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34
SPORTSMAN 90 Model #A04FA09CA Model #A04FA09CB E 2003 Polaris Sales Inc. PARTS MANUAL PN 9918780 and MICROFICHE PN 9918781 7/03 World of Powersports.com 800-407-7218
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SPORTSMAN 90Model #A04FA09CAModel #A04FA09CB
E 2003 Polaris Sales Inc.
PARTS MANUAL PN 9918780 and MICROFICHE PN 9918781 7/03
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TABLE OF CONTENTSSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
Parts Manual
AAIR CLEANER A7. . . . . . . . . . . . . . . . . . . . . . .AXLE, REAR WHEEL B12. . . . . . . . . . . . . . . . . .
BBRAKE, FRONT B9. . . . . . . . . . . . . . . . . . . . . .BRAKE, REAR B10. . . . . . . . . . . . . . . . . . . . . . .BRAKELIGHT C1. . . . . . . . . . . . . . . . . . . . . . . .BUMPER B2. . . . . . . . . . . . . . . . . . . . . . . . . . .
CCAB B4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR A8. . . . . . . . . . . . . . . . . . . . . . .CHAIN B13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .CRANKCASE A10. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT A4. . . . . . . . . . . . . . . . . . . . . . .CYLINDER HEAD A3. . . . . . . . . . . . . . . . . . . . .
DDECALS C4. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE PULLEY A12. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT A13. . . . . . . . . . . . . . . . . . . . . . .
EELECTRICAL PARTS C3. . . . . . . . . . . . . . . . . .ENGINE BRACKET A14. . . . . . . . . . . . . . . . . . .EXHAUST PIPE A9. . . . . . . . . . . . . . . . . . . . . .
FFAN COVER A5. . . . . . . . . . . . . . . . . . . . . . . .FOOTREST B3. . . . . . . . . . . . . . . . . . . . . . . . .FRAME BODY B1. . . . . . . . . . . . . . . . . . . . . . .
FFUEL TANK B5. . . . . . . . . . . . . . . . . . . . . . . . .
GGENERATOR C2. . . . . . . . . . . . . . . . . . . . . . . .
HHANDLEBAR B11. . . . . . . . . . . . . . . . . . . . . . . .HEADLIGHT C1. . . . . . . . . . . . . . . . . . . . . . . . .
OOIL PUMP ASSEMBLY A6. . . . . . . . . . . . . . . . .OIL TANK B5. . . . . . . . . . . . . . . . . . . . . . . . . . .
RRACKS B2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SSEAT B4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTER A11. . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR C2. . . . . . . . . . . . . . . . . . .STEERING B14. . . . . . . . . . . . . . . . . . . . . . . . . .SUSPENSION B6. . . . . . . . . . . . . . . . . . . . . . .SWING ARM B3. . . . . . . . . . . . . . . . . . . . . . . .
WWHEEL, FRONT B7. . . . . . . . . . . . . . . . . . . . . .WHEEL, REAR B8. . . . . . . . . . . . . . . . . . . . . . .
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
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A3
CYLINDER HEADSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
3
4
1
5
6
7
2
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450005 1 Plug, Spark2 0450012 4 Nut, Flange3 0451091 1 Head, Cylinder4 0450004 1 Gasket, Cylinder Head
5 0450007 1 Cylinder6 0450009 1 Gasket, Cylinder7 0450011 4 Bolt, Stud
7/03
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A4
CRANKSHAFTSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
3
12
2
4
1
5
10
811
9
79
2
6
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450018 1 Seal, Oil2 0450016 2 Bearing, Ball, Radial3 0450649 1 Crankshaft4 0450017 1 Seal, Oil5 0450650 1 Collar, Crank, LH6 0450653 1 Washer, Plain7 0450029 1 Bearing, Needle8 0450023 1 Pin, Piston
9 0450027 2 Clip, Piston Pin10 0450802
04506510450704
111
Piston (Std)Piston (.25 mm O/S)Piston (.50 mm O/S)
11 045087704500250450705
222
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
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A5
FAN COVERSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
15 14
9
11
8
16
10
13
127
54
1
8
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3
6
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0451664 1 Cover, Fan Inlet2 0451666 1 Strap3 0451665 1 Duct, Cooling Fan4 0450041 1 Washer, Plain5 0450040 1 Screw, Tapping6 0451667 1 Gasket, Fan Inlet7 0450039 2 Bolt, Socket8 0450034 5 Washer
9 0451712 1 Cover, Fan10 0450036 3 Damper, Air Shroud11 0450033 3 Bolt, Socket, Hex12 0450038 1 Deflector13 0450037 1 Fan14 0450031 2 Grommet, Cylinder15 0450030 1 Shroud, Air, Cylinder16 0450035 1 Screw, Tapping
7/03
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A6
OIL PUMP ASSEMBLYSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
16
1211
76
17
5
14
9
810
15
3
4
1
13
2
1
910
13
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450060 2 Circlip, External2 0450655 1 Washer, Wave3 0450058 1 Gear, Drive, Oil Pump4 0450059 1 Pin, Dowel5 0450052 1 Circlip, External6 0450050 1 Gear, Worm, Oil Pump7 0450048 1 O-Ring8 0450055 1 Tube, Oil9 0450054 2 Clip
10 0450056 2 Clip11 0450046 1 Washer12 0450884 1 Bolt, Phillips13 0450061 2 Spring, Protective, Oil Pipe14 0450053 1 Tube, Oil15 0450057 2 Bolt, Pan, Phillips16 0450846 1 Asm., Oil Pump
(Incl. 5,6,7,8,9,10,11,12,13,14,17)17 0450051 1 Pin, Shaft
6/01
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A7
AIR CLEANERSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
1716
2
1
3
4
8
14
6
15
109 5
7
1112
13
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450066 4 Bolt, Hex, Washer Face2 0450065 1 Manifold, Intake3 0450067 1 Clamp, Hose4 0450068 1 Clip5 0451077 1 Elbow, Air Cleaner6 0450071 1 Cover, Air Cleaner7 0450076 3 Screw, Tapping8 0451080 1 Cleaner, Air (Incl. 5,6,7,9,10,13,14,15)9 0451081 1 Seal
10 0450073 1 Element, Air Cleaner11 0450039 2 Bolt, Socket12 0450034 2 Washer, Plain13 0450079 2 Grommet14 0450070 1 Case, Air Cleaner15 0450072 1 Pipe, Guide16 0450064 1 Gasket17 0450063 1 Asm., Reed Valve
6/02
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A8
CARBURETORSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
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
2143
27
12
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450119 1 Nut, Cable Adjust2 0450082 1 Gasket3 0451014 1 Plug, Oil4 0451013 1 Pipe, Oil5 0450102 1 Screw Set, Air Adjust6 0450113 1 Screw Set, Throttle7 0451024 1 Jet, Pilot8 0451053 1 Nozzle, Needle9 0450097 1 Jet, Main10 0450976 1 Float, Carb11 0450117 1 Pin, Float12 0451032 1 Cable, Choke13 0450086 6 Bolt, Pan, Phillips14 0450098 1 Tube, Overflow15 0450104 1 Plug, Drain16 0450108 1 Bolt, Pan, Phillips
17 0451669 1 Valve Set, Needle18 0451054 1 Seal, Float Chamber19 0451668 1 Asm., Carburetor (Incl. All Less 12)20 0450923 1 Nozzle, Choke21 0451055 1 Valve, Choke22 0451057 1 Spring, Choke Return23 0451028 1 O-Ring24 0451058 1 Base, Manual Choke25 0451056 1 Bracket, Manual Choke26 0450106 2 Bolt, Pan, Phillips27 0451060 1 Support, Cable28 0451059 1 Cover, Cable Support29 0451051 1 Slide, Carburetor30 0451052 1 Needle Set31 0451050 1 Spring, Carb Slide32 0450087 2 Washer, Spring
7/03
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A9
EXHAUST PIPESPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
6 15
14
4
3
2
1
13
9
148
9
2
1
7
10
11
12
5
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450658 2 Bolt, Pan, Phillips2 0450126 2 Gasket3 0450657 1 Protector4 0450684 1 Bolt, Hex, Washer Face5 0450279 1 Washer, Plain6 0450656 1 Pipe, Exhaust7 0450282 1 Nut, Hex, Washer Face8 0450659 1 Gasket
9 0450325 5 Bolt, Hex10 0450859 1 Protector, Exhaust Pipe11 0450126 4 Gasket12 0450860 2 Bolt, Pan, Phillips13 0450128 1 Plate, Fixed14 0450123 2 Bolt, Hex, Washer Face15 0450122 1 Gasket
7/02
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A10
CRANKCASESPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
12
117
4
65
2
2627
32
25
30 3122
33
23
18
17
9
10
1413
2829
1
34
8
1516
20
3
24
2525
25
2 18
1719
3536 21
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450159 1 Gasket, Generator2 0450138 8 Bolt, Socket3 0450170 1 Plug, Rubber4 0450135 1 Crankcase, RH5 0450137 2 Pin, Dowel6 0451670 1 Hose, Breather7 0450133 1 Head, Breather Hose8 0450161 1 Circlip, Internal9 0450153 1 Plug, Oil10 0450154 1 O-Ring11 0451139 1 Bushing, Rubber12 0451082 1 Crankcase, LH13 0450156 1 Washer14 0450298 1 Bolt, Hex15 0450162 1 Circlip, Internal16 0451672 1 Gaurd, Clutch Cover17 0450168 2 Grommet18 0450167 2 Bolt, Flat Head, Phillips
19 0450150 3 Nut, Flange, Hex20 0450152 1 Protector B21 0450151 1 Bolt, Socket, Hex22 0451671 1 Cover, Clutch23 0450148 8 Bolt, Socket, Hex24 0450674 1 Tube, Breather25 0450142 4 Pin, Dowel26 0450139 1 Cover, Mission27 0450140 1 Gasket, Cover, Mission28 0450157 1 Bracket, Oil Seal29 0450158 1 Bolt, Socket, Hex30 0450143 2 Bolt, Pan Head31 0450039 3 Bolt, Pan Head32 0450141 1 Gasket, Crankcase Cover, LH33 0450147 1 Shaft, Pin34 0450160 1 Bracket, Carburetor Tube35 0450164 1 Filter36 0450166 1 Protector A
7/03
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A11
STARTERSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
1012
13
14
9
16
1817
1920
1
2
34
11
6
5
7
8
15
2117 20
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450183 1 Asm., Kick Shaft2 0450184 1 Spring, Reset, Starter Shaft3 0450185 1 Bushing4 0450186 1 Washer5 0450189 1 Bolt, Hex6 0450570 1 Asm., Kick Crank7 0450190 1 Asm., Kick Pinion8 0450191 1 Clip, Spring9 0450176 1 Clutch Set, Starter, Electric10 0450171 1 Wheel, Starter11 0450187 1 Circlip, External
12 0450172 1 Bearing, Needle13 0450173 1 Boss, Gear14 0450174 1 Washer15 0450192 1 Washer16 0450178 1 Asm., Idle Gear17 0450180 2 Washer18 0450682 1 Pin, Shaft19 0450181 1 Plate, Idle Gear20 0450805 2 Bolt, Socket, Hex21 0450193 1 Washer, Wave
6/01
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A12
DRIVE PULLEYSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
25
2223
21
24
20
1
65
15
13
2
12
16
4
3
7 8
91110
29
27
26
30
14
31 32 3334 35
36
2
26
28
1918 17
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450202 1 Asm., Secondary Sheave(Incl. 2,3,4,5,6,7,8,12,13,15,16)
2 0450211 2 Seal, Oil3 0450219 1 Seat, Spring, Secondary4 0450217 1 Spring, Compression5 0450206 3 Spring, Weight, Clutch6 0450204 1 Carrier, Clutch7 0450221 1 Nut8 0450223 1 Cover, Clutch9 0450224 1 Nut, Hex10 0450226 1 O-Ring11 0450225 1 Bearing12 0450213 2 Ring, Oil13 0450210 1 Wheel, Slot, Sliding, Secondary14 0450239 1 V-Belt15 0450208 1 Wheel, Slot, Fixed, Secondary16 0450215 2 Pin, Guide17 0451016 1 Bearing, Ball18 0451017 1 Circlip
19 0451015 1 Bearing, Needle20 0450200 1 Seal, Oil21 0450198 1 Circlip, External22 0450041 1 Washer, Plain23 0450158 1 Bolt, Socket, Hex24 0450199 1 Bearing25 0450195 1 Asm., Primary Drive26 0450234 3 Slider27 0450232 1 Plate, Cam28 0450229 6 Roller, Weight29 0450228 1 Wheel, Slot, Sliding, Primary30 0450236 1 Bushing31 0450241 1 Sheave, Fixed, Primary32 0450243 1 Washer, Claw33 0450245 1 Clutch, One-Way34 0450247 1 Washer, Spring, Cone35 0450249 1 Nut, Flange36 0450251 1 Asm., Sliding Drive Face
(Incl. 26,27,28,29,30,31,32)7/03
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A13
DRIVE SHAFTSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
1112
10
9
8
6
4
5
7
321
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450265 1 Nut, Lock2 0450264 1 Washer3 0450263 1 Sprocket, Drive4 0450162 1 Circlip5 0450261 1 Bearing, Ball6 0450259 1 Seal, Oil
7 0450161 1 Circlip8 0450258 1 Bearing9 0450585 1 Asm., Drive Axle10 0450255 1 Washer11 0450253 1 Axle, Main12 0450254 1 Bearing, Ball
6/01
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A14
ENGINE BRACKETSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
6
13
14
9
5
1
16
874
3
15
2
1110
3
21
812
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450271 2 Nut, Hex2 0450286 2 Washer3 0450284 2 Bushing, Rubber, Front4 0450283 1 Tube, Fixed, Front5 0450270 1 Bolt, Hex6 0450266 1 Shaft, Fixed7 0450709 1 O-Ring8 0450684 2 Bolt, Hex, Washer Face
9 0450269 1 Bracket, Engine10 0450132 1 Bushing, Rubber11 0450287 1 Plate, Fixed, Oil Tank12 0451511 1 Asm., Engine, 90cc13 0450192 1 Washer14 0450268 1 Nut, Flange15 0450285 1 Bolt, Hex16 0450278 1 Collar
1/03
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B1
FRAME BODYSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
17
65
16
15
109
8
14
109
5
7
3
1
1
2
2
4
4
11
12
13
E 2003 Polaris Sales Inc.
3
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450325 8 Bolt, Hex, Washer Face2 0450613 8 Grommet3 0451698
045169911
Support, Footrest, LHSupport, Footrest, RH
4 0450887 4 Bolt, Hex, Washer Face5 0450299 2 Plate, Engine Bracket6 0450290 2 Rubber, Seat7 0450878 1 Nut, Lock8 0450304 1 Sleeve, Rubber
9 0450303 2 Cover, Swing Arm Seal10 0450302 2 Seat, Grease Contain11 0450900 1 Flag12 0450844 1 Washer, Spring13 0450845 1 Nut, Hex14 0450305 1 Bolt, Hex15 0450301 1 Tube, Spacer16 0451697 1 Asm., Swing Arm, Silver17 0451696 1 Frame, Main, Silver
7/03
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B2
BUMPER / RACKSSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
17
9
2
5
13
15
12
7
4
4
4
12
11
6
6
3
3
E 2003 Polaris Sales Inc.
11
1011
10
14
143
6
16
18
16
1
1
6
87
3
6
88
7
7
6
33
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450310 10 Bolt2 0451172-070 1 Rack, Front3 0450879 12 Washer, Plain4 0450304 4 Bolt, Hex, Washer5 0451700 1 Bumper, Front6 0450808 12 Nut, Lock7 0450298 6 Bolt, Hex, Washer Face8 0451702 6 Washer, Spring9 0450862 2 Asm., Light, Low Beam
10 0451703 2 Screw, Tapping w/Washer11 0450824 2 Bolt12 0450150 4 Nut13 0451174-070 1 Bumper, Front14 0450606 2 Nut, Lock15 0451701 1 Support, Rear Rack16 0451310 2 Grommet, Footrest17 0451173-070 1 Rack, Rear18 0451704 2 Bolt, Hex, Flange
7/03
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B3
SWING ARM / FOOTRESTSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
20
18
14
13
16 15
12
17
19
1110
3
4
6
1718
1415
1312
1110
5
7
2
1
9
8
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450622 3 Bolt, Pan, Phillips2 0450618 1 Shield, Heat3 0451170-070 1 Footrest, RH4 0450710 3 Washer, Plain5 0450741 3 Nut, Lock6 0450340 8 Bolt, Hex7 0451171-070 1 Footrest, LH8 0450879 8 Washer, Plain9 0450808 8 Nut, Lock10 0450321 2 Cap, Rubber
11 0450320 2 Valve, Grease12 0450317 2 Rubber, Dustproof13 0450314 2 Seat, Grease Contain14 0450313 2 Seat, Grease Contain15 0450316 2 Cover, Waterproof16 0451705 1 Arm, Suspension, LH17 0450820 4 Bolt, Hex18 0450288 4 Bushing19 0450249 4 Nut, Flange20 0451706 1 Arm, Suspension, RH
7/03
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18
B4
CAB/SEATSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
49
19
5
1617
6 7
14
15
5
12
10
22
21
20
20
3
18
8
13
11
1011
12
23
1
E 2003 Polaris Sales Inc.
12
1211
10
12
12
2
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0451076 4 Rivet2 0451164-400
0451167-47311
Cover, Front (CA)Cover, Front (CB)
3 0451166-070 1 Mudflap, Front, RH4 0451163-400
0451163-47311
Cab, Front (CA)Cab, Front. N.B.U. (CB)
5 0450340 4 Bolt, Hex6 0450897 1 Strap, Battery7 0450898 1 Strap, Tool Box8 0451168-070 1 Mudflap, Rear, RH9 0451144
0451144-47311
Cab, Rear, Camo Green Metallic (CA)Cab, Rear, N.B.U. (CB)
10 0450741 36 Nut, Lock11 0450710 36 Washer, Plain
12 0450622 36 Bolt, Phillips13 0451169-070 1 Mudflap, Rear, LH14 0450345 1 Pad, Protector15 0450346 1 Rubber, Battery16 0450297 2 Bolt, Pan, Phillips17 0450342 2 Nut, U-Plate18 0451167-070 1 Mudflap, Front, LH19 0450824 2 Bolt, Hex20 0450880 2 Nut, Flange, Hex21 0450356 1 Hook, Seat22 0450631 1 Asm., Seat23 9918778 1 Manual, Owner’s, 2004 Youth ATV
7/03
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18
B5
OIL TANK/FUEL TANKSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
7
5
13
18 17
16
14
9
21
12
10
6
12
11
15
4
4
4 1419
20
8
3
E 2003 Polaris Sales Inc.
4
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450903 1 Cap, Oil Tank2 0450927 1 Asm., Oil Tank3 0451035 1 Bolt, Hex4 0450054 8 Clip5 5433687 1 Cap, Fuel Tank6 5812123 1 Gasket, Fuel Cap7 0451175 1 Tank, Fuel8 0450041 1 Washer9 0450826-035 1 Tube, Oil, Side10 0450373 1 Hook, Fuel Tank
11 0450632 2 Mat, Rubber, Fuel Tank12 0450340 3 Bolt, Hex13 0450864 2 Asm., Fuel Line and Clip14 0450866 3 Bolt, Pan, Phillips15 0450636 1 Knob, Fuel Shut-Off16 0450996 1 Asm., Manual Fuel Cup17 0451089 1 Asm., Fuel Filter18 0450825 1 Hose19 0450363-220 1 Hose20 0450363-440 1 Hose
7/03
Worl
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ports
.com
800-4
07-72
18
B6
SUSPENSIONSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
8
17
65
5
1
7
7
76
5
5
5
4
24
2
10
12
11
9
E 2003 Polaris Sales Inc.
3
3
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450868 2 Bolt, Hex2 0450738 2 Tube, Inner, Front Suspension3 0451675 2 Collar, Adjustment, Front Spring4 0450737 2 Spring, Front Suspension5 0450380 4 Bolt, Hex6 0450869 2 Suspension, Front (Incl. 2-4)
7 0450249 4 Nut, Flange8 0451071 1 Asm., Rear Shock (Incl. 9,10,11,12)9 0450929 1 Retainer, Spring10 0450949 1 Spring, Rear Suspension11 0450894 1 Collar, Adjustment12 0451078 1 Shock, Rear
7/03
Worl
d of P
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ports
.com
800-4
07-72
18
B7
FRONT WHEELSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
8
3
13
214
1112
1
9
2
10
5
4
67
3
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450393 2 Bearing2 0450389 4 Seal, Oil3 0450386 2 Rim, Wheel (Silver)4 0450394 2 Nut, Lock5 0450395 2 Pin, Cotter6 0450829 2 Cap, Rubber7 0450397 2 Washer
8 0450950 2 Tire (19x7-8)9 0450124 8 Bolt, Washer Face, Hex10 0450401 2 Valve, Rim11 0450391 2 Spacer, Outer12 0450392 2 Bearing13 0450388 2 Drum, Brake, Front14 0450390 2 Spacer, Inner
7/02
Worl
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ports
.com
800-4
07-72
18
B8
REAR WHEELSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
32
1
4
57
89
6E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450408 2 Connector, Shaft2 0450386 2 Rim, Wheel (Silver)3 0450909 2 Tire (18x9.5-8)4 0450395 2 Pin, Cotter5 0450829 2 Cap, Rubber
6 0450409 2 Nut, Lock7 0450412 2 Washer8 0450124 8 Bolt, Washer Face, Hex9 0450401 2 Valve, Rim
7/02
Worl
d of P
owers
ports
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800-4
07-72
18
B9
FRONT BRAKESPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
9
8
4
6
3 2
7
5
1
32
7
5
1 E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450426 2 Cable, Front Brake2 0450422 2 Asm., Shoe, Front Brake3 0450421 2 Shaft, Cam, Front Brake4 0450912 1 Plate, Front Brake, RH5 0450425 2 Bolt, Hex
6 0450913 1 Arm, Front Brake, RH7 0450424 2 Spring, Return, Front8 0450911 1 Arm, Front Brake, LH9 0450910 1 Plate, Front Brake, LH
6/01
Worl
d of P
owers
ports
.com
800-4
07-72
18
B10
REAR BRAKESPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
22
8
76
209
10
17
354
1
2
21
19
18
23
26
28
25
1412
15
11
27
16
13
25 24
12
1415
76
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450438 1 Cable, Rear Brake2 0450268 2 Bolt, Hex3 0450435 1 Spring, Cable, Rear Brake4 0450437 1 Thru-Shaft, Rear Brake5 0451079 1 Nut, Adjust, Brake6 0450430 2 Seal, Oil7 0450429 2 Bearing8 0450428 1 Tube, Spacer9 0450432 1 Arm, Rear Brake10 0450433 1 Bolt, Hex11 0450453 1 Spring, Arm, Rear Brake12 0450451 2 Bolt, Hex, Washer Face13 0450881 1 Nut, Lock14 0450529 2 Nut, Flange
15 0450452 2 Bolt, Hex16 0450854 1 Shaft, Fixed, Rear Brake17 0450434 1 Shoe, Rear Brake18 0450442 1 Rubber, Protective19 0450441 1 Drum, Rear Brake20 0450431 1 Shaft, Cam, Rear Brake21 0450440 1 Plate, Rear Brake22 0450427 1 Seat, Fix, Rear Axle23 0450751 1 Cover, Rear24 7171069 1 Decal, Drive Chain25 0450340 2 Bolt, Hex26 0450446 1 Reflector, Rear27 0450643 1 Washer28 0450447 1 Nut, Flange
7/03
Worl
d of P
owers
ports
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800-4
07-72
18
B11
HANDLEBARSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
30
1
22
2129
734
23
24
5
128
27
2028
1
4
33
18 16
6
26
9
25
25
26
3
11
17
17
19
2
3231
1314
14
15E 2003 Polaris Sales Inc.
10
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0451097 2 Grip, Hand2 7080891 1 Wristband3 0450806 1 Bolt, Brake Lever, RH4 0451040 1 Asm., Throttle5 0451165-400
0451165-47311
Pod, Upper (CA)Pod, Upper, N.B.U. (CB)
6 0450556 2 Bolt, Washer Face, Hex7 0450148 4 Screw, Socket, Hex8 0451090 1 Plate, Fix, Protective Cover9 0450752 6 U-Nut10 0451707 1 Speedometer, Bezel11 0450807 1 Bolt, Brake Lever, LH12 0451684 1 Asm., Switch, LH13 0451037 1 Asm., Manual Choke (Incl. 14,15)14 0451148 2 Bolt15 0451149 1 Bolt16 0450693 1 Lever, Brake, LH17 0450808 2 Nut, Lock
18 0450692 1 Lock, Park Brake19 0450836 1 Harness, Sensor Switch20 0450463 1 Asm., Lever, LH (Incl. 11,16,17,18)21 0450460 1 Cover, Clamp, LH22 0450459 2 Clamp, Saddle23 0450279 2 Washer24 0450276 2 Nut, Lock25 0451132 6 Screw, Tapping26 0450667 4 Bolt, Pan, Phillips27 0450669 1 Pod, Lower, Handlebar28 0450471 1 Cable, Throttle29 0450461 1 Cover, Clamp, RH30 0451161 1 Handlebar, Silver31 0450994 1 Bracket, Brake Cable32 0450309 1 Bolt33 0450694 1 Lever, Brake, RH34 0451096 1 Asm., Brake Lever, RH (Incl. 4,31-33)
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
B12
REAR WHEEL AXLESPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
34
5
7
2
6
1
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450479 1 Tube, Spacer, LH2 0450477 1 Axle, Rear3 0450484
045048011
Asm., Final Drive Sprocket (Incl. 3,4,5,7)Sprocket, Drive, Final
4 0450481 1 Hub, Sprocket5 0450323 3 Bolt, Hex6 0450478 1 Tube, Spacer, RH7 0450483 3 Washer, Spring
6/01
Worl
d of P
owers
ports
.com
800-4
07-72
18
B13
CHAINSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
1
10
3
2
9
11
E 2003 Polaris Sales Inc.
9
4
5
6
7
8
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450695 1 Asm., Drive Chain2 0450489 2 Nut, Hex3 0450856 1 Adjuster, Chain4 0451685 1 Guard, Chain/Brake5 0451687 1 Spring, Torsion6 0451686 1 Asm., Chain Tensioner (Incl. 5-7)
7 0451688 1 Roller, Chain Tensioner8 0451689 1 Bolt9 0450325 3 Bolt, Hex10 0450298 1 Bolt11 0450972 1 Link, Master, Drive Chain
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
B14
STEERINGSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
2
101112
1314
15
17
18
7
16
5
3
1
8
6
1
6 5 8
8
9
9
9
9
9
4
4
E 2003 Polaris Sales Inc.
3
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450505 2 Bracket, Upper, Steering Shaft2 0450915 1 Shaft, Steering3 0451690 2 Asm., Tie Rod4 0450395 2 Pin, Cotter5 0450502 2 Nut, Lock6 0450507 2 Pin, Cotter7 0450916 1 Knuckle, LH8 0450276 4 Nut, Lock9 0450719 5 Pin, Cotter
10 0450491 1 Seal, Oil11 0450161 1 Circlip12 0450493 1 Bearing, Ball13 0450389 1 Seal, Oil14 0450390 1 Spacer15 0450878 1 Nut, Lock16 0450917 1 Knuckle, RH17 0450268 2 Nut, Flange18 0450499 1 Sleeve, Steering Shaft
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
C1
HEADLIGHT / BRAKELIGHTSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
5
4
3
1 2
1 2
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450880 2 Nut, Flange, Hex2 0450041 2 Washer, Plain3 0451691
045099511
Asm., BrakelightBulb, Taillight
4 0450676 2 Screw, Tapping5 0450718 1 Asm., Headlight
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
C2
GENERATOR / STARTING MOTORSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
3
21
5 6
7
8
9
13
10
11
12
4
E 2003 Polaris Sales Inc.
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450529 1 Nut, Flange, Hex2 0450545 1 Washer, Spring3 0450525 1 Flywheel4 0451000 1 Stator5 0450033 2 Bolt, Socket, Hex6 0450034 2 Washer, Plain7 0451692 1 Asm., Starting Motor
(Incl. 8,9,10,11,13)
8 0450535 1 Brush Set9 0450537 1 Ring, Oil10 0450541 2 Bolt Set11 0450857 1 Cord12 0450039 2 Bolt, Socket, Hex13 0450539 1 Ring, Oil
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
C3
ELECTRICAL PARTSSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
23
183
25
13
7
5
16
24
9
1
19
10
6
4
14
2021
15
2726
17
2
8
12
11
E 2003 Polaris Sales Inc.
422
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450558 1 Asm., Oil Level Gauge2 0450886 1 Clip, Main Switch3 0450549 1 Asm., Main Switch (Incl. 2)4 0450701 2 Bolt, Washer Face, Hex5 0450554 1 Asm., Resistor6 0450057 2 Bolt, Pan, Phillips7 0450553 1 Rectifier/Regulator8 0451693 1 Switch, Safety9 0451710 1 Lamp, Warning, Low Oil10 0450309 1 Bolt, Hex11 0451020 2 Screw, Fixing12 0451019 1 Jumper13 0451018 1 Asm., CDI Unit14 0450563 1 Bag, Tool
15 0450842 1 Fuse16 0450555 1 Asm., Starter Relay17 0450888 2 Bolt and Nut, Battery18 0451043 1 Battery19 0450559 3 Strap20 0450721 1 Strap21 0450742 1 Strap22 0451695 1 Horn23 0451694 1 Asm., Main Wire Harness24 0450556 2 Bolt, Hex25 0450753 1 Asm., Ignition Coil (Incl. 27)26 0451018 1 Washer, Star27 0451162 1 Cap, Spark Plug
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
C4
DECALSSPORTSMAN 90 A04FA09CA and SPORTSMAN 90 A04FA09CB
4
15
6
12
14
9
8
2
10
11
13
LH
RH
7
51
1
4
E 2003 Polaris Sales Inc.
3
‘
3
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7170037 2 Decal, Warning, Rack2 7079091 1 Decal, Age Warning, 12, ATV, Youth3 7171819
717182071718217171822717194571719467171947717194871718237171824
1111111111
Decal, Tankside, LHDecal, Tankside, RHDecal, Side, Top, LHDecal, Side, Top, RHDecal, Side Panel, Vent, Top, LHDecal, Side Panel, Vent, Top, LHDecal, Side, Bottom, LHDecal, Side, Bottom, RHDecal, Side Panel, Vent, Bottom, LHDecal, Side Panel, Vent, Bottom, RH
4 71720227172023
11
Decal, Tank Side, LHDecal, Tank Side, RH
5 7078465 1 Logo, Polaris Star
6 70799767172175
11
Decal, Frt. Cvr., “POLARIS”, White (CA)Decal, Frt. Cvr., “POLARIS”, Gold (CB)
7 7171920 1 Decal, Speedo, Sportsman 908 7079971 1 Decal, Rear Cab, “POLARIS”9 0451715
045171611
Decal, Rear Rack, Side Reflector, LHDecal, Rear Rack, Side Reflector, RH
10 7077920 1 Decal, Passenger Warning11 7170108 1 Decal, Tire Pressure/Load 9012 7079288 1 Decal, Youth Warning, Clutch Cover13 7079133 1 Decal, Warning, General, CPSC, Youth14 7079287 1 Decal, Youth Carb/Filter Info15 0451713
045171411
Decal, Front Rack, Side Reflector, LHDecal, Front Rack, Side Reflector, RH
7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
PRINTED IN THE USA PARTS MANUAL PN 9918780 and MICROFICHE PN 9918781 7/03
Worl
d of P
owers
ports
.com
800-4
07-72
18
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