Polaris Predator Parts Manual

PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04
PREDATOR 90
Model #A05KA09CA
Model #A05KA09CB
E 2004 Polaris Sales Inc.
This page left blank intentionally.
TABLE OF CONTENTS
PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB
Parts Manual
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 . . . . . . . . . . . . . . . . . . . . .
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

6
5
4
3
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
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
2
3
12
9
2
11
8
10
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
4
3
2

5
13
10
11
12
17
9
14
15
16
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

1
2
3
1
4
10
8
12
13
9
10
17
11
16
14
13
15
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
1
2
3
17
16
15
14
13
12
11
10
6
7
8
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
13
32
2
28
26
27
31
25
30
24
23
22
21
29
3
4
5
20
19
18
7
17
9
10
11
16
12
15
13
14
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
1
1
17
9
10
11
15
12
16
13
14
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
Washer, Plain
Pipe, Exhaust
Nut, Hex, Washer Face
Gasket
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
Plate, Fixed, Exhaust
Gasket
7/04
A9
CRANKCASE
19
9
10
16
11
18
17
12
8
7
1
2
15
13
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
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
1
6
2
3
14
11
13
12
10
9
8
7

15
16
17
18
19
20
21
20
17
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
3
4
5
6
7
25
24 23
8
9
22
10
21
20
11
19
18 17 16
15
14
26
13
27
26
12
28
29
33
30
35
36
31
32
34
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
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
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
1
2
3
4
3
6
7
8
9
10
12
11
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

Washer
Nut, Flange, Hex
Bolt, Hex
Collar
7/04
A14
TRANSMISSION LEVER
2
3
8
10
4
5
11
5
12
14
4
17
16
14
13
15
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

7
1
8
9
3
3
4
11
12
10
13 14
15
18
15
14
17
16
3
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
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
2
4
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

1
2
3
4
5
15
10
14
11
20
17
18
13
19
12
16
15
14
18
17
10
11
13
12
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
Cover, Waterproof
Arm, Suspension, Silver, LH
Bushing
Nut, Flange
Arm, Suspension, Silver, RH
7/04
B4
CAB / SEAT
7
6
10
12
2
13
1
17
13
11
18
12
11
14
15
16
19
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)
Screw, Tapping
Manual, Owners, 05 Sportsman 90,
Predator 50/90
7/04
B5
OIL TANK / FUEL TANK

5
3
10
8
11
12
1
13
20
14
15
20
14
8
15
8
15
19
16
17
18
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
7
4
3
10
3
11
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
3
2
14
13
12
11
4
5
9
7
10
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
1
2
4
9
8
7
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

1
7
8
6
4
5
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
19
18
17
16
15
14
13
12
20
11
10
15
9
8
21
14
12
22
28
27
26
25
24
23
25
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
6
5
2
1
3
7
9
31 30
29
32
12
11
19
13
10
28
27
14
15
22
15
16
23
21
24
26
19
20
25
18
17
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


7
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

11
2
3
4
5
6
10
7
9
8
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
18

17
5
6
4
4
3
6
16
9
8
9
8
10
11
12
8
9
13
14
9
15
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

4
6
6
7
7
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
1 2
3
13
5
6
8
7
10
12
11
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
10
13
12
16
14
15
11
17
18
19
20
2
25
1
29
28
27
24
26
21
22
23
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
4
2
RH
12
7
14
13
11
15
16 17 18
19
20
21
22
10
9
24
23
LH
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
This page left blank intentionally.
PRINTED IN THE USA
PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

Polaris Predator Parts Manual

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Polaris Predator Parts Manual

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PARTS MANUAL PN 9919525 and MICROFICHE PN 9919526 7/04

E 2004 Polaris Sales Inc.

This page left blank intentionally.

E 2004 Polaris Sales Inc.

Ref. Part No.

Ref. Part No.

Clip, Piston Pin

E 2004 Polaris Sales Inc.

Ref. Part No.

Cover, Fan Inlet

OIL PUMP ASSEMBLY

E 2004 Polaris Sales Inc.

Ref. Part No.

Ref. Part No.

Bolt, Hex, Washer Face

Element, Air Cleaner

E 2004 Polaris Sales Inc.

Ref. Part No.

Nut, Cable Adjust

Valve Set, Needle

E 2004 Polaris Sales Inc.

Ref. Part No.

Bolt, Pan, Phillips

Gasket, Exhaust Bracket

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Asm., Kick Shaft

Ref. Part No.

1 Asm., Secondary Sheave

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

Ref. Part No.

Asm., Engine, 90cc

E 2004 Polaris Sales Inc.

Ref. Part No.

Gasket, Transmission Cover

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

1 Bumper, Front, Silver

SWING ARM / FOOTREST

E 2004 Polaris Sales Inc.

Ref. Part No.

Ref. Part No.

OIL TANK / FUEL TANK

E 2004 Polaris Sales Inc.

Ref. Part No.

Asm., Oil Tank

Boot, Tank Neck

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

E 2004 Polaris Sales Inc.

Ref. Part No.

Hub, Rear Wheel (CA)

E 2004 Polaris Sales Inc.

Ref. Part No.

Cable, Front Brake

Arm, Front Brake, RH

E 2004 Polaris Sales Inc.

Cable, Rear Brake