2005 Polaris Predator 90 Parts Manual

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 AIR CLEANER A7 ....................... AXLE, REAR WHEEL B13 .................. B BRAKE, FRONT B10 ...................... BRAKE, REAR B11 ....................... BRAKELIGHT C2 ........................ BUMPER B3 ........................... C CAB B5 ............................... CARBURETOR A8 ....................... CHAIN B14 ............................. CRANKCASE A10 ........................ CRANKSHAFT A4 ....................... CYLINDER HEAD A3 ..................... D DECALS C5 ........................... DRIVE PULLEY A12 ...................... DRIVE SHAFT A13 ....................... E ELECTRICAL PARTS C4 .................. ENGINE BRACKET A14 ................... EXHAUST PIPE A9 ...................... F FAN COVER A5 ........................ F FOOTREST B4 ......................... FRAME BODY B2 ....................... FUEL TANK B6 ......................... G GENERATOR C3 ........................ H HANDLEBAR B12 ........................ HEADLIGHT C2 ......................... O OIL PUMP ASSEMBLY A6 ................. OIL TANK B6 ........................... S SEAT B5 .............................. STARTER A11 ........................... STARTING MOTOR C3 ................... STEERING C1 .......................... SUSPENSION B7 ....................... SWING ARM B4 ........................ T TRANSMISSION LEVER B1 ................ W WHEEL, FRONT B8 ...................... WHEEL, REAR B9 ....................... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

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

A4 CRANKSHAFT PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 3 12 2 4 1 5 10 8 11 9 7 9 2 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 0450018 1 Seal, Oil 2 0450016 2 Bearing, Ball, Radial 3 0450649 1 Crankshaft 4 0450017 1 Seal, Oil 5 0450650 1 Collar, Crank, LH 6 0450653 1 Washer, Plain 7 0450029 1 Bearing, Needle 8 0450023 1 Pin, Piston 9 0450027 2 Clip, Piston Pin 10 0450802 0450651 0450704 1 1 1 Piston (Std) Piston (.25 mm O/S) Piston (.50 mm O/S) 11 0450877 0450025 0450705 2 2 2 Ring Set, Piston (Std) Ring Set, Piston (.25 mm O/S) Ring Set, Piston (.50 mm O/S) 12 0450015 1 Key, Semicycle 6/01

A5 FAN COVER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 16 15 10 12 9 17 11 14 13 8 7 6 1 9 2 3 5 4 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 2 0451666 1 Strap 3 0451665 1 Duct, Cooling Fan 4 0452119 1 Filter, Cooling Fan 5 0451667 1 Gasket, Fan Inlet 6 0450041 1 Washer, Plain 7 0450040 1 Screw, Tapping 8 0450039 2 Bolt, Socket 9 0450034 5 Washer 10 0451712 1 Cover, Fan 11 0450036 3 Damper, Air Shroud 12 0450033 3 Bolt, Socket, Hex 13 0450038 1 Deflector 14 0450037 1 Fan 15 0450031 2 Grommet, Cylinder 16 0450030 1 Shroud, Air, Cylinder 17 0450035 1 Screw, Tapping 7/04

A6 OIL PUMP ASSEMBLY PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 16 12 11 7 6 17 5 14 9 8 10 15 3 4 1 13 2 1 9 10 13 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 2 0450655 1 Washer, Wave 3 0450058 1 Gear, Drive, Oil Pump 4 0450059 1 Pin, Dowel 5 0450052 1 Circlip, External 6 0450050 1 Gear, Worm, Oil Pump 7 0450048 1 O-Ring 8 0450055 1 Tube, Oil 9 0450054 2 Clip 10 0450056 2 Clip 11 0450046 1 Washer 12 0450884 1 Bolt, Phillips 13 0450061 2 Spring, Protective, Oil Pipe 14 0450053 1 Tube, Oil 15 0450057 2 Bolt, Pan, Phillips 16 0450846 1 Asm., Oil Pump (Incl. 5,6,7,8,9,10,11,12,13,14,17) 17 0450051 1 Pin, Shaft 6/01

A7 AIR CLEANER PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 17 16 2 1 3 4 8 14 6 15 10 9 5 7 11 12 13 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 2 0450065 1 Manifold, Intake 3 0450067 1 Clamp, Hose 4 0450068 1 Clip 5 0451077 1 Elbow, Air Cleaner 6 0450071 1 Cover, Air Cleaner 7 0450076 3 Screw, Tapping 8 0451080 1 Cleaner, Air (Incl. 5,6,7,9,10,13,14,15) 9 0451081 1 Seal 10 0450073 1 Element, Air Cleaner 11 0450039 2 Bolt, Socket 12 0450034 2 Washer, Plain 13 0450079 2 Grommet 14 0450070 1 Case, Air Cleaner 15 0451138 1 Tube, Inlet, Air Cleaner 16 0450064 1 Gasket 17 0450063 1 Asm., Reed Valve 9/02

A8 CARBURETOR PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 19 2 31 13 32 29 30 8 18 9 14 7 5 15 26 16 23 6 17 11 1 13 20 10 28 24 22 25 21 4 3 27 12 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 2 0450082 1 Gasket 3 0451014 1 Plug, Oil 4 0451013 1 Pipe, Oil 5 0450102 1 Screw Set, Air Adjust 6 0450113 1 Screw Set, Throttle 7 0451024 1 Jet, Pilot 8 0452197 1 Nozzle, Needle 9 0450097 1 Jet, Main 10 0450976 1 Float, Carb 11 0450117 1 Pin, Float 12 0451032 1 Cable, Choke 13 0450086 6 Bolt, Pan, Phillips 14 0450098 1 Tube, Overflow 15 0450104 1 Plug, Drain 16 0450108 1 Bolt, Pan, Phillips 17 0451669 1 Valve Set, Needle 18 0451054 1 Seal, Float Chamber 19 0451668 1 Asm., Carburetor (Incl. All Less 12) 20 0450923 1 Nozzle, Choke 21 0451055 1 Valve, Choke 22 0451057 1 Spring, Choke Return 23 0451028 1 O-Ring 24 0451058 1 Base, Manual Choke 25 0451056 1 Bracket, Manual Choke 26 0450106 2 Bolt, Pan, Phillips 27 0451060 1 Support, Cable 28 0451059 1 Cover, Cable Support 29 0451051 1 Slide, Carburetor 30 0452196 1 Needle Set 31 0451050 1 Spring, Carb Slide 32 0450087 2 Washer, Spring 7/04

A9 EXHAUST PIPE PREDATOR 90 A05KA09CA and PREDATOR 90 A05KA09CB 6 17 16 4 3 2 1 14 8 2 1 7 9 5 15 10 12 13 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 0450658 2 Bolt, Pan, Phillips 2 0450126 2 Gasket 3 0450657 1 Protector, Pipe, Exhaust 4 0450684 1 Bolt, Hex, Washer Face 5 0450279 1 Washer, Plain 6 0452121 1 Pipe, Exhaust 7 0450282 1 Nut, Hex, Washer Face 8 0452198 1 Gasket 9 0450325 1 Bolt, Hex, Washer Face 10 0452122 2 Gasket, Exhaust Bracket 11 0452123 1 Bolt, Hex 12 0451702 1 Washer, Spring 13 0450323 1 Bolt, Hex 14 0450298 1 Bolt, Hex, Washer Face 15 0450128 1 Plate, Fixed, Exhaust 16 0450123 2 Bolt, Hex, Washer Face 17 0450122 1 Gasket 7/04

2005 Polaris Predator 90 Parts Manual

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