PARTS MANUAL PN and MICROFICHE PN /04. PREDATOR 90 Model #A05KA09CA Model #A05KA09CB. E 2004 Polaris Sales Inc.

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1 PARTS MANUAL PN and MICROFICHE PN /0 PREDATOR 0 Model #A0KA0CA Model #A0KA0CB E 00 Polaris Sales Inc.

2 This page left blank intentionally.

3 TABLE OF CONTENTS PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB Parts Manual A AIR CLEANER... AXLE, REAR WHEEL... A B F FOOTREST... FRAME BODY... FUEL TANK... B B B B BRAKE, FRONT... BRAKE, REAR... BRAKELIGHT... BUMPER... C CAB... CARBURETOR... CHAIN... CRANKCASE... CRANKSHAFT... CYLINDER HEAD... B0 B C B B A B A0 A A G GENERATOR... H HANDLEBAR... HEADLIGHT... O OIL PUMP ASSEMBLY... OIL TANK... C B C A B D DECALS... DRIVE PULLEY... DRIVE SHAFT... E ELECTRICAL PARTS... ENGINE BRACKET... EXHAUST PIPE... C A A C A A S SEAT... STARTER... STARTING MOTOR... STEERING... SUSPENSION... SWING ARM... T TRANSMISSION LEVER... B A C C B B B FAN COVER F... A W WHEEL, FRONT... WHEEL, REAR... B B The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 CYLINDER HEAD PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Plug, Spark 000 Nut, Flange 0 Head, Cylinder 0000 Gasket, Cylinder Head 0000 Cylinder 0000 Gasket, Cylinder 000 Bolt, Stud /0 A

5 CRANKSHAFT PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Seal, Oil 000 Bearing, Ball, Radial 00 Crankshaft 000 Seal, Oil 000 Collar, Crank, LH 00 Washer, Plain 000 Bearing, Needle 000 Pin, Piston 000 Clip, Piston Pin Piston (Std) Piston (. mm O/S) 000 Piston (.0 mm O/S) Key, Semicycle Ring Set, Piston (Std) Ring Set, Piston (. mm O/S) Ring Set, Piston (.0 mm O/S) /0 A

6 FAN COVER PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 0 0 Cover, Fan Inlet 0 Strap 0 Duct, Cooling Fan 0 Filter, Cooling Fan 0 Gasket, Fan Inlet 000 Washer, Plain 0000 Screw, Tapping 000 Bolt, Socket 000 Washer 0 0 Cover, Fan 000 Damper, Air Shroud 000 Bolt, Socket, Hex 000 Deflector 000 Fan 000 Grommet, Cylinder 0000 Shroud, Air, Cylinder 000 Screw, Tapping /0 A

7 OIL PUMP ASSEMBLY PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Circlip, External 00 Washer, Wave 000 Gear,Drive,OilPump 000 Pin, Dowel 000 Circlip, External 0000 Gear, Worm, Oil Pump 000 O-Ring 000 Tube, Oil 000 Clip Clip 000 Washer 00 Bolt, Phillips 000 Spring, Protective, Oil Pipe 000 Tube, Oil 000 Bolt, Pan, Phillips 00 Asm., Oil Pump (Incl.,,,,,0,,,,,) 000 Pin, Shaft /0 A

8 AIR CLEANER PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Bolt, Hex, Washer Face 000 Manifold, Intake 000 Clamp, Hose 000 Clip 00 Elbow, Air Cleaner 000 Cover, Air Cleaner 000 Screw, Tapping 000 Cleaner, Air (Incl.,,,,0,,,) 00 Seal Element, Air Cleaner 000 Bolt, Socket 000 Washer, Plain 000 Grommet 0000 Case, Air Cleaner 0 Tube, Inlet, Air Cleaner 000 Gasket 000 Asm., Reed Valve /0 A

9 CARBURETOR PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB 0 0 E 00 Polaris Sales Inc Nut, Cable Adjust 000 Gasket 00 Plug, Oil 00 Pipe, Oil 000 Screw Set, Air Adjust 00 Screw Set, Throttle 00 Jet, Pilot 0 Nozzle, Needle 000 Jet, Main 0 00 Float, Carb 00 Pin, Float 00 Cable, Choke 000 Bolt, Pan, Phillips 000 Tube, Overflow 000 Plug, Drain 000 Bolt, Pan, Phillips 0 Valve Set, Needle 00 Seal, Float Chamber 0 Asm., Carburetor (Incl. All Less ) 0 00 Nozzle, Choke 00 Valve, Choke 00 Spring, Choke Return 00 O-Ring 00 Base, Manual Choke 00 Bracket, Manual Choke 000 Bolt, Pan, Phillips 000 Support, Cable 00 Cover, Cable Support 00 Slide, Carburetor 0 0 Needle Set 000 Spring, Carb Slide 000 Washer, Spring /0 A

10 EXHAUST PIPE PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Bolt, Pan, Phillips 00 Gasket 00 Protector, Pipe, Exhaust 00 Bolt, Hex, Washer Face 00 Washer, Plain 0 Pipe, Exhaust 00 Nut, Hex, Washer Face 0 Gasket 00 Bolt, Hex, Washer Face 0 0 Gasket, Exhaust Bracket 0 Bolt, Hex 00 Washer, Spring 00 Bolt, Hex 00 Bolt, Hex, Washer Face 00 Plate, Fixed, Exhaust 00 Bolt, Hex, Washer Face 00 Gasket /0 A

11 CRANKCASE PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Protector A 00 Filter 00 Pin, Dowel 00 Gasket, Crankcase 0 Cover, Clutch 00 Bolt, Hex 00 Bracket, Oil Seal 00 Bolt, Hex 00 Gasket, Generator 0 00 Bolt 000 Plug, Rubber 00 Crankcase, RH 00 Pin, Dowel 0 Breather, Crankcase, Upper 00 Bearing, Needle 00 Shaft, Primary Drive 00 Bearing 00 Bolt, Hex 00 Bolt, Hex 0 0 Mount, Engine, Rear 00 Bushing, Rubber 000 Washer 00 Circlip, External 0000 Seal, Oil A0 0 0 Bearing, Needle 0 Bushing, Rubber 0 Breather, Crankcase, Lower 0 Crankcase, LH 0 Ball, Steel 0 0 Spring, Detent 0 Washer, Flat 0 Bolt, Hex 0 Bolt, Hex 0 O-Ring 0 Sensor, Gear Position 0 Bolt, Hex, Flange 00 Circlip, Internal 0 Bolt, Hex 0 Washer, Flat 0 00 Bolt 00 Grommet 0 Guard, Clutch Cover 000 Nut, Hex, Flange 00 Protector B 00 Bolt, Hex 000 Bracket, Carburator Tube 00 Shaft, Pin /0

12 STARTER PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB 0 E 00 Polaris Sales Inc Asm., Kick Shaft 00 Spring, Reset, Starter Shaft 00 Bushing 00 Washer 00 Bolt, Hex 00 Asm., Kick Crank 000 Asm., Kick Pinion 00 Clip, Spring 00 Clutch Set, Starter, Electric 0 00 Wheel, Starter 00 Circlip, External 00 Bearing, Needle 00 Boss, Gear 00 Washer, Plain 00 Washer 00 Asm., Idle Gear 000 Washer 00 Pin, Shaft 00 Plate, Idle Gear Bolt, Socket, Hex 00 Washer, Wave /0 A

13 DRIVE PULLEY PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Asm., Secondary Sheave (Incl.,,,,,,,,,,) 00 Seal, Oil 00 Seat, Spring, Secondary 00 Spring, Compression 000 Spring, Weight, Clutch 000 Carrier, Clutch 00 Nut 00 Cover, Clutch 00 Nut, Hex 0 00 O-Ring 00 Bearing 00 Ring, Oil 000 Wheel, Slot, Sliding, Secondary 00 V-Belt 000 Wheel, Slot, Fixed, Secondary 00 Pin, Guide 00 Bearing, Ball 00 Circlip A 00 Bearing, Needle Seal, Oil 00 Circlip, External 000 Washer 00 Bolt, Socket, Hex 00 Bearing 00 Asm., Primary Drive 00 Slider 00 Plate, Cam 00 Roller, Weight 00 Wheel, Slot, Sliding, Primary 0 00 Bushing 00 Sheave, Fixed, Primary 00 Washer, Claw 00 Clutch, One-Way 00 Washer, Spring 00 Nut, Flange 00 Asm., Sliding (Incl.,,,,0,,) /0

14 DRIVE SHAFT PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Nut, Lock 0 Sprocket, Drive 00 Circlip, Internal 00 Bearing, Ball 00 Cover, Transmission 00 Pin, Dowel 00 Seal, Oil 0 Gear, Final 0 Shaft, Final 0 00 Bearing, Ball 0 Shaft, Counter 0 Gear, Counter 0 Bearing 0 Shaft, Main Transmission 0 Bushing, Reverse Gear 0 Gear, Reverse A 0 Washer, Flat 0000 Circlip, External 0 Ratchet, Shift 0 00 Bushing, Spur Gear 0 Gear, Spur 0 Washer, Flat 0 Collar, Shaft 0 Asm., Gear Shift Drum 0 Fork, Shift 0 Roller, Drum Sensor 0 Shaft, Gear Shift 0 Spring, Drum Sensor 00 Spindle, Shift 0 0 E-Clip 00 Washer /0

15 ENGINE BRACKET PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Nut, Hex 00 Washer 00 Bushing, Rubber, Front 00 Tube, Fixed, Front 00 Bushing, Rubber 0 Bracket, Oil Tank 0 Asm., Engine, 0cc 00 Bolt, Hex, Washer Face 00 Washer 0 00 Nut, Flange, Hex 00 Bolt, Hex 00 Collar /0 A

16 TRANSMISSION LEVER PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 0 0 Gasket, Transmission Cover 0 Plug, Oil 00 O-Ring 0 Bolt, Hex, Flange 000 Bolt, Hex, Washer 0 Seal, Oil 0 Lever, Transmission 0 Knob, Transmission Lever 00 Cover, Transmission Lever Knob Bolt, Hex 00 Gate, Shift 0 Mount, Shift Lever 00 Bolt, Hex 00 Washer 0 Spring, Transmission Lever 0 Pin, Transmission Lever 00 Pin, Cotter /0 B

17 FRAME BODY PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Grommet 0 0 Support, Footwell, LH Support, Footwell, RH 000 Bolt, Hex, Washer Face 00 Plate, Engine Bracket 0000 Rubber 0 Bracket, Rear Cab Support 00 Flag 00 Washer, Spring 00 Nut, Hex Washer 0 Frame, Main 00 Nut, Lock 000 Sleeve, Rubber 000 Cover, Swing Arm Seal 000 Seat, Grease Contain 000 Bolt, Hex 000 Tube, Spacer 0 Arm, Swing /0 B

18 BUMPER PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 00 Bolt, Hex 000 Bolt, Hex, Washer Face 0 Bumper, Front, Silver 000 Nut, Lock /0 B

19 SWING ARM / FOOTREST PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Bolt, Hex 00 Shield, Heat 00 Bolt, Hex 0 Bracket, Heat Shield 0 Footwell, RH 0 Bolt, Hex 0 Footwell, LH 00 Washer, Plain 000 Nut, Lock 0 00 Cap, Rubber 000 Valve, Grease 00 Rubber, Dustproof 00 Seat, Grease Contain 00 Seat, Grease Contain 00 Cover, Waterproof 0 Arm, Suspension, Silver, LH 000 Bolt, Hex, Washer Face 00 Bushing 00 Nut, Flange 0 0 Arm, Suspension, Silver, RH /0 B

20 CAB / SEAT PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 0 0 Screw, Tapping 0 Cover, Front, Black Metallic 0-0- Cab, Front, Cosmic Sunburst (CA) Cab, Front, Indy Red (CB) 0 0 Panel, Side, LH Panel, Side, RH 00 Screw, Tapping 000 Bolt, Hex 00 Strap, Battery 0 Strap, Tool Box 000 Rubber, Seat Cab, Rear, Cosmic Sunburst (CA) Cab, Rear, Indy Red (CB) B 00 Nut, Lock 000 Washer, Plain 00 Bolt, Phillips 00 Rubber, Battery 00 Pad, Protector 0 0 Asm., Seat (CA) Asm., Seat, Dale Jr. (CB) 00 Bolt, Hex, Washer Face 0 Screw, Tapping 0 Manual, Owner s, 0 Sportsman 0, Predator 0/0 /0

21 OIL TANK / FUEL TANK PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 00 Asm., Oil Tank 000 Cap, Oil Tank 00 Bolt, Hex 0 Bracket, Fuel Tank 000 Washer 00-0 Tube, Oil, Side 00-0 Hose 000 Clip 00 Cap, Fuel Tank 0 00 Film, Breather 00 Boot, Tank Neck 00 Tank, Fuel 00 Mat, Rubber, Fuel Tank 00 Clip 00 Line, Fuel 000 Bolt, Hex 00 Asm., Manual Fuel Cup 00 Hose 0 Filter, Fuel Bolt, Hex /0 B

22 SUSPENSION PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Bolt, Hex 00 Tube, Inner, Suspension, Front 0 Collar, Adjustment, Spring, Front 0-0- Spring, Suspension, Front (CA) Spring, Suspension, Front (CB) 000 Bolt, Hex 00 Nut, Flange 00 Retainer, Spring 0-0- Spring, Suspension, Rear (CA) Spring, Suspension, Rear (CB) 00 Collar, Adjustment 0 00 Shock, Rear 0 Bolt, Hex /0 B

23 FRONT WHEEL PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB 0 E 00 Polaris Sales Inc. 00 Bearing 00 Seal, Oil 00 Wheel, Rim 00 Nut, Lock 00 Pin, Cotter 00 Cap, Rubber 00 Washer 000 Tire (x-) 00 Bolt, Carriage Valve, Rim 00 Spacer, Outer 00 Bearing 0 0- Drum, Brake, Front, Orange (CA) Drum, Brake, Front, Indy Red (CB) 000 Spacer, Inner /0 B

24 REAR WHEEL PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 0 0 Hub, Rear Wheel (CA) Hub, Rear, Orange (CB) 00 Wheel, Rim 0 Tire (x.-) 00 Pin, Cotter 00 Cap, Rubber 000 Nut, Lock 00 Washer 00 Bolt, Carriage 000 Valve, Rim /0 B

25 FRONT BRAKE PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 00 Cable, Front Brake 00 Asm., Shoe, Front Brake 00 Shaft, Cam, Front Brake 00 Plate, Front Brake, RH 00 Bolt, Hex 00 Arm, Front Brake, RH 00 Spring, Return, Front 00 Arm, Front Brake, LH 000 Plate, Front Brake, LH /0 B0

26 REAR BRAKE PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB 0 E 00 Polaris Sales Inc Cable, Rear Brake 00 Bolt, Hex 00 Spring, Cable, Rear Brake 00 Thru-Shaft, Rear Brake 00 Nut, Adjust, Brake 000 Seal, Oil 00 Bearing 00 Tube, Spacer 00 Arm, Rear Brake 0 00 Bolt, Hex 00 Spring, Arm, Rear Brake 00 Bolt, Hex 00 Nut, Lock 00 Nut, Flange 00 Bolt, Hex 00 Shaft, Fixed, Rear Brake 00 Shoe, Rear Brake 00 Rubber, Protective 00 Drum, Rear Brake 0 00 Shaft, Cam, Rear Brake 000 Plate, Rear Brake 0 Housing, Rear Axle, Silver 00 Cover, Rear 0 Decal, Drive Chain 000 Bolt, Hex 00 Reflector, Rear 0 Washer, Black 00 Nut, Flange /0 B

27 HANDLEBAR PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Grip, Hand 00 Wristband 000 Switch, Safety 000 Bolt, Brake Lever, RH 0 Cover, Handlebar 0 Bolt, Philips 0 Bracket, Instrument Panel 000 Bolt, Washer Face 00 Bolt, Hex 0 0 Handlebar, Silver 000 Bolt, Brake Lever, LH 00 Hose, Breather 0 Asm., Switch, LH 00 Asm., Manual Choke (Incl.,) 0 Bolt 0 Bolt B 00 Asm., Lever LH (Incl. -) 00 Lever, Brake, LH 000 Nut, Lock 0 00 Lock, Park Brake 000 Harness, Sensor Switch 000 Cover, Clamp, LH 00 Clamp, Saddle 00 Washer 00 Nut, Lock 00 Cable, Throttle 00 Cover, Clamp, RH 00 Arm, Throttle 00 Bracket, Brake Cable Bolt 00 Lever, Brake, RH 00 Asm., Lever, RH (Incl. -) /0

28 REAR WHEEL AXLE PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 00 Tube, Spacer, LH 00 Axle, Rear Asm., Final Drive Sprocket (Incl.,,,) Sprocket, Drive, Final 00 Hub, Sprocket 00 Bolt, Hex 00 Tube, Spacer, RH 00 Washer, Spring /0 B

29 CHAIN PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Asm., Drive Chain 00 Nut, Hex 00 Adjuster, Chain 0 Guard, Chain/Brake 0 Spring, Torsion 0 Asm., Chain Tensioner (Incl. -) 0 Roller, Chain Tensioner 0 Bolt 00 Bolt, Hex 0 00 Bolt 00 Link, Master, Drive Chain /0 B

30 STEERING PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Bracket, Upper, Steering Shaft 00 Shaft, Steering 00 Asm., Tie Rod 00 Pin, Cotter 000 Nut, Lock 000 Pin, Cotter 00 Knuckle, LH 00 Nut, Lock 00 Pin, Cotter 0 00 Seal, Oil 00 Circlip 00 Bearing, Ball 00 Seal, Oil 000 Spacer 00 Nut, Lock 00 Knuckle, RH 00 Nut, Flange 00 Sleeve, Steering Shaft /0 C

31 HEADLIGHT / BRAKELIGHT PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc. 000 Nut, Flange, Hex 000 Washer, Plain 0 00 Asm., Taillight Bulb, Taillight 0 Screw, Tapping 0 Asm., Headlight, LH 0 Screw, Tapping 0 U-Nut 00 Asm., Headlight, RH /0 C

32 GENERATOR/STARTING MOTOR PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB E 00 Polaris Sales Inc Nut, Flange 00 Washer, Plain 00 Flywheel 000 Bolt, Socket, Hex 000 Washer, Plain 0 Asm., Starting Motor (Incl.,,,0,) 00 Brush Set 00 Ring, Oil 00 Bolt Set 0 00 Cord 000 Bolt, Socket 00 Ring, Oil 0 Asm., Stator /0 C

33 ELECTRICAL PARTS PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB 0 0 E 00 Polaris Sales Inc. 00 Clip, Main Switch 00 Asm.,MainSwitch(Incl.) 000 Bolt, Washer Face, Hex 00 Asm., Resistor 000 Bolt, Pan, Phillips 00 Regulator, Voltage 00 Asm., Oil Level Gauge 00 Indicator, Neutral 0 Switch, Safety 0 0 Indicator, Reverse 00 Lamp, Warning, Low Oil 000 Bolt, Hex 000 Screw, Fixing 00 Jumper 0 Asm., CDI Unit C 00 Bag, Tool 00 Fuse 00 Asm., Starter Relay 00 Bolt and Nut, Battery 0 00 Battery 00 Strap 00 Strap 00 Strap 0 Horn 0 Harness, Main Wire 00 Bolt, Hex 00 Asm., Ignition Coil (Incl. ) 00 Washer, Star 0 Cap, Spark Plug /0

34 DECALS PREDATOR 0 A0KA0CA and PREDATOR 0 A0KA0CB RH E 00 Polaris Sales Inc. 0 0 LH 000 Decal, Reflector, Red, RH 0 Decal, POLARIS, Front/Rear, Black 0 Urocal, 0th Anniversary 0 Decal, Amber, RH 0 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 00 Decal, Youth, CE 00 Decal, Age Warning, (CA) Decal, Age Warning, (CB) 0 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) 0 Decal, Front Cover, Red (CB) Decal, Headlight, Front, LH Decal, Headlight, Side, LH 0 Decal, Front Cab, LH (CA) Decal, Front Cab, RH (CA) Decal, Front Cab, LH (CB) Decal, Front Cab RH (CB) C 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) 0 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) 0 Decal, Tire Pressure 0 0 Decal, Reflector, Red, LH Decal, General Warning, CPSC Decal, Youth Warning, Clutch Cover 0 Decal, Youth Carb/Filter Information /0

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