2005 Polaris Predator 90 Parts Manual – PDF DOWNLOAD

PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

PREDATOR 90 Model #A05KA09CA Model #A05KA09CB

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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.

CYLINDER HEAD PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

7 6 5 4 3 2

1

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

Ref. Part No.

1 2 3 4

0450005 0450012 0452117 0450004

Qty.

1 4 1 1

Description

Ref. Part No.

Plug, Spark Nut, Flange Head, Cylinder Gasket, Cylinder Head

5 0450007 6 0450009 7 0450011

Qty.

Description

1 Cylinder 1 Gasket, Cylinder 4 Bolt, Stud 7/04

A3

CRANKSHAFT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1

2

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8

0450018 0450016 0450649 0450017 0450650 0450653 0450029 0450023

Qty.

1 2 1 1 1 1 1 1

Description

Ref. Part No.

Qty.

Seal, Oil Bearing, Ball, Radial Crankshaft Seal, Oil Collar, Crank, LH Washer, Plain Bearing, Needle Pin, Piston

9 0450027 10 0450802 0450651 0450704 11 0450877 0450025 0450705 12 0450015

2 1 1 1 2 2 2 1

Description

Clip, Piston Pin Piston (Std) Piston (.25 mm O/S) Piston (.50 mm O/S) Ring Set, Piston (Std) Ring Set, Piston (.25 mm O/S) Ring Set, Piston (.50 mm O/S) Key, Semicycle 6/01

A4

FAN COVER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 4

3 2

1

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

0451664 0451666 0451665 0452119 0451667 0450041 0450040 0450039 0450034

Qty.

1 1 1 1 1 1 1 2 5

Description

Ref. Part No.

Cover, Fan Inlet Strap Duct, Cooling Fan Filter, Cooling Fan Gasket, Fan Inlet Washer, Plain Screw, Tapping Bolt, Socket Washer

10 11 12 13 14 15 16 17

0451712 0450036 0450033 0450038 0450037 0450031 0450030 0450035

Qty.

1 3 3 1 1 2 1 1

Description

Cover, Fan Damper, Air Shroud Bolt, Socket, Hex Deflector Fan Grommet, Cylinder Shroud, Air, Cylinder Screw, Tapping 7/04

A5

OIL PUMP ASSEMBLY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2

3 1 4

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

0450060 0450655 0450058 0450059 0450052 0450050 0450048 0450055 0450054

Qty.

2 1 1 1 1 1 1 1 2

Description

Ref. Part No.

Circlip, External Washer, Wave Gear, Drive, Oil Pump Pin, Dowel Circlip, External Gear, Worm, Oil Pump O-Ring Tube, Oil Clip

10 11 12 13 14 15 16

0450056 0450046 0450884 0450061 0450053 0450057 0450846

17 0450051

Qty.

Description

2 1 1 2 1 2 1

Clip Washer Bolt, Phillips Spring, Protective, Oil Pipe Tube, Oil Bolt, Pan, Phillips Asm., Oil Pump (Incl. 5,6,7,8,9,10,11,12,13,14,17) 1 Pin, Shaft 6/01

A6

AIR CLEANER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 2 3

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

0450066 0450065 0450067 0450068 0451077 0450071 0450076 0451080 0451081

Qty.

4 1 1 1 1 1 3 1 1

Description

Ref. Part No.

Bolt, Hex, Washer Face Manifold, Intake Clamp, Hose Clip Elbow, Air Cleaner Cover, Air Cleaner Screw, Tapping Cleaner, Air (Incl. 5,6,7,9,10,13,14,15) Seal

10 11 12 13 14 15 16 17

0450073 0450039 0450034 0450079 0450070 0451138 0450064 0450063

Qty.

1 2 2 2 1 1 1 1

Description

Element, Air Cleaner Bolt, Socket Washer, Plain Grommet Case, Air Cleaner Tube, Inlet, Air Cleaner Gasket Asm., Reed Valve 9/02

A7

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

8 17

9 10 11

16

12

15 13

14

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

Ref. Part No.

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.

1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1

Description

Ref. Part No.

Nut, Cable Adjust Gasket Plug, Oil Pipe, Oil Screw Set, Air Adjust Screw Set, Throttle Jet, Pilot Nozzle, Needle Jet, Main Float, Carb Pin, Float Cable, Choke Bolt, Pan, Phillips Tube, Overflow Plug, Drain Bolt, Pan, 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.

1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2

Description

Valve Set, Needle Seal, Float Chamber Asm., Carburetor (Incl. All Less 12) Nozzle, Choke Valve, Choke Spring, Choke Return O-Ring Base, Manual Choke Bracket, Manual Choke Bolt, Pan, Phillips Support, Cable Cover, Cable Support Slide, Carburetor Needle Set Spring, Carb Slide Washer, Spring 7/04

A8

EXHAUST PIPE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 1

2

2 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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

0450658 0450126 0450657 0450684 0450279 0452121 0450282 0452198 0450325

Qty.

2 2 1 1 1 1 1 1 1

Description

Ref. Part No.

Bolt, Pan, Phillips Gasket Protector, Pipe, Exhaust Bolt, Hex, Washer Face Washer, Plain Pipe, Exhaust Nut, Hex, Washer Face Gasket Bolt, Hex, Washer Face

10 11 12 13 14 15 16 17

0452122 0452123 0451702 0450323 0450298 0450128 0450123 0450122

Qty.

2 1 1 1 1 1 2 1

Description

Gasket, Exhaust Bracket Bolt, Hex Washer, Spring Bolt, Hex Bolt, Hex, Washer Face Plate, Fixed, Exhaust Bolt, Hex, Washer Face Gasket 7/04

A9

CRANKCASE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 19

9

16

11

10

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.

Ref. Part No.

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.

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, Dowel Gasket, Crankcase Cover, Clutch Bolt, Hex Bracket, Oil Seal Bolt, Hex Gasket, Generator Bolt Plug, Rubber Crankcase, RH Pin, Dowel Breather, Crankcase, Upper Bearing, Needle Shaft, Primary Drive Bearing Bolt, Hex Bolt, Hex Mount, Engine, Rear Bushing, Rubber Washer Circlip, External Seal, Oil

Ref. Part No.

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.

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, Needle Bushing, Rubber Breather, Crankcase, Lower Crankcase, LH Ball, Steel Spring, Detent Washer, Flat Bolt, Hex Bolt, Hex O-Ring Sensor, Gear Position Bolt, Hex, Flange Circlip, Internal Bolt, Hex Washer, Flat Bolt Grommet Guard, Clutch Cover Nut, Hex, Flange Protector B Bolt, Hex Bracket, Carburator Tube Shaft, Pin 7/04

STARTER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1 6

2 3

5

4

14 11

13 12

10

9 8 7 15

16 17 18 19 20

21

20

17

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

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11

0450183 0450184 0450185 0450186 0450883 0450569 0450190 0450191 0450176 0450171 0450187

Qty.

1 1 1 1 1 1 1 1 1 1 1

Description

Asm., Kick Shaft Spring, Reset, Starter Shaft Bushing Washer Bolt, Hex Asm., Kick Crank Asm., Kick Pinion Clip, Spring Clutch Set, Starter, Electric Wheel, Starter Circlip, External

Ref. Part No.

12 13 14 15 16 17 18 19 20 21

0450172 0450173 0450174 0450192 0450178 0450180 0450682 0450181 0450805 0450193

Qty.

1 1 1 1 1 2 1 1 2 1

Description

Bearing, Needle Boss, Gear Washer, Plain Washer Asm., Idle Gear Washer Pin, Shaft Plate, Idle Gear Bolt, Socket, Hex Washer, Wave 6/01

A11

DRIVE PULLEY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 2

1

3 4

5 6 7

25 24 23

8 9

22

10 21

20

11

19

16 18 17 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. Electronic records are the most current.

Ref. Part No.

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.

Description

1 Asm., Secondary Sheave (Incl. 2,3,4,5,6,7,8,12,13,15,16) 2 Seal, Oil 1 Seat, Spring, Secondary 1 Spring, Compression 3 Spring, Weight, Clutch 1 Carrier, Clutch 1 Nut 1 Cover, Clutch 1 Nut, Hex 1 O-Ring 1 Bearing 2 Ring, Oil 1 Wheel, Slot, Sliding, Secondary 1 V-Belt 1 Wheel, Slot, Fixed, Secondary 2 Pin, Guide 1 Bearing, Ball 1 Circlip

Ref. Part No.

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.

1 1 1 1 1 1 1 3 1 6 1 1 1 1 1 1 1 1

Description

Bearing, Needle Seal, Oil Circlip, External Washer Bolt, Socket, Hex Bearing Asm., Primary Drive Slider Plate, Cam Roller, Weight Wheel, Slot, Sliding, Primary Bushing Sheave, Fixed, Primary Washer, Claw Clutch, One-Way Washer, Spring Nut, Flange Asm., Sliding (Incl. 26,27,28,29,30,31,32) 7/03

A12

DRIVE SHAFT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1

2 3 4

31

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. Electronic records are the most current.

Ref. Part No.

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.

1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1

Description

Nut, Lock Sprocket, Drive Circlip, Internal Bearing, Ball Cover, Transmission Pin, Dowel Seal, Oil Gear, Final Shaft, Final Bearing, Ball Shaft, Counter Gear, Counter Bearing Shaft, Main Transmission Bushing, Reverse Gear Gear, Reverse

Ref. Part No.

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.

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description

Washer, Flat Circlip, External Ratchet, Shift Bushing, Spur Gear Gear, Spur Washer, Flat Collar, Shaft Asm., Gear Shift Drum Fork, Shift Roller, Drum Sensor Shaft, Gear Shift Spring, Drum Sensor Spindle, Shift E-Clip Washer 7/04

A13

ENGINE BRACKET PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6

0450271 0450286 0450284 0450283 0450132 0452165

Qty.

2 2 2 1 1 1

Description

Nut, Hex Washer Bushing, Rubber, Front Tube, Fixed, Front Bushing, Rubber Bracket, Oil Tank

Ref. Part No.

7 8 9 10 11 12

0451151 0450684 0450192 0450268 0451107 0451108

Qty.

1 2 1 1 1 1

Description

Asm., Engine, 90cc Bolt, Hex, Washer Face Washer Nut, Flange, Hex Bolt, Hex Collar 7/04

A14

TRANSMISSION LEVER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1 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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

0452169 0451813 0450154 0452176 0450701 0452175 0452167 0452168 0450967

Qty. Description

1 1 1 8 2 1 1 1 1

Ref. Part No.

Gasket, Transmission Cover Plug, Oil O-Ring Bolt, Hex, Flange Bolt, Hex, Washer Seal, Oil Lever, Transmission Knob, Transmission Lever Cover, Transmission Lever Knob

10 11 12 13 14 15 16 17

0450309 0452170 0452171 0450189 0450192 0452173 0452174 0450719

Qty. Description

1 1 1 1 2 1 1 1

Bolt, Hex Gate, Shift Mount, Shift Lever Bolt, Hex Washer Spring, Transmission Lever Pin, Transmission Lever Pin, Cotter 7/04

B1

FRAME BODY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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. Electronic records are the most current.

Ref. Part No.

1 0450613 2 0451112 0451113 3 0452030 4 0450299 5 0450800 6 0451114 7 0450993 8 0450844 9 0450845

Qty.

8 1 1 16 2 2 2 1 1 1

Description

Ref. Part No.

Grommet Support, Footwell, LH Support, Footwell, RH Bolt, Hex, Washer Face Plate, Engine Bracket Rubber Bracket, Rear Cab Support Flag Washer, Spring Nut, Hex

10 11 12 13 14 15 16 17 18

0450180 0452178 0450265 0450304 0450303 0450302 0450305 0450301 0452179

Qty.

1 1 1 1 2 2 1 1 1

Description

Washer Frame, Main Nut, Lock Sleeve, Rubber Cover, Swing Arm Seal Seat, Grease Contain Bolt, Hex Tube, Spacer Arm, Swing 7/04

B2

BUMPER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

3 2 4

2

1

1

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

Ref. Part No.

1 0450298 2 0450309

Qty.

Description

Ref. Part No.

2 Bolt, Hex 2 Bolt, Hex, Washer Face

3 0451154 4 0450150

Qty.

Description

1 Bumper, Front, Silver 2 Nut, Lock 7/04

B3

SWING ARM / FOOTREST PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 1

2 3

4 5

6 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. Electronic records are the most current.

Ref. Part No.

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. Part No.

Bolt, Hex Shield, Heat Bolt, Hex Bracket, Heat Shield Footwell, RH Bolt, Hex Footwell, LH Washer, Plain Nut, Lock Cap, 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 Rubber, Dustproof Seat, Grease Contain Seat, Grease Contain Cover, Waterproof Arm, Suspension, Silver, LH Bolt, Hex, Washer Face Bushing Nut, Flange Arm, Suspension, Silver, RH 7/04

B4

CAB / SEAT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

8

7 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. Electronic records are the most current.

Ref. Part No.

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.

2 1 1 1 1 1 4 4 1 1 2 1 1

Description

Ref. Part No.

Screw, Tapping Cover, Front, Black Metallic Cab, Front, Cosmic Sunburst (CA) Cab, Front, Indy Red (CB) Panel, Side, LH Panel, Side, RH Screw, Tapping Bolt, Hex Strap, Battery Strap, Tool Box Rubber, Seat Cab, Rear, Cosmic Sunburst (CA) Cab, Rear, Indy Red (CB)

11 12 13 14 15 16

0450741 0450710 0450622 0450346 0450345 0451125 0452213 17 0450824 18 0451674 19 9919505

Qty.

8 8 8 1 1 1 1 2 2 1

Description

Nut, Lock Washer, Plain Bolt, Phillips Rubber, Battery Pad, Protector Asm., Seat (CA) Asm., Seat, Dale Jr. (CB) Bolt, Hex, Washer Face Screw, Tapping Manual, Owner’s, ’05 Sportsman 90, Predator 50/90 7/04

B5

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 17

18

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

Ref. Part No.

1 2 3 4 5 6 7 8 9 10

0450927 0450903 0451035 0451126 0450041 0450826-035 0450363-430 0450054 0451098 0450375

Qty.

1 1 1 1 1 1 1 7 1 1

Description

Ref. Part No.

Asm., Oil Tank Cap, Oil Tank Bolt, Hex Bracket, Fuel Tank Washer Tube, Oil, Side Hose Clip Cap, Fuel Tank Film, Breather

11 12 13 14 15 16 17 18 19 20

0450827 0450358 0450632 0450361 0451110 0450701 0450366 0451110 2520462 0450340

Qty.

1 1 2 2 3 1 1 1 1 2

Description

Boot, Tank Neck Tank, Fuel Mat, Rubber, Fuel Tank Clip Line, Fuel Bolt, Hex Asm., Manual Fuel Cup Hose Filter, Fuel Bolt, Hex 7/04

B6

SUSPENSION PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

7

8

9

6

5

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4

0450868 0450714 0451675 0452193-446 0452193-293 5 0450380 6 0450249

Qty.

2 2 2 2 2 3 4

Description

Ref. Part No.

Bolt, Hex Tube, Inner, Suspension, Front Collar, Adjustment, Spring, Front Spring, Suspension, Front (CA) Spring, Suspension, Front (CB) Bolt, Hex Nut, Flange

7 0450929 8 0452181-446 0452181-293 9 0450894 10 0451072 11 0451135

Qty.

1 1 1 1 1 1

Description

Retainer, Spring Spring, Suspension, Rear (CA) Spring, Suspension, Rear (CB) Collar, Adjustment Shock, Rear Bolt, Hex 7/04

B7

FRONT WHEEL PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1

3 2

2

14 13

12

11

4 5 9 7

10

6

8

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

Ref. Part No.

1 2 3 4 5 6 7 8

0450393 0450389 0450386 0450394 0450395 0450829 0450397 0450870

Qty.

2 4 2 2 2 2 2 2

Description

Ref. Part No.

Bearing Seal, Oil Wheel, Rim Nut, Lock Pin, Cotter Cap, Rubber Washer Tire (19x7-8)

9 10 11 12 13

0450398 0450401 0450391 0450392 0451681 0451681-293 14 0450390

Qty.

8 2 2 2 2 2 2

Description

Bolt, Carriage Valve, Rim Spacer, Outer Bearing Drum, Brake, Front, Orange (CA) Drum, Brake, Front, Indy Red (CB) Spacer, Inner 7/04

B8

REAR WHEEL PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1 2

3

4 9

8 7

6

5

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

Ref. Part No.

1 0452194 0451682 2 0450386 3 0451127 4 0450395

Qty.

2 2 2 2 2

Description

Ref. Part No.

Hub, Rear Wheel (CA) Hub, Rear, Orange (CB) Wheel, Rim Tire (18x9.5-8) Pin, Cotter

5 6 7 8 9

0450829 0450409 0450412 0450398 0450401

Qty.

2 2 2 8 2

Description

Cap, Rubber Nut, Lock Washer Bolt, Carriage Valve, Rim 7/04

B9

FRONT BRAKE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5

0450985 0450422 0450421 0450912 0450425

Qty.

2 2 2 1 2

Description

Ref. Part No.

Cable, Front Brake Asm., Shoe, Front Brake Shaft, Cam, Front Brake Plate, Front Brake, RH Bolt, Hex

6 7 8 9

0450913 0450424 0450911 0450910

Qty.

1 2 1 1

Description

Arm, Front Brake, RH Spring, Return, Front Arm, Front Brake, LH Plate, Front Brake, LH 7/02

B10

REAR BRAKE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1

19

2

3

4

5

18 17

16

15 14 13 12

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. Electronic records are the most current.

Ref. Part No.

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.

1 2 1 1 1 2 2 1 1 1 1 2 1 2

Description

Cable, Rear Brake Bolt, Hex Spring, Cable, Rear Brake Thru-Shaft, Rear Brake Nut, Adjust, Brake Seal, Oil Bearing Tube, Spacer Arm, Rear Brake Bolt, Hex Spring, Arm, Rear Brake Bolt, Hex Nut, Lock Nut, Flange

Ref. Part No.

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.

2 1 1 1 1 1 1 1 1 1 2 1 1 1

Description

Bolt, Hex Shaft, Fixed, Rear Brake Shoe, Rear Brake Rubber, Protective Drum, Rear Brake Shaft, Cam, Rear Brake Plate, Rear Brake Housing, Rear Axle, Silver Cover, Rear Decal, Drive Chain Bolt, Hex Reflector, Rear Washer, Black Nut, Flange 7/04

B11

HANDLEBAR PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 6 5 2 1

4

3 7

8 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. Electronic records are the most current.

Ref. Part No.

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.

2 1 1 1 1 2 1 2 4 1 1 1 1 1 2 1

Description

Grip, Hand Wristband Switch, Safety Bolt, Brake Lever, RH Cover, Handlebar Bolt, Philips Bracket, Instrument Panel Bolt, Washer Face Bolt, Hex Handlebar, Silver Bolt, Brake Lever, LH Hose, Breather Asm., Switch, LH Asm., Manual Choke (Incl. 15,16) Bolt Bolt

Ref. Part No.

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.

1 1 2 1 1 1 2 2 2 1 1 1 1 1 1 1

Description

Asm., Lever LH (Incl. 18-21) Lever, Brake, LH Nut, Lock Lock, Park Brake Harness, Sensor Switch Cover, Clamp, LH Clamp, Saddle Washer Nut, Lock Cable, Throttle Cover, Clamp, RH Arm, Throttle Bracket, Brake Cable Bolt Lever, Brake, RH Asm., Lever, RH (Incl. 28-31) 7/04

B12

REAR WHEEL AXLE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

6

3

4

5

7

2

1

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

Ref. Part No.

1 0450479 2 0450477 3 0450484 0450480

Qty.

1 1 1 1

Description

Ref. Part No.

Tube, Spacer, LH Axle, Rear Asm., Final Drive Sprocket (Incl. 3,4,5,7) Sprocket, Drive, Final

4 5 6 7

0450481 0450323 0450478 0450483

Qty.

1 3 1 3

Description

Hub, Sprocket Bolt, Hex Tube, Spacer, RH Washer, Spring 6/01

B13

CHAIN PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1 11

2 3 4

9

5 6 10 7

9 8

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

Ref. Part No.

1 2 3 4 5 6

0450695 0450489 0450856 0451685 0451687 0451686

Qty.

1 2 1 1 1 1

Description

Asm., Drive Chain Nut, Hex Adjuster, Chain Guard, Chain/Brake Spring, Torsion Asm., Chain Tensioner (Incl. 5-7)

Ref. Part No.

7 8 9 10 11

0451688 0451689 0450325 0450298 0450972

Qty.

1 1 3 1 1

Description

Roller, Chain Tensioner Bolt Bolt, Hex Bolt Link, Master, Drive Chain 7/03

B14

STEERING PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

1

18

1

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9

0450505 0450915 0451690 0450395 0450502 0450507 0450916 0450276 0450719

Qty.

2 1 2 2 2 2 1 4 5

Description

Ref. Part No.

Bracket, Upper, Steering Shaft Shaft, Steering Asm., Tie Rod Pin, Cotter Nut, Lock Pin, Cotter Knuckle, LH Nut, Lock Pin, 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, Oil Circlip Bearing, Ball Seal, Oil Spacer Nut, Lock Knuckle, RH Nut, Flange Sleeve, Steering Shaft 7/03

C1

HEADLIGHT / BRAKELIGHT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

2

1

3

2

1

4 8

5

6 6 7 7

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

Ref. Part No.

1 0450880 2 0450041 3 0451691 0450995 4 0451133

Qty.

2 2 1 1 2

Description

Ref. Part No.

Nut, Flange, Hex Washer, Plain Asm., Taillight Bulb, Taillight Screw, Tapping

5 6 7 8

0451131 0451132 0451134 0451130

Qty.

1 2 2 1

Description

Asm., Headlight, LH Screw, Tapping U-Nut Asm., Headlight, RH 7/03

C2

GENERATOR/STARTING MOTOR PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB

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. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6

0450529 0450545 0450525 0450033 0450034 0451692

Qty.

1 1 1 2 2 1

Description

Ref. Part No.

Nut, Flange Washer, Plain Flywheel Bolt, Socket, Hex Washer, Plain Asm., Starting Motor (Incl. 7,8,9,10,12)

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, Oil Bolt Set Cord Bolt, Socket Ring, Oil Asm., Stator 7/03

C3

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

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

Ref. Part No.

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.

1 1 2 1 2 1 1 1 1 1 1 1 2 1 1

Description

Ref. Part No.

Clip, Main Switch Asm., Main Switch (Incl. 1) Bolt, Washer Face, Hex Asm., Resistor Bolt, Pan, Phillips Regulator, Voltage Asm., Oil Level Gauge Indicator, Neutral Switch, Safety Indicator, Reverse Lamp, Warning, Low Oil Bolt, Hex Screw, Fixing Jumper 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.

1 1 1 2 1 3 1 1 1 1 2 1 1 1

Description

Bag, Tool Fuse Asm., Starter Relay Bolt and Nut, Battery Battery Strap Strap Strap Horn Harness, Main Wire Bolt, Hex Asm., Ignition Coil (Incl. 29) Washer, Star Cap, Spark Plug 7/04

C4

DECALS PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 4 2

5

6

3

1

RH

8

12 7

2

14

13

11

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. Electronic records are the most current.

Ref. Part No.

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.

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. Part No.

Qty.

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, Reflector, Red, RH Decal, “POLARIS”, Front/Rear, Black Urocal, 50th Anniversary Decal, Amber, RH Decal, Fender, Front, LH (CA) Decal, Fender, Front, RH (CA) Decal, Fender, Front, Stripes, LH (CB) Decal, Fender, Front, StripesRH (CB) Decal, Headlight, Front, RH Decal, Headlight, Side, RH Decal, Youth, CE Decal, Age Warning, 12 (CA) Decal, Age Warning, 12 (CB) Logo, Polaris Star Decal, Front Cover, LH (CA) Decal, Front Cover, RH (CA) Decal, Front Cover, Stripes, LH (CB) Decal, Front Cover, Stripes, RH (CB) Decal, Front Cover, Red (CB) Decal, Headlight, Front, LH Decal, Headlight, Side, LH Decal, Front Cab, LH (CA) Decal, Front Cab, RH (CA) Decal, Front Cab, LH (CB) Decal, Front Cab RH (CB)

Description

Decal, “PREDATOR”, LH (CA) Decal, “PREDATOR”, RH (CA) Urocal, “PREDATOR”, Red (CB) Decal, Tank Side, LH (CA) Decal, Tank Side, RH (CA) Decal, Tank Side, LH (CB) Decal, Tank Side, RH (CB) Decal, Amber, LH Decal, Passenger Warning Decal, Rear Fender, Inside, LH (CA) Decal, Rear Fender, Inside, RH (CA) Decal, Fender, Rear, Outside, LH (CA) Decal, Fender, Rear, Outside, RH (CA) Decal, Fender, Rear, Stripes, LH (CB) Decal, Fender, Rear, Stripes, RH (CB) Decal, Tire Pressure 90 Decal, Reflector, Red, LH Decal, General Warning, CPSC Decal, Youth Warning, Clutch Cover Decal, Youth Carb/Filter Information

7/04

C5

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PRINTED IN THE USA

PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04