SPORTSMAN 700 Rev. 04pi54.com/corp/manuals/Parts/9917555r04.pdf · · 2004-09-14(If built before...

PARTS MANUAL PN 9917555 and MICROFICHE PN 9918976 3/03

SPORTSMAN 700Model #A03CH68AAModel #A03CH68ACModel #A03CH68AFModel #A03CH68AHModel #A03CH68AL

Rev. 04

E 2002 Polaris Sales Inc.

TABLE OF CONTENTSSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and

SPORTSMAN 700 A03CH68AH and SPORTSMAN 700 A03CH68ALParts Manual

AA--ARM/STRUT MOUNTING B6. . . . . . . . . . . . .AIR BOX B1. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBRAKE LINE B13. . . . . . . . . . . . . . . . . . . . . . . .BRAKE, FRONT B9. . . . . . . . . . . . . . . . . . . . .BUMPER MOUNTING A7-8. . . . . . . . . . . . . . . . .

CCAB, FRONT A5. . . . . . . . . . . . . . . . . . . . . . . .CAB, REAR A3-4. . . . . . . . . . . . . . . . . . . . . . . . .CABLE B10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .CALIPER, REAR B11. . . . . . . . . . . . . . . . . . . . .CARBURETOR D7-8. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C5. . . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE B13. . . . . . . . . . . .CONTROLS -- THROTTLE ASM./CABLE B10. . . .COOLING SYSTEM A10. . . . . . . . . . . . . . . . . . .CRANKCASE D3. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT D4. . . . . . . . . . . . . . . . . . . . . . .CYLINDER D5-6. . . . . . . . . . . . . . . . . . . . . . . . . .CYLINDER HEAD D5-6. . . . . . . . . . . . . . . . . . . . .

DDECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . . .DIPSTICK D10. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C3. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT, FRONT B2. . . . . . . . . . . . . . . . .DRIVE SHAFT, REAR B3. . . . . . . . . . . . . . . . .DRIVEN CLUTCH C4. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL C9. . . . . . . . . . . . . . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST D9. . . . . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A11. . . . . . . . . . . . . . . . . . .

FFOOT PEDAL B12. . . . . . . . . . . . . . . . . . . . . . . .FRAME A3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C11. . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C10. . . . . . . . . . . . . . . . . . . .GEARCASE C13-14. . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE, REAR D1. . . . . . . . . . . . . . . . . . .GEARCASE MOUNTING, REAR D2. . . . . . . . . .

HHANDLEBAR C1-2. . . . . . . . . . . . . . . . . . . . . . . .HEADLIGHT POD C1-2. . . . . . . . . . . . . . . . . . . . .

IINTAKE D9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MMAGNETO D13. . . . . . . . . . . . . . . . . . . . . . . . . .MASTER CYLINDER B13. . . . . . . . . . . . . . . . . .MASTER CYLINDER, REAR B12. . . . . . . . . . . .

OOIL PUMP D12. . . . . . . . . . . . . . . . . . . . . . . . . .

PPISTON D4. . . . . . . . . . . . . . . . . . . . . . . . . . . .PROP SHAFT, FRONT B4. . . . . . . . . . . . . . . . .PROP SHAFT, REAR B5. . . . . . . . . . . . . . . . .

RRACK MOUNTING, FRONT A7-8. . . . . . . . . . . . .REAR RACK MOUNTING A6. . . . . . . . . . . . . . .REAR WHEEL DRIVE C6. . . . . . . . . . . . . . . . . .

SSEAT A3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D14. . . . . . . . . . . . . . . . . . .STEERING POST B14. . . . . . . . . . . . . . . . . . . . .STRUT, FRONT B7. . . . . . . . . . . . . . . . . . . . . .SUSPENSION, REAR C7-8. . . . . . . . . . . . . . . . .

TTAILLIGHT C9. . . . . . . . . . . . . . . . . . . . . . . . . .THROTTLE ASM. B10. . . . . . . . . . . . . . . . . . . . .TOOL KIT E1. . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING C12. . . . . . . . . . . .

WWATER PUMP D11. . . . . . . . . . . . . . . . . . . . . . .WHEEL, FRONT B8. . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

REAR CAB, SEAT and MAIN FRAMESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN

700 A03CH68AH and SPORTSMAN 700 A03CH68AL

6

7

2

1011

17

16

1819

20

8

14

15

22

23

36

5

39

40

1

3334

13

4

32

21

3

3029

9

31

38

28

27

32


2524

26

37

12

35

A4

REAR CAB, SEAT and MAIN FRAMESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


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 7661645 10 Rivet, T-Lock2 7541925 4 Nut, Nylok3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-400

5434852-419A5432117-1775432117-3415435137-460A

11111

Cab, Rear, Camo Green Met (AA)Cab, Rear, New Break-Up (AC)Cab, Rear, Black Met (AF)Cab, Rear, Sonic Blue (AH)Cab, Rear, NBU No Shadow (AL)

6 7511930 2 Bolt7 5246076 1 Retainer, Seat Latch8 7079902 1 Decal, 4 Stroke, Carb/Filter Information9 5811308 1 Foil, Tape, Rear Cab10 7512242 4 Screw11 7555859 4 Washer, Flat12 7556034 4 Washer13 7512085 2 Screw14 5431786 1 Box, Tool15 7517375 2 Screw16 7621403 2 Rivet17 5211033 2 Bracket, Lever Retainer18 1040387 1 Latch, Seat19 7041370 1 Spring, Latch20 2682957-070

2682958-07011

Asm., Seat, BlackCovering, Seat, Black

21 5412067 8 Bumper, Rubber22 5431787 1 Cover, Tool Box23 5410896 1 Cap, Drain24 7517377 4 Screw25 5432280 2 Spacer26 7542153 6 Nut27 7512283 6 Screw28 5244751-067 1 Brace, Frame29 1014006-067 1 Frame, Main30 7542122 8 Nut, Nylok31 7170509 1 Decal, Hitch32 5811106 2 Foil, Rear Cab, Front33 5811087 1 Foil34 5811111 1 Foil, Rear Fender35 7512232 12 Screw36 7517264

751737644

Screw (LH Side)Screw (RH Side)

37 7517312 2 Screw38 5432221-070

5433929-07011

Footwell, Black, LHFootwell, Black, RH

39 7670057 12 Nut, U-Type Speed40 5431796-070

5431797-07011

Guard, Mud, Rear, LHGuard, Mud, Rear, RH

3/03

A5

FRONT CABSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


5

7

6

9

16

23

1415

18 17

19

6

1

8

4

10 13

8

10

1112



1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5433853-400

2632471-4005434917-419A2632696-4195433853-3822632471-3825433853-3412632471-3415435140-460A2632814-460

1111111111

Panel, Side,Camo Green Met, LH (AA)Panel/Foil, Camo Green Met, RH (AA)Panel, Side, New Break-Up, LH (AC)Panel/Foil, New Break-Up, RH (AC)Panel, Side, Silver Vapor Met, LH (AF)Panel/Foil, Silver Vapor Met, RH (AF)Panel, Side, Sonic Blue, LH (AH)Panel/Foil, Sonic Blue, RH (AH)Panel, Side, NBU No Shadow, LH (AL)Panel/Foil, NBU No Shadow, RH (AL)

3 5812326 1 Foil, Side Panel, RH4 7512232 14 Screw5 2632748-400

2632750-4192632748-1772632748-3412632813-460

11111

Cab, Front, Camo Green Met (AA)Cab, Front, New Break-Up (AC)Cab, Front, Black Met (AF)Cab, Front, Sonic Blue Met (AH)Cab, Front, NBU No Shadow (AL)

6 7670057 12 Nut, U-Type Speed

7 5432088-4005434857-419A5432088-1775432088-3415435139-460A

11111

Cover, Front, Camo Green Met (AA)Cover, Front, New Break-Up (AC)Cover, Front, Black Met (AF)Cover, Front, Sonic Blue (AH)Cover, Front, NBU No Shadow (AL)

8 7517312 2 Screw9 7670135 4 Nut, Push-on10 7517386 3 Screw11 5246872 1 Guard, Splash, LH/Pump Mount12 7517867 2 Screw13 5246021-067 1 Guard, Splash, RH14 7555931 2 Washer, Flat15 7542122 2 Nut, Nylok16 5431798-070

5431799-07011

Guard, Mud, Front, Black, LHGuard, Mud, Front, Black, RH

17 7541925 2 Nut, Nylok18 7555792 2 Washer19 7512085 2 Screw

3/03

A6

REAR RACK MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

2

3

4

6

78

9

10

11

5

2

8



1 1040510-3851040510-067

11

Extender, Rack, Rear (Incl. 11)Extender, Rack, Rear(Incl. 11)(AC)(AL)

2 7517983 2 Screw3 7517685 2 Screw4 2632667-070 1 Asm., Rack, Rear (Incl. Warning Decal)5 5334092 2 Spacer

6 7512329 4 Bolt7 ---- -- -- -- -- -- 1 Bracket, Silencer, Frame (See Ex-

haust System Pg. A11, Ref. 6)8 7558402 8 Washer, Flat9 7542324 4 Nut, Nylok10 1013724-067 1 Support, Rear Rack11 7512310 6 Screw (AC)(AL)

3/03

A7

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


4

6

18

10

5

14

15

21

22

3

8

1

20

2

12

13

19

25

24

7

8

8

8 23

27

26

9

16

22

8

8

7

10

26

18

10

10

710

10

4

11

17

10


A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN



1 1040526-3851040526-067

11

Extender, Front RackExtender, Front Rack (AC)(AL)

2 7517685 4 Screw3 2632666-070 1 Asm., Front Rack (Incl. Warning Decal)4 7512232 6 Screw5 1013744-067

1013746-06711

Support, Front Rack, LHSupport, Front Rack, RH

6 243101424310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

7 7542324 8 Nut, Nylok8 7515399 14 Screw9 5432387 4 Insert10 7558402 12 Washer, Flat11 7556175 2 Washer, Flat12 7512392 4 Screw13 1014020-067 1 Support, Front Rack14 5434001-070 1 Bumper

15 7515306 4 Screw16 5434002-070 1 Panel17 7512093 2 Screw18 7512329 2 Screw19 1013667-067 1 Guard, Brush20 7512097 6 Screw21 7670094 6 Nut, U-Type22 5434314

543431511

Shield, Side, Radiator, LHShield, Side, Radiator, RH

23 5410774 4 Grommet24 5434313

5435046

1

1

Cover, Radiator(If built before 11/01/02)Cover, Radiator(If built after 11/01/02)

25 5244808-0675247137-067

11

Grill (If built before 11/01/02)Grill (If built after 11/01/02)

26 7518046 4 Screw27 5245767-067 1 Bracket, Bumper, Lower

3/03

A9

DECALSSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


RH

LH

16

3 54

8

18

7

1315

17

19

16

2

1

14

12

10

9

11



1 7170912 2 Decal, Warning, Front/Rear Rack2 7170730

71707317170948717094971706927170693

111111

Decal, “4X4”, Side Panel, LH (AA)(AF)Decal, “4X4”, Side Panel, RH (AA)(AF)Decal, “4X4”, Side Panel, LH (AC)(AL)Decal, “4X4”, Side Panel, RH (AC)(AL)Decal, “4X4”, Side Panel, LH (AH)Decal, “4X4”, Side Panel, RH (AH)

3 7078253 1 Decal, Age Warning4 7079780 1 Decal, Warning AWD Switch5 7078003 1 Decal, Headlight Adjustment6 7170728

7170729717070271707037170735717073671706887170689

11111111

Decal, “SPORTSMAN 700”, LH (AA)Decal, “SPORTSMAN 700”, RH (AA)Decal, “SPORTSMAN 700”, LH (AC)(AL)Decal, “SPORTSMAN 700”, RH (AC)(AL)Decal, “SPORTSMAN 700”, LH (AF)Decal, “SPORTSMAN 700”, RH (AF)Decal, “SPORTSMAN 700”, LH (AH)Decal, “SPORTSMAN 700”, RH (AH)

7 7078465 1 Logo, Polaris Star8 7170694

707977311

Decal, “POLARIS”, Front CoverDecal, “POLARIS”, Front Cover (AC)(AL)

9 7079926 2 Decal, Reflector, Amber10 7079927 2 Decal, Reflector, Red11 7171067 1 Decal, Cover, Front, New Break-Up

(AC)(AL)12 7079672 1 Decal, Foot Brake13 7079604 1 Decal, Override Switch, AWD14 7170690

71706917170950

7170951

111

1

Decal, “POLARIS”, Side Panel, LHDecal, “POLARIS”, Side Panel, RHDecal, “POLARIS”, Side Panel, LH(AC)(AL)Decal, “POLARIS”, Side Panel, RH(AC)(AL)

15 7077920 1 Decal, Passenger Warning16 7079959 1 Decal, “POLARIS”, Rear17 7079084 1 Decal, Tire Pressure/Load18 7171383 1 Decal, Discretionary Warning19 7079083 1 Decal, Warning, General, CPSC

3/03

A10

COOLING SYSTEMSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


101

3536

20

37

33

13

17

11

1514

3

122

25

26

30

6

29

3124

24

17187

19

32

3

5

2140

38

34

2728

16

89

8

3922

2317

3

19

20

24

3

4



1 1240044 1 Cap, Pressure2 5434325 1 Filler, Coolant3 7512084 7 Screw4 5521644 1 Guard, Hose5 7042089 1 Retainer, Hose6 5412311 1 Hose, Filler Neck7 7080827 1 Clamp, 1 Inch8 7080003 4 Clamp, Hose9 8450040-150 AR Line, Fuel10 5430743 1 Cap, Overflow, Drilled11 5810279 1 Gasket, Overflow Cap12 5433774 1 Plug, Cap13 5431673 1 Tank, Surge14 7052065 1 Fitting, Barbed, 90 Degree15 8450003-1525 1 Line, Fuel16 7080307 1 Clamp, Hose17 7080826 3 Clamp18 5412030 1 Hose, Engine, Upper19 7080614 2 Clamp, Hose20 5521597 2 Hose, Guard

21 5246656 1 Bracket, Radiator Mount, Upper22 7518014 2 Screw23 7556196 2 Washer24 7547197 6 U-Clip25 4010161 1 Sensor, Thermal26 1240103 1 Radiator27 5411975 2 Grommet28 7515179 2 Screw29 7052296 1 Valve, Drain30 5410584 2 Bushing, Mount31 5245773-067 1 Bracket, Radiator, Lower32 7517386 2 Screw33 5434171 1 Shroud, Fan34 4010631 1 Clip, Wiring35 2410288 1 Asm., Fan and Motor36 7517975 4 Screw37 5412313 1 Hose, Engine, Lower38 7052282 1 Connector, Tee39 7081047 2 Clamp40 5412312 1 Hose

9/02

A11

EXHAUST SYSTEMSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


2411

15

9

4

1

12

2

18

6

5

3

10

1

2

34

5

10

9

14 23

20 21

13

13

16

19

19

19

18

22

2526

78

17

17


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 7542324 2 Nut, Nylok2 7555716 2 Washer, Flat3 5010192 2 Bushing4 5410436 2 Washer, Rubber5 7555863 2 Washer6 5241663 1 Bracket, Silencer, Frame7 7558402 8 Washer, Flat8 7512329 4 Bolt9 5410241 2 Dampener, Vibration10 7515316 2 Bolt, Carriage11 1261223-029 1 Silencer, Exhaust12 7512666 1 Bolt13 3610047 2 Seal, Exhaust

14 7041804 2 Spring, Exhaust15 1261242-029 1 Pipe, Exhaust16 5244014 1 Shield, Heat17 7555935 5 Washer18 7515197 5 Screw19 7041789 3 Spring, Exhaust20 7542301 1 Nut21 3110064 1 Mount, Torque Stop22 7547101 1 Nutsert23 1261077-029 1 Manifold24 5245502 1 Shield, Heat, Exhaust25 7512329 4 Bolt26 7558402 4 Washer, Flat

9/02

A12

FUEL TANKSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


4

18

14

13

16

9

10

1

19

5

3

6

7

11

2

8

17

8

7

12

15



1 5433687 1 Cap, Gas Tank (Incl. 19)2 8360009-600 AR Line, Fuel3 5812265 1 Seal, Foam4 2520203 1 Asm., Fuel Tank (Incl. 13,14,18)5 5182004 1 Foil, Fuel Tank6 7052161 1 Valve, 3-Way7 7080003 4 Clamp, Hose, Red8 8450040-600 AR Line, Fuel9 5432733 1 Nut, Fuel Valve10 5432559 1 Knob, Fuel Valve

11 7517505 1 Screw12 8450080-65 2 Sheath, Foil13 7052150 1 Fitting, Fuel Outlet, Main14 7052149 1 Fitting, Fuel Outlet, Reserve15 5812005 1 Foil, Fuel Tank16 5246069-067

5246070-06711

Bracket, Mounting, Rear, LHBracket, Mounting, Rear, RH

17 7517685 2 Bolt18 5431053 1 Vent, Tank19 5812123 1 Gasket

6/02

A13

ENGINE MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


28

37

2625

10

38 36

32

39

15

41

8 9

4

14

35

24

3

22

21

3334

27

30 29

16

8

8

8

9

23

24

31

26

24

24

8

811

40

13

12

6

12

7

5

17

1819

20

7

42


A14

ENGINE MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN



1 7517867 2 Screw2 7558301 2 Washer, Flat3 2520227 1 Pump, Fuel4 7546601 2 Nut, Nylok5 7512329 4 Bolt6 5243829 1 Strap, Fuel Pump Mounting7 7541923 2 Nut, Well8 7080003 8 Clamp, Hose9 8450040--600 AR Line, Fuel10 2530009 2 Filter11 8450080-50 1 Sheath, Foil12 2202082 1 Kit, Short Block, ATV NOTE: The

Short Block assembly contains acrankcase assembly, cylinder & cylin-der head assembly and a piston &crankshaft assembly. Prior authoriza-tion is required for warranty consider-ation.

13 7555770 2 Washer14 4010132 1 Cable, Ground, Engine15 7517386 4 Screw16 8360009--600 AR Line, Fuel17 5412287 1 Hose, Formed, Vent18 5246647 1 Strap, Carburetor Mounting19 7517867 2 Screw

20 7512247 2 Bolt21 7051011 1 Valve, Check22 7516714 2 Screw23 7552901 2 Washer, Spring Lock24 7547108 6 Nut, Flange Lock25 5244622--067 1 Bracket, Mount, Top26 7555823 3 Washer, Flat27 7517868 1 Screw28 4010470 1 Cable, Black29 5411944 1 Boot, Intake30 7080451 1 Clamp, Hose31 3021119 2 Mount, Rubber32 7518197 1 Screw33 7575202 1 Washer, Interlock34 5210748 1 Washer, Flat35 5430261 1 Bushing36 7552603 2 Washer, Spring Lock37 7512492 2 Screw38 3110044 2 Mount, Rubber, Top39 5244771--067 1 Mount, Lower, Front40 7555823 AR Washer, Flat41 5245043--067 1 Bracket, Torque Stop42 7516734 2 Screw

9/02

B1

AIR BOXSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

4

9

5

25

27

10

28

7

8

2

26

11

3

30

24

6

21

17

29

20

17

17

18

15

14

23

31

1416

19

12

13

22




1 5811633 1 Filter, Precleaner Sleeve2 7080595 1 Filter, Air Intake3 7080413 1 Clamp, Narrow Band4 5433847 1 Sleeve5 5432868 1 Cover, Air Box6 7517317 4 Screw7 5434013 1 Duct, Air Inlet8 5411422 1 Gasket, Intake9 5811482 1 Seal, Air Box Cover10 5433678 1 Box, Air11 5434044 1 Duct, Clutch Air Inlet12 7670102 1 Clip13 5812316 1 Seal, Foam14 7080451 2 Clamp, Hose15 ------ -- -- -- -- 1 Boot, Intake (See Engine Mounting

Pg. A14, Ref. 29)

16 7080511 1 Clamp, Narrow Band17 7080699 3 Clamp, Hose18 8450073-600 AR Line, Breather19 7080694 1 Clamp20 5411966 1 Hose, Breather, Formed21 2530029 1 Filter, Breather22 7080534 1 Clamp, Hose23 5433396 1 Cap, End24 5242044 6 Clip, Air Box25 5432377 1 Plug, Trap26 8450059-150 AR Line, Fuel27 7080650 1 Clamp, Hose28 5811650 1 Foil, Air Box29 7558301 2 Washer, Flat30 7515179 2 Screw31 5412066 1 Boot, Carb

6/02

B2

FRONT DRIVE SHAFTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


4

5

3

21 E 2002 Polaris Sales Inc.



1380199

1380218

2

2

Asm., Drive Shaft(If built before 10/03/02)Asm., Drive Shaft(If built after 10/03/02)

1 7670092 2 Circlip2 1590358 2 Joint, CV

3 2201015 2 Kit, Boot (Incl. Clamps and Grease)4 1380186 2 Shaft (Incl. 5)5 3260104

2202015

2

2

Kit, Cross and Bearing(If built before 10/03/02)Kit, Cross and Bearing(If built after 10/03/02)

9/02

B3

REAR DRIVE SHAFTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


986 73

5

11

42

10

35

1E 2002 Polaris Sales Inc.



1 1380197 2 Asm., Drive Shaft, Rear (Incl. 2-9)2 1590362 1 CV Joint3 1350044 2 Clamp, Large4 1350046 1 Grease, 30g5 1350045 2 Boot6 1350043 2 Clamp, Small

7 1350047 1 Grease, 50g8 1590281 1 Joint, Plunging9 1350042 1 Ring, Spring10 2201374 1 Kit, Boot (Gear Side)11 2201373 1 Kit, Boot (Wheel Side)

12/02

B4

FRONT PROP SHAFTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


2

34

5 7

1

3 6

(If built before 10/03/02)

(If built after 10/03/02)

7

1

2

34

35 6




1380174

1380221

1

1

Asm., Front Prop Shaft(If built before 10/03/02)Asm., Front Prop Shaft(If built after 10/03/02)

1 7661913 1 Pin, Spring2 3260133 1 Yoke, Gear Case, Front3 3260104

2202015

2

2

Kit, Cross and Bearing(If built before 10/03/02)Kit, Cross and Bearing(If built after 10/03/02)

4 1350089 1 Shaft, Bar5 3260131 1 Yoke, Prop Shaft, Transmission6 7080424 1 Fitting, Lubrication7 5411092 1 O-Ring

9/02

B5

REAR PROP SHAFTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


12

311




1380208 1 Asm, Prop Shaft, Rear1 1350039 3 Yoke, Prop Shaft, Rear

2 2202015 2 Kit, Cross and Bearing3 1380197 1 Shaft, Rear

4/03

B6

A-ARM/STRUT MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


14

56

7

89

2

11

13

14

12

15

16

18

17

1920

24

2326

25

22

21

27

3

10

14

25

26 22




1 7542439 2 Nut, Nylok2 1820805 2 Asm., Tie Rod3 7517909 2 Bolt4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061054 2 Rod End, LH10 5411920 1 Boot, Seal, Rod End11 7556099 4 Washer, Flat12 ------ -- -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B7 for Details)13 7547177 2 Nut14 7661203 4 Pin, Cotter15 7080927 2 Joint, Ball16 5211121 2 Bracket, Ball Joint

17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 7512084 6 Screw21 5433927-070

5433928-070

5435028-070

5435029-070

1

1

1

1

Shield, CV Joint, LH(If built before 11/18/02)Shield, CV Joint, RH(If built before 11/18/02)Shield, CV Joint, LH(If built after 11/18/02)Shield, CV Joint, RH(If built after 11/18/02)

22 5434551 4 Bushing, A-Arm, Long23 5133806 2 Shaft, A-Arm24 2202274

220227511

Kit, A-Frame, LH (Incl. 14,22,23,25,26)Kit, A-Frame, RH (Incl. 14,22,23,25,26)

25 7571611 4 Washer, Dish Lock26 7512492 4 Screw27 7515415 2 Screw

10/02

B7

FRONT STRUTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


22

21

20

1918

17

14

1211

16

158

7

6

5

9

4

3

2

1

10 18

10

10

13




1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7042054-067

7042054-29322

Spring, Compression, BlackSpring, Compression, Red

9 7515339 4 Bolt10 7558402 10 Washer, Flat11 5132301

513230211

Hubstrut, LHHubstrut, RH

12 3514342 2 Bearing, Hubstrut13 7710507 2 Ring, Retaining14 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, LH

(See Front Brake Pg. B9 for Details)15 7080306 2 Fitting, Lubrication16 7552901 4 Washer, Spring Lock17 7512365 4 Screw18 7542324 4 Nut, Nylok19 7080367 2 Clamp, Cable20 5211115 2 Washer21 7041761 2 Strut, Front22 5411608 2 Bumper

3/03

B8

FRONT WHEELSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

2

4

3

6

12

5

8

9

7

11

10




1 7512325 8 Bolt2 5244314 2 Disc, Brake3 7515513 8 Stud4 5133360 2 Hub, Wheel5 1520519

1520587

1520563-067

2

2

2

Rim, Front, Chrome(If built before 6/17/02)Rim, Front, Chrome(If built after 6/17/02)Rim, Front, Black (AC)(AL)

6 5411952 2 Tire (25x8-12)7 7547237 8 Nut, Flange8 7556004 2 Washer9 7542810 2 Nut, Slotted10 5411164 2 Cover, Dust11 7661401 2 Pin, Cotter12 1525017 2 Valve, Rim

3/03

B9

FRONT BRAKESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


11

12

8

9

3

10

4

56

7




1910549 1 Asm., Brake Caliper, LH(Incl. 11-7,9,10)

1910550 1 Asm., Brake Caliper, RH(Incl. 11-7,9,10)

1 7515489 1 Screw, Socket Set2 5132960

51329611930642

111

Caliper, Brake, LHCaliper, Brake, RHKit, Front Brake Boot

3 5410494 1 Boot, Pin Seal

4 1930665 1 Kit, Piston and Seal (Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long8 2201398 1 Kit, Front Brake Pad9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder

4/01

B10

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


5

2

4

3

6




1 5410193 1 O-Ring2 5434113 1 Cover, Throttle Control3 5411439 1 O-Ring

4 7081025 1 Cable, Throttle5 2010205 1 Asm., Throttle Control (Incl. 6)6 2010191 1 Asm., Throttle Clamp

7/03

B11

REAR CALIPERSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1 2 3

4

59

8

12

15,

17

16

14

12,

12

12,

12

15,

17

16

16

16

14

14

14

14,

11

710

6

13




1910455

1910690

1

1

Asm., Brake Caliper(If built before 7/12/02)Asm., Caliper (If built after 7/12/02)

1 7512365 2 Screw2 7552901 2 Washer, Spring Lock3 7558402 2 Washer, Flat4 ---- -- -- -- -- -- 2 Carrier, Bearing5 1910529 1 Bracket, Caliper6 7080960 1 Clamp, Nylon7 7621462 1 Rivet8 ------ -- -- -- -- 1 Line, Brake, Hand, Rear (See Controls

- Master Cylinder/Brake Line Pg. B13,Ref. 9)

9 1910429 1 Line, Brake, Rear, Foot10 7517756 1 Screw11 7670126 1 Clip, Retaining, Dual12 2201873 1 Kit, Anvil Body13 1910538 2 Fitting,Bleed, Compact14 2201870 1 Kit, Slide Bolt15 2201872 1 Kit, Seal16 2201869 1 Kit, Piston and Seal17 2201871

220241411

Kit, Brake Pad (If built before 7/12/02)Kit, Brake Pad (If built after 7/12/02)

9/02

B12

REAR MASTER CYLINDER/FOOT PEDALSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


5

7

2 3

4

129

1011

8

1314

16

4

10

6

1

15

7

7

9




1 7512240 1 Screw2 1930854 1 Reservoir, Brake, Rear3 7542153 1 Nut4 7080003 2 Clamp, Hose5 1910331

1910438

1

1

Hose, Reservoir(If built before 7/15/02)Hose, Reservoir(If built after 7/15/02)

6 1013414-067 1 Mount, Brake7 7517386 3 Screw

8 7661401 1 Pin, Cotter9 7555919 2 Washer10 5433189 2 Bushing, Pivot, Pedal11 1013415-067 1 Rod, Brake12 7041750 1 Spring13 1910301 1 Master Cylinder, Brake, Rear14 7515158 2 Screw15 7042075 1 Spring, Gear Selector Lockout16 1910429 1 Line, Rear Brake, Foot

9/02

B13

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


15

18

9

12

13

14

1617

3

1011

19

2

1

8

7

6

5

4

4




2010196 1 Asm., Master Cylinder1 5411297 1 Boot, Brake Line, Rubber2 5410988 2 Seal3 4110164 1 Switch4 7517899 2 Screw5 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)8 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)

9 1910430 1 Line, Brake, Hand, Rear10 7621462 1 Rivet11 7080539 1 Clamp, Nylon12 8360031-34 1 Conduit13 1910474 1 Line, Brake, Left Front14 7080138 4 Cable Tie15 7512024 2 Screw16 1910475 1 Line, Brake, Right Front17 7052292 1 Fitting, Cross18 1910470 1 Line, Brake, Pod19 1910499 1 Bolt, Banjo

9/01

B14

STEERING POSTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


31

42

5

9

11

7

10

8

2

5

7

112

6




1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1013920-067 1 Post, Steering4 5246732 1 Bracket, Steering Post, Upper5 7512377 2 Bolt, Carriage6 7515321 2 Screw

7 7556162 2 Bushing8 5222393 1 Flangette9 3514352 1 Bearing10 7547158 1 Nut11 7661633 1 Pin, Cotter12 7558402 2 Washer, Flat

6/02

C1

HANDLEBAR and HEADLIGHT PODSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


24

47

29

2

1

5

3332

34

6

12

8

9

13

17

22 19

30

25

23

25

15

1826

14

16

1011

27

20

28

3

31

21


C2

HANDLEBAR and HEADLIGHT PODSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN




1 5434380 1 Bezel2 3280425 1 Cluster3 5412138 1 Mount, Rubber4 7511881 3 Screw5 5434284-400

5434848-419A5434284-3825434284-3415435142-460A

11111

Pod, Headlight, Upper (AA)Pod, Headlight, Upper (AC)Pod, Headlight, Upper (AF)Pod, Headlight, Upper (AH)Pod, Headlight, Upper (AL)

6 7517238 4 Screw7 5433903 1 Spacer, Switch, LH8 4010560 1 Switch, Handlebar9 5433834-070 2 Grip, Handlebar10 5432952 1 Plug11 7517625 1 Screw, Set12 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B13 for details)

13 5244969-067 1 Bracket, Pod Mounting14 7517317 2 Screw15 4032079 1 Knob, Adjusting16 4032078 1 Rod, Adjusting17 2410268

401025311

Asm., HeadlampBulb, Headlight

18 5410163 2 O-Ring19 7081008 1 Cable, Choke20 4010638 1 Receptacle, Pod Mount, 12V

21 2461045 1 Harness, Light, Pod/Accy.22 7542122 4 Nut, Nylok23 5433762-070

5433762-17711

Pod, HeadlightPod, Headlight (AF)

24 7080631 1 Clip, Cable Retaining25 4010390

4010278

4010321

11

1

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, Key, Series 2200, 2300, 2700,2800 NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

26 5433534 1 Cover, Key27 5132382 1 Cap28 4010298 1 Sensor29 7517658 1 Screw30 7080922 1 Nut, Choke31 7670127 1 Clip, Screw32 5242987-067 1 Tube, Handlebar33 ------ -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B10, Ref. 5)34 5631146

563114711

Block, Handlebar, PeggedBlock, Handlebar

1/03

C3

DRIVE CLUTCHSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


17

11

10

9

12

5

6

14

13

5

72

4

1615

31

18

8




1 1520231 1 Clutch, One Way Drive2 7556202 1 Washer, Brass3 5631119 1 Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 7547130 1 Nut, Jam9 3576510 1 Cover, Bearing10 7552801 6 Washer, Spring Lock

11 7512176 6 Bolt12 7041157 1 Spring, Clutch13 1321622 3 Roller and Bushing14 5430945 6 Washer, Multilube15 7512266 3 Bolt, Shoulder16 5631215 3 Weight, Shift, 20-5617 1321971 1 Asm., Drive Clutch, EBS, Wide

(Incl. All Less 12,16)18 7556204 1 Washer, Thrust

4/01

C4

DRIVEN CLUTCHSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


10

3

78

9

13

15

16

17

19

3

2

18

14

12

11

654

1




1 5010409 1 Spacer, Driven2 7556120 2 Bushing3 1321973 1 Asm., Driven Clutch, EBS

(Incl. 5-7,13-19)4 7556203 1 Washer5 7556010 1 Bushing6 7710461 1 Ring, Retaining7 5220646 1 Washer, Domed8 7552901 1 Washer, Spring Lock9 7515382 1 Bolt

10 3211091 1 Belt, Drive11 7517323 3 Screw12 1321977 3 Roller, Taper13 3585710 1 Bearing14 5211115 1 Washer15 3576511 1 Bearing, Moveable, 1 Inch16 7041636 1 Spring17 5132751 1 Ramp, Stationary18 5210753 1 Spacer19 7710448 1 Ring, Retaining

6/02

C5

CLUTCH COVERSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

12

7

6

11

10

1314

15

2

4

3

5

6

89




1 54342352201955

11

Cover, Clutch, InnerKit, Inner Clutch Cover (Incl. 6,15)

2 7517599 5 Bolt/Washer3 5434012 1 Duct, Clutch Outlet4 7080707 2 Clamp, Narrow Band5 5411489 1 Boot, Duct6 7512094 9 Screw7 5434255-070 1 Cover, Clutch, Outer

8 5410542 1 O-Ring9 5434264 1 Plug10 7077666 1 Decal, “Automatic/EBS”, Clutch11 7078689 1 Decal, Warning, Clutch Cover12 5521578 1 Seal, Cover, Clutch, Outer13 7517867 3 Screw14 5244527-067 1 Bracket, Retainer, Seal15 5411918 1 Seal, Cover, Inner

6/02

C6

REAR WHEEL DRIVESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


11

13

3

15

2

1

12

4

14

5

7

9

8

6

10




1 5411164 2 Cover, Dust, Hub2 7661404 2 Pin, Cotter3 7555796 4 Washer, Cone4 1520520

1520588

1520564-067

2

2

2

Rim, Rear, Chrome(If built before 6/17/02)Rim, Rear, Chrome(If built after 6/17/02Rim, Rear, Black (AC)(AL)

5 5133361 2 Hub, Rear Wheel6 5244635 2 Disc, Brake, Rear

7 7710440 2 Ring, Retaining8 3585502 2 Bearing9 5631142 2 Bushing, Bearing Carrier10 7512325 8 Screw11 5411949 2 Tire, 25x11-1212 7515513 8 Stud13 1525017 2 Valve, Rim14 7547237 8 Nut, Flange15 7543005 2 Nut, Castle

3/03

C7

REAR SUSPENSIONSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


24

3725

27

17

13

16

3130

22

36

34

35

32

39

38

28

29

23

5

12

86

10

11

7

4

9

3

2

1

18

14

36

13

1615

154

1318

13

182

33

2

22

4

3

2611

109

20

33

21

14

26

19

1919

19

13


C8

REAR SUSPENSIONSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN

700 A03CH68AH and SPORTSMAN 700 A03CH68ALPart numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.


1 7517231 4 Screw2 7555761 8 Washer, Flat3 5432598 8 Bushing, Stabilizer4 7512329 6 Bolt5 1580107-067 2 Arm, Stabilizer Bar6 7542324 6 Nut, Nylok7 5020827 2 Rod, Linkage, Stabilizer8 5334114-067 1 Bar, Stabilizer Tube9 5434549 2 Bushing, Stabilizer Tube10 7555939 2 Washer11 7558402 8 Washer, Flat12 1541801-067 1 Support, Stabilizer13 5434548 12 Bushing, A-Arm, Short14 7515472 6 Screw15 7512492 4 Screw16 7552603 4 Washer, Spring Lock17 1013766-067

1013767-0671014320-2931014321-293

1111

Arm, Control, Upper, Black, LHArm, Control, Upper, Black, RHArm, Control, Upper, Red, LHArm, Control, Upper, Red, RH

18 5020826 6 Shaft, A-Arm, Short19 7542439 10 Nut, Nylok20 5245140-067 1 Strap, Rear Skid Plate21 7555806 2 Washer, Flat22 5434551 4 Bushing, A-Arm, Long

23 7515433 2 Screw24 5630885 2 Retainer, Spring25 7041453-067

7041453-29322

Spring, Compression, BlackSpring, Compression, Red

26 5433551 2 Sleeve, Shock Protector27 5631014 2 Cam, Adjusting, Spring28 7041959 2 Shock, Rear29 7515415 2 Screw30 5133806 2 Shaft, A-Arm31 1013220-067

1013221-0671014174-2931014175-293

1111

Arm, Control, Lower, Black, LHArm, Control, Lower, , Black, RHArm, Control, Lower, , Red, LHArm, Control, Lower, Red, RH

32 5631142 4 Bushing, Bearing Carrier33 7552614 4 Washer, Lock34 7517873 4 Screw35 7555740 4 Washer, Flat36 5434550 8 Bushing, Control, Lower37 5434022-1038

5434023-10385434890-10385434891-1038

1111

Shield, LH (If built before 8/07/02)Shield, RH (If built before 8/07/02)Shield, LH (If built after 8/07/02)Shield, RH (If built after 8/07/02)

38 7512084 4 Screw39 5133663

513366411

Carrier, Wheel Bearing, LHCarrier, Wheel Bearing

3/03

C9

ELECTRICAL/TAILLIGHTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1 2

3

6 754

1112

22

18

14

13

9

19

10

23

24

2015

26

21

17

162725

2

8

20




1 2461047 1 Harness, Main2 2200593 2 Kit, Circuit Breaker, 20 AMP3 2410320 1 Asm., Taillight, 12V (Incl. 6-12)4 4032045 1 Gasket, Taillight5 4030043 1 Bulb, Taillight6 4032046 1 Lens, Taillight7 4032029 2 Screw, Taillight8 7517386 1 Screw9 5245125-067 1 Strap, Battery Holddown10 4010630 1 Battery, 30 AMP11 4032064 1 Backing, Taillight/Brake Light12 7670054 2 Nut, Speed13 4010470 1 Cable14 2202099 1 Kit, Battery Bolt

15 4010471 1 Cable, Battery/Solenoid16 7512232 2 Screw17 7555859 2 Washer, Flat18 5434037 1 Box, Battery19 5432077 AR Tube, Battery Vent20 7512024 6 Screw21 3085521 1 Switch, Magnetic22 4010376 1 Cable, Solenoid/Starter23 4010796 1 Rectifier, Regulator24 5133182 1 Sink, Heat25 4020139 3 Clip, Rosebud (Small)26 7080138 7 Cable Tie27 7512027 2 Screw

9/02

C10

GEAR SELECTORSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

2

3

10

4

6

11

6

7

5

98

5




1 5412003 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 5435042 2 Mount, Gear Selector5 7515175 2 Screw6 7542122 2 Nut, Nylok

7 1821055 1 Asm., Linkage8 7542324 2 Nut, Nylok9 7558402 2 Washer, Flat10 1013315-067 1 Selector, Gear11 7515306 2 Screw

12/02

C11

FRONT HOUSINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


12

34 5

67

89 10

1112

1314 15 16

17

20

2122

23

2425

26272829

30

3132

3334

3536

37

2329

13

6

18



1341344 1 Asm., Front Gearcase(Incl. 1-16,21-30,33-37)

3233950 1 Gearcase (Incl. 16,27,28)3233951 1 Asm., Drain Plug (Incl. 33,34)3233998 1 Asm., Cover Plate (Incl. 1,3,4)3233953 1 Asm., Race/Output Hub

(Incl. 7,14,15,35)3233954 1 Asm., Clutch (Incl. 9-13,36)3233956 1 Kit, Minor Repair (Incl. 2,21,22,29)3233949 1 Asm., Roll Cage (Incl. 11,36)

1 ------ -- -- -- -- 1 Cover, Output2 ------ -- -- -- -- 1 O-Ring3 ------ -- -- -- -- 1 Insert4 ---- -- -- -- -- -- 1 Coil5 3233925 1 Kit, Shim Set (Incl. Shims)6 3233926 2 Bearing, Roller Ball7 ---- -- -- -- -- -- 1 Hub, Race/Output, Male8 3233928 1 Pin, Dowel9 3233932 1 Bearing, Roller Ball10 3233933 1 Clutch Housing/Ring Gear11 ------ -- -- -- -- 1 Spring12 3233957 1 Kit, Roll13 3233934 2 Ring, Retaining14 ------ -- -- -- -- 1 Bushing

15 ------ -- -- -- -- 1 Hub, Race/Output, Female16 ------ -- -- -- -- 1 Bushing17 8450003-1525 AR Line, Fuel18 7080693 1 Clamp, Hose19 7512024 1 Screw20 7080307 1 Clamp, Hose21 ------ -- -- -- -- 1 O-Ring22 ------ -- -- -- -- 1 Seal23 3233955 11 Kit, Bolt24 3233947 1 Cover, Input25 3233945 1 Bearing, Roller Ball26 3233944 1 Shaft, Pinion, 11T27 ------ -- -- -- -- 1 Bushing28 ------ -- -- -- -- 1 Gearcase, LH29 ------ -- -- -- -- 2 Seal, Oil30 3233942 1 Plug, Oil Fill31 7552603 4 Washer, Spring Lock32 7512492 4 Screw33 ------ -- -- -- -- 1 Plug, Oil Drain34 ------ -- -- -- -- 1 Washer35 3233929 1 Bearing, Needle, Roller Thrust36 ------ -- -- -- -- 1 Roll Cage, Aluminum37 3233924 1 Plate Armature

3/03

C12

TRANSMISSION MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


12

7

10

8

1514

16

16

1415

11

7

1211

9

13

17

7

7

2

3

3 4

1

1

1

6

5

3




-- -- -- -- -- -- -- 1 Asm., Main Gearcase(See Gearcase Pg. C14 for Details)

1 8450003-1525 AR Line, Fuel2 7052075 1 T-Fitting3 7080307 3 Clamp, Hose4 7080756 2 Clip5 7670102 1 Clip6 8450003-1525 AR Line, Fuel7 7547108 6 Nut, Flange, Lock8 7542321 2 Nut, Flange

9 5244599-067 1 Mount, Rear Transmission10 7515398 2 Screw11 7555976 3 Washer, Flat12 7515417 2 Screw13 5245524-067 1 Mount, Transmission14 7552603 4 Washer, Spring Lock15 7515522 4 Bolt16 7517289 4 Screw17 1013134-067 1 Mount, Rear Engine

9/01

C13

GEARCASESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

68

2 34

65

5 68

58

6766

646362

6160

9

5915

10

18

7

1442

43

54

44

15

454856

55

53

4647

49 50

52

14

7

51

4140

38 3736

35

11

2324

11

26272829

3031

3233 34

19

20

21

12

13

16

17

26

24 2329

11

15

15

2019

11

14

2

2225

57

2927 25

39

69


C14

GEARCASESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN



1 3233961 1 Nut2 3233826 8 Screw3 3233827 1 Cover4 3233829 1 Pawl, Detent5 3233869 1 O-Ring6 3233831 1 Shaft, Shift7 3233788 2 Seal8 3233832 1 Gear, 31T9 3233711 1 Plug, Oil Fill10 3233524 1 Tube, Vent11 3233018 4 Bearing12 3233036 1 Chain, Silent13 3233890 1 Shaft, Input14 3233019 4 Bearing15 3233529 4 Pipe, Knock16 3233865 1 Cover, LH17 3233874 1 Seal18 3233910 1 Drum, Shift19 3233858 2 Fork, Shift20 3233859 2 Pin, Dowel21 3233860 1 Rail, Shift Shaft22 3233915 1 Plate, Park23 3233916 1 Engagement Dog24 3233849 2 Spring, Wave25 3233875 3 Engagement Dog26 3233850 2 Ring, Retaining27 3233851 2 Washer28 3233852 1 Gear, 33T29 3233718 2 Bearing, Needle30 3233853 1 Shaft, Reverse31 3233854 1 Sprocket, 24T32 3233855 1 Washer33 3233912 1 Gear, 28T34 3233913 1 Gear, 40T35 3234039 1 Gear, 44T

36 3233608 4 Screw37 3233609 1 Cover, Bearing38 3233106 1 Ring39 3233357 1 Spacer40 3233607 1 Bearing, Ball41 3233606 1 Shaft, Pinion, 10T42 3233619 1 Washer, Thrust43 3233782 1 Sprocket, 22T/18T44 3233621 1 Gear, 31T45 3233911 1 Shaft, Output, Main, Rear46 3233582 1 Button, Thrust47 3233583 AR Shim48 3233611 AR Shim49 3233781 1 Cover, Output, Front50 3233846 17 Screw51 3233777 1 Plug52 3233254 1 Washer53 3233625 1 Shaft, Output, Front54 3233784 1 Chain, Silent55 3233844 1 Sprocket, 22T56 3233552 1 Bushing57 3233917 1 Lockout, Park58 3233867 1 Gearcase, Main59 3233324 1 Washer60 3233548 1 O-Ring61 3233839 1 Gear, 16T62 3233838 1 Disc, Lockout63 3233909 1 Star, Detent64 3233076 1 O-Ring65 3233830 1 Spring, Compression66 3233835 1 Switch67 3233834 1 Ring, Retaining68 3233906 1 Bellcrank69 1341343 1 Asm., Main Gearcase

5/03

D1

REAR GEARCASESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


12 3

4 5

6

9

78

19

1718

16

17

6

54 2

1011 12 13 14

15




1341352 1 Asm., Gearcase, Rear1 3233876 1 Cover, Output, LH2 3233846 8 Screw3 3233524 1 Tube, Vent4 3233254 2 Washer5 3233777 2 Plug6 3233878 2 Seal7 3233583 AR Shim8 3233582 1 Button, Thrust9 3233529 2 Pipe, Knock

10 3233577 1 Bushing11 3233881 1 Shaft, Pinion, 10T12 3233714 1 Bearing, Ball13 3233588 1 O-Ring14 3233882 1 Cover, Input15 3233785 1 Seal16 3233880 1 Gearcase, Housing, Rear17 3233268 2 Bearing, Ball18 3233879 1 Gear, 31T19 3233581 AR Shim

4/01

D2

REAR GEARCASE MOUNTINGSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


14

3

5

2

1

2

2

2

4

45

5

3

2




1 7517878 5 Screw2 7555806 12 Washer, Flat3 7547008 5 Nut, FLEXLOC

4 7512492 6 Screw5 7552603 6 Washer, Spring Lock

4/01

D3

CRANKCASESPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


4

10

11

2

20

1

22

6

16

3

19

17

8

15 14

12

13

21

6

7

11

11

5

18

18

9

20




1 5412114 1 Seal, Flanged2 3514361 1 Bearing, Ball3 7556194 1 Bushing4 3514318 1 Bearing, Ball5 7518007 1 Plug6 1201655

771051211

Asm., Crankcase (Incl.14-22)Ring, Retaining

7 5132753 4 Bearing8 5411184 1 Seal, Oil9 5812364 1 Gasket, Cover10 1202384 1 Cover, Engine, Magneto11 7517950 4 Screw

12 5412048 1 Seal13 3585704 4 Bearing, Main Journal14 7052306 1 Plug, Magnetic15 5812232 1 Washer, Copper16 7517793 9 Screw17 7517792 6 Screw18 7663001 2 Pin, Dowel19 5211785 1 Plate, Baffle20 7516603 6 Bolt21 1201970 1 Pickup, Oil22 5812016 2 O-Ring

11/02

D4

CRANKSHAFT and PISTONSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


6

10

5

98

3

11

2

1

4

32

7




1 2202107 2 Kit, Piston (Incl. 2,3,4)2 3022996 4 Circlip, Piston3 ------ -- -- -- -- 2 Pin, Piston4 2202127 1 Kit, Piston Ring (Incl. Control,Iron, and

Chrome Rings)5 2202109 1 Kit, Crankshaft (Incl. 7, from Crank-

case Pg. D3, Ref. 2,3,4,13)

6 7721117 1 Key, Woodruff7 2202145 1 Kit, Gear Set8 7517865 1 Screw9 7555982 1 Washer10 7721131 1 Key, Woodruff11 5132396 1 Shaft, Balance

9/02

D5

CYLINDER and CYLINDER HEADSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


2

20

23

22

25

12

4

107

16

17

3

6

18

1

8

11

14

15

19

5

13

921

2624


D6

CYLINDER and CYLINDER HEADSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN



1 7517277 2 Screw2 5432533 1 Cover, Breather3 3021352 1 Reed w/Gasket4 7516822 7 Screw5 1201973 1 Cover, Rocker6 5411862 1 Seal7 7517883 6 Screw8 5811511 1 Gasket, Exhaust9 ------ -- -- -- -- 1 Manifold

(See Exhaust System Pg. A11, Ref. 23)10 7516730 4 Screw11 1201657

513142914

Head, CylinderGuide, Valve

12 5812193 1 Gasket, Head13 2202158 1 Kit, Cylinder (Incl. 15)

14 5811455 1 Gasket, Base15 7051534 1 Plug16 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D8, Ref. 48)17 7080681 1 Clamp, Hose18 7516734 2 Screw19 1253415 1 Adapter, Carburetor20 3070195 2 Spark Plug, RC7YC21 7516822 2 Screw22 5631196 1 Cover, Thermostat23 7052308 1 Thermostat24 5411521 1 O-Ring25 4010356 1 Switch, Temperature26 7052135 2 Fitting

5/02

D7

CARBURETORSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


48

38

35

9

50

5

49

12

4

6

4243

39

37

1336

1413

1516

22

20

28

31

30

27

1110

3

23

21

17

25

19

26

41

24

51

4546

87

47

40

3433

32

29

18

44

12


D8

CARBURETORSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN



1 3130507 1 Ring2 3130508 1 E-Ring3 3131449 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131363 1 Needle, Jet (P-6)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130571 1 Jet, Main (#155)12 3131393 2 Cap13 3130515 2 Seal14 3130517 1 Packing15 3130518 1 E-Ring16 3130519 1 Cap17 3130361 1 Pin, Float18 3130594 1 Plate19 3130532 1 O-Ring20 3130520 4 Screw21 3130590 1 Asm., Float Body22 3130521 1 Screw23 3130529 1 Asm., Float24 3130591 1 Screw25 3131360 1 Valve, Needle (1.5)26 3130533 1 O-Ring

27 3131226 1 Jet, Pilot (#47.5)28 3130522 1 O-Ring29 3130523 1 Washer30 3130525 1 Spring31 3130524 1 Adjuster32 3130546 1 Screw, Adjust33 3130545 1 Ring34 3130544 1 Spring35 3130502 1 Valve, Throttle (100)36 3131398 1 Spring37 3130514 1 Ring38 3130501 2 Screw39 ------ -- -- -- -- 1 Asm., Throttle Shaft40 3130543 1 Guide, Cable41 3130535 4 Screw42 3130511 1 Cover43 3130512 1 O-Ring44 3131396 1 Holder, Guide45 3130538 1 Spring46 3131395 1 Asm., Plunger47 3130625 1 Jet, Air (#160)48 1253493 1 Asm., Carburetor (Incl. 1-12)49 3131451 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

9/02

D9

INTAKE and EXHAUSTSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


15

16

1

11

5

9

32

4

10

13

14

11

12

8

76

6




1 1202169 4 Asm., Rocker Arm2 5132402 4 Pushrod3 2202110 1 Kit, Camshaft (Incl. 7)4 5244286 1 Plate, Thrust5 7517598 3 Screw6 2202145 1 Kit, Gear Set 680/7807 7041999 3 Spring, Compression8 7556183 1 Washer, Spring

9 7517865 1 Screw10 5131415 4 Lifter, Valve11 5133141 2 Valve, Exhaust12 5132696 2 Valve, Intake13 5411895 4 Seal, Valve Guide14 7041565 4 Spring, Valve15 5131413 4 Retainer, Spring16 5910042 8 Lock, Valve Stem

6/02

D10

OIL DIPSTICKSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


4

5

3

1

2




1 1202109 1 Asm., Dipstick2 1202110 1 Tube, Oil Fill3 7517795 2 Screw

4 5245805 1 Clamp5 5812016 1 O-Ring

4/01

D11

WATER PUMPSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


11

6

7

32

1

8

9

10

5

4

7

8

8




1 5131419 1 Shaft, Oil/Water Pump2 3584404 1 Bearing3 ------ -- -- -- -- 1 Kit, Gear Set 680/780 (See Intake and

Exhaust Pg. D9, Ref. 6)4 5433684 1 Impeller5 7555874 1 Washer, Flat

6 7546804 1 Nut, Nylok7 7517950 2 Screw8 7516822 5 Screw9 1202019 1 Cover10 5812048 1 O-Ring11 3610075 1 Seal, Water Pump

6/02

D12

OIL PUMPSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


5

2

7

3

6

4

8

9

1




2202159 1 Kit, Oil Pump (Incl. 4,5 from WaterPump Pg. D11, Ref. 1,2,3)

1 2540006 1 Filter, Oil2 2540023 1 Nipple, Oil Filter3 7517807 4 Screw4 5131426 1 Housing, Oil Pump

5 1202079 1 Gerotor6 7661127 1 Pin, Dowel7 7041563 1 Spring8 7556005 1 Washer9 7516824 1 Screw

9/01

D13

MAGNETOSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


54

7

89

12

1415

3

6

12

1613

1011

17




1 5245364 1 Holddown, Wire2 4010709 1 Asm., Stator3 7517847 2 Screw4 7517848 3 Screw5 4060152 1 Asm., Flywheel6 7555907 1 Washer7 7546909 1 Nut8 5812359 1 O-Ring9 1201684 1 Housing, Stator

10 5812283 1 Cover, Sound11 5434310 1 Cover, Outer12 5411564 1 O-Ring13 7517950 10 Screw14 5433820 1 Plug15 4010124-66 2 Wire, Ignition16 4010526 2 Boot, Spark Plug17 4010696 1 Asm., Controller, Ignition (Incl. 15,16)

10/02

D14

STARTING MOTORSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

4

3

2

67


5



1 7516823 2 Screw2 4010417 1 Starter3 7555908 1 Washer, Thrust4 4010418 1 Bendix

5 3514378 1 Bushing, Shaft6 7552616 1 Washer, Lock7 7546705 1 Nut

4/03

E1

TOOL KITSPORTSMAN 700 A03CH68AA and SPORTSMAN 700 A03CH68AC and SPORTSMAN 700 A03CH68AF and SPORTSMAN


1

3

8

2

94

5

6

7

10


Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the PartSmart, which is updated monthly.


1 2873687 1 Kit, Tool (Incl. 2-8)2 2870725 1 Gauge, Tire Pressure3 ------ -- -- -- -- 1 Screwdriver4 ------ -- -- -- -- 1 Wrench, 8-10 Open5 ------ -- -- -- -- 1 Wrench, 9/16 x 1 1/2 Open6 ------ -- -- -- -- 1 Wrench, Plug

7 ------ -- -- -- -- 1 Puller, Spark Plug (Wrench Handle)8 2682572 1 Pouch, Tool Kit9 9918213 1 Owner’s Manual, ‘03 Sportsman

600/70010 2873647 1 Wrench, Torx

12/02

PRINTED IN THE USA PARTS MANUAL PN 9917555 and MICROFICHE PN 9918976 3/03

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SPORTSMAN 700 Rev. 04pi54.com/corp/manuals/Parts/9917555r04.pdf · · 2004-09-14(If built before...

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Transcript of SPORTSMAN 700 Rev. 04pi54.com/corp/manuals/Parts/9917555r04.pdf · · 2004-09-14(If built before...