WHEEL
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

2
3

9
8
7 6
E 2004 Polaris Sales Inc. 5

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 0452194 2 Hub, Rear Wheel (CA) 5 0450829 2 Cap, Rubber
0451682 2 Hub, Rear, Orange (CB) 6 0450409 2 Nut, Lock
2 0450386 2 Wheel, Rim 7 0450412 2 Washer
3 0451127 2 Tire (18x9.5-8) 8 0450398 8 Bolt, Carriage
4 0450395 2 Pin, Cotter 9 0450401 2 Valve, Rim
7/04

B9
 FRONT BRAKE
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc.

1 1

7
7
8
6
2 3
4
5 3
9 2
5

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 0450985 2 Cable, Front Brake 6 0450913 1 Arm, Front Brake, RH
2 0450422 2 Asm., Shoe, Front Brake 7 0450424 2 Spring, Return, Front
3 0450421 2 Shaft, Cam, Front Brake 8 0450911 1 Arm, Front Brake, LH
4 0450912 1 Plate, Front Brake, RH 9 0450910 1 Plate, Front Brake, LH
5 0450425 2 Bolt, Hex
7/02

B10
 REAR BRAKE
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

19 2
3
4
5
18
17
16 15
14
13 11
12
10
20 6
E 2004 Polaris Sales Inc. 7
9
15 21 8
14
12 7
22 6

28
27
26

23
25 24
25

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 0450438 1 Cable, Rear Brake 15 0450452 2 Bolt, Hex
2 0450268 2 Bolt, Hex 16 0450854 1 Shaft, Fixed, Rear Brake
3 0450435 1 Spring, Cable, Rear Brake 17 0450434 1 Shoe, Rear Brake
4 0450437 1 Thru-Shaft, Rear Brake 18 0450442 1 Rubber, Protective
5 0451079 1 Nut, Adjust, Brake 19 0450441 1 Drum, Rear Brake
6 0450430 2 Seal, Oil 20 0450431 1 Shaft, Cam, Rear Brake
7 0450429 2 Bearing 21 0450440 1 Plate, Rear Brake
8 0450428 1 Tube, Spacer 22 0451683 1 Housing, Rear Axle, Silver
9 0450432 1 Arm, Rear Brake 23 0450751 1 Cover, Rear
10 0450433 1 Bolt, Hex 24 7171069 1 Decal, Drive Chain
11 0450453 1 Spring, Arm, Rear Brake 25 0450340 2 Bolt, Hex
12 0450451 2 Bolt, Hex 26 0450446 1 Reflector, Rear
13 0450881 1 Nut, Lock 27 0451822 1 Washer, Black
14 0450529 2 Nut, Flange 28 0450447 1 Nut, Flange
7/04

B11
 HANDLEBAR
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

6
5

2 3
1 4
7 8
E 2004 Polaris Sales Inc.

9
12
11
31 30
29 13
19 10
1
28
32

27 14
22 15 15
16
23

21
24 20 19
18
25
26 17

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 0451097 2 Grip, Hand 17 0450463 1 Asm., Lever LH (Incl. 18-21)
2 7080891 1 Wristband 18 0450693 1 Lever, Brake, LH
3 0450550 1 Switch, Safety 19 0450808 2 Nut, Lock
4 0450806 1 Bolt, Brake Lever, RH 20 0450692 1 Lock, Park Brake
5 0452195 1 Cover, Handlebar 21 0451090 1 Harness, Sensor Switch
6 0451137 2 Bolt, Philips 22 0450460 1 Cover, Clamp, LH
7 0451129 1 Bracket, Instrument Panel 23 0450459 2 Clamp, Saddle
8 0450701 2 Bolt, Washer Face 24 0450279 2 Washer
9 0450148 4 Bolt, Hex 25 0450276 2 Nut, Lock
10 0451161 1 Handlebar, Silver 26 0450471 1 Cable, Throttle
11 0450807 1 Bolt, Brake Lever, LH 27 0450461 1 Cover, Clamp, RH
12 0452203 1 Hose, Breather 28 0452202 1 Arm, Throttle
13 0451684 1 Asm., Switch, LH 29 0450994 1 Bracket, Brake Cable
14 0451037 1 Asm., Manual Choke (Incl. 15,16) 30 0450309 1 Bolt
15 0451148 2 Bolt 31 0450694 1 Lever, Brake, RH
16 0451149 1 Bolt 32 0451099 1 Asm., Lever, RH (Incl. 28-31)
7/04
B12
 REAR WHEEL AXLE
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

5
4
3

E 2004 Polaris Sales Inc.

7

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 0450479 1 Tube, Spacer, LH 4 0450481 1 Hub, Sprocket
2 0450477 1 Axle, Rear 5 0450323 3 Bolt, Hex
3 0450484 1 Asm., Final Drive Sprocket (Incl. 3,4,5,7) 6 0450478 1 Tube, Spacer, RH
0450480 1 Sprocket, Drive, Final 7 0450483 3 Washer, Spring
6/01

B13
 CHAIN
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc.

1
11

2
3

4 9

5
6

10
7
9

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 0450695 1 Asm., Drive Chain 7 0451688 1 Roller, Chain Tensioner
2 0450489 2 Nut, Hex 8 0451689 1 Bolt
3 0450856 1 Adjuster, Chain 9 0450325 3 Bolt, Hex
4 0451685 1 Guard, Chain/Brake 10 0450298 1 Bolt
5 0451687 1 Spring, Torsion 11 0450972 1 Link, Master, Drive Chain
6 0451686 1 Asm., Chain Tensioner (Incl. 5-7)
7/03

B14
 STEERING
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

18 1
1
E 2004 Polaris Sales Inc.

17
6
5
2 4
3

4
3
16 9
6 5 8
9
9
8
10
7 11
8 12
13
9 14

15 9

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 0450505 2 Bracket, Upper, Steering Shaft 10 0450491 1 Seal, Oil
2 0450915 1 Shaft, Steering 11 0450161 1 Circlip
3 0451690 2 Asm., Tie Rod 12 0450493 1 Bearing, Ball
4 0450395 2 Pin, Cotter 13 0450389 1 Seal, Oil
5 0450502 2 Nut, Lock 14 0450390 1 Spacer
6 0450507 2 Pin, Cotter 15 0450878 1 Nut, Lock
7 0450916 1 Knuckle, LH 16 0450917 1 Knuckle, RH
8 0450276 4 Nut, Lock 17 0450268 2 Nut, Flange
9 0450719 5 Pin, Cotter 18 0450499 1 Sleeve, Steering Shaft
7/03

C1
 HEADLIGHT / BRAKELIGHT
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1 2
3

2
1
E 2004 Polaris Sales Inc.

5
6

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 0450880 2 Nut, Flange, Hex 5 0451131 1 Asm., Headlight, LH
2 0450041 2 Washer, Plain 6 0451132 2 Screw, Tapping
3 0451691 1 Asm., Taillight 7 0451134 2 U-Nut
0450995 1 Bulb, Taillight 8 0451130 1 Asm., Headlight, RH
4 0451133 2 Screw, Tapping
7/03

C2
 GENERATOR/STARTING MOTOR
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

E 2004 Polaris Sales Inc.

1 2
3 13

4 5

9
6

10

12

11

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 0450529 1 Nut, Flange 7 0450535 1 Brush Set
2 0450545 1 Washer, Plain 8 0450537 1 Ring, Oil
3 0450525 1 Flywheel 9 0450541 2 Bolt Set
4 0450033 2 Bolt, Socket, Hex 10 0450857 1 Cord
5 0450034 2 Washer, Plain 11 0450039 2 Bolt, Socket
6 0451692 1 Asm., Starting Motor 12 0450539 1 Ring, Oil
(Incl. 7,8,9,10,12) 13 0451692 1 Asm., Stator
7/03

C3
 ELECTRICAL PARTS
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

8 10
13
9 12
14 16

7 15
11
17

5 6
18

19
3 4
20
2
1 25

29 3
28 24 21
27
26 22
23

E 2004 Polaris Sales Inc.

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 0450886 1 Clip, Main Switch 16 0450563 1 Bag, Tool
2 0450549 1 Asm., Main Switch (Incl. 1) 17 0450842 1 Fuse
3 0450701 2 Bolt, Washer Face, Hex 18 0450555 1 Asm., Starter Relay
4 0450554 1 Asm., Resistor 19 0450888 2 Bolt and Nut, Battery
5 0450057 2 Bolt, Pan, Phillips 20 0451043 1 Battery
6 0452061 1 Regulator, Voltage 21 0450559 3 Strap
7 0450558 1 Asm., Oil Level Gauge 22 0450721 1 Strap
8 0452190 1 Indicator, Neutral 23 0450742 1 Strap
9 0451693 1 Switch, Safety 24 0451695 1 Horn
10 0452189 1 Indicator, Reverse 25 0452186 1 Harness, Main Wire
11 0451710 1 Lamp, Warning, Low Oil 26 0450556 2 Bolt, Hex
12 0450309 1 Bolt, Hex 27 0450753 1 Asm., Ignition Coil (Incl. 29)
13 0451020 2 Screw, Fixing 28 0451018 1 Washer, Star
14 0451019 1 Jumper 29 0451162 1 Cap, Spark Plug
15 0452187 1 Asm., CDI Unit
7/04
C4
 DECALS
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

4 5 6
2 3

8
RH 2
12
13 14
15
7 16 17 18
11 19 20
21
E 2004 Polaris Sales Inc. 22
10
9

23
2 24
LH
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 7170300 1 Decal, Reflector, Red, RH 14 7172819 1 Decal, “PREDATOR”, LH (CA)
2 7170896 3 Decal, “POLARIS”, Front/Rear, Black 7172820 1 Decal, “PREDATOR”, RH (CA)
7172909 2 Urocal, “PREDATOR”, Red (CB)
3 7173013 1 Urocal, 50th Anniversary
15 7172821 1 Decal, Tank Side, LH (CA)
4 7170295 1 Decal, Amber, RH 7172822 1 Decal, Tank Side, RH (CA)
5 7172823 1 Decal, Fender, Front, LH (CA) 7172907 1 Decal, Tank Side, LH (CB)
7172824 1 Decal, Fender, Front, RH (CA) 7172908 1 Decal, Tank Side, RH (CB)
7172914 1 Decal, Fender, Front, Stripes, LH (CB) 16 7170286 1 Decal, Amber, LH
7172915 1 Decal, Fender, Front, StripesRH (CB)
17 7172566 1 Decal, Passenger Warning
6 7171150 1 Decal, Headlight, Front, RH
7171152 1 Decal, Headlight, Side, RH 18 7172825 1 Decal, Rear Fender, Inside, LH (CA)
7172826 1 Decal, Rear Fender, Inside, RH (CA)
7 0451809 1 Decal, Youth, CE
19 7172858 1 Decal, Fender, Rear, Outside, LH (CA)
8 7172677 1 Decal, Age Warning, 12 (CA) 7175859 1 Decal, Fender, Rear, Outside, RH (CA)
7173040 1 Decal, Age Warning, 12 (CB) 7172912 1 Decal, Fender, Rear, Stripes, LH (CB)
9 7078465 1 Logo, Polaris Star 7172913 1 Decal, Fender, Rear, Stripes, RH (CB)
10 7172829 1 Decal, Front Cover, LH (CA) 20 7172682 1 Decal, Tire Pressure 90
7172830 1 Decal, Front Cover, RH (CA) 21 7170296 1 Decal, Reflector, Red, LH
7172905 1 Decal, Front Cover, Stripes, LH (CB)
7172906 1 Decal, Front Cover, Stripes, RH (CB) 22 7172678 1 Decal, General Warning, CPSC
11 7172904 1 Decal, Front Cover, Red (CB) 23 7172679 1 Decal, Youth Warning, Clutch Cover
12 7171149 1 Decal, Headlight, Front, LH 24 7079287 1 Decal, Youth Carb/Filter Information
7171151 1 Decal, Headlight, Side, LH
13 7172827 1 Decal, Front Cab, LH (CA)
7172828 1 Decal, Front Cab, RH (CA)
7172910 1 Decal, Front Cab, LH (CB)
7172911 1 Decal, Front Cab RH (CB)
7/04
C5
This page left blank intentionally.
PRINTED IN THE USA PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04