Sportsman 700 Twin Parts Manual Pn 9918612

SPORTSMAN 700Model #A04CH68ACModel #A04CH68AFModel #A04CH68AHModel #A04CH68AJModel #A04CH68ATModel #A04CH68AV

Rev. 02E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918612 and MICROFICHE PN 9918613 6/03

TABLE OF CONTENTSSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700

A04CH68AJ and SPORTSMAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AVParts 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. . . . . . . . . . . . . . . . . . . . .WINCH ASM. E2. . . . . . . . . . . . . . . . . . . . . . . .

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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-

MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

5

6

1

910

16

15

1718

19

7

13

14

21

38

4

35

3432

31

12

3

33

20

2

2827

8

29

39

26

25

21

E 2003 Polaris Sales Inc.

2322

24

30

11

3736

A4

REAR CAB, SEAT and MAIN FRAMESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 7541925 4 Nut, Nylok2 7555792 4 Washer3 5811107 1 Foil, Rear Cab, Rear4 5432117-400

5435164-4555432117-3415432117-0535435164-456

11111

Cab, Rear, Camo Green Met (AH)Cab, Rear, New Break-Up (AC)(AT)Cab, Rear, Sonic Blue (AF)Cab, Rear, Yellow (AJ)Cab, Rear, Shadowgrass (AV)

5 7511930 2 Bolt6 5246076 1 Retainer, Seat Latch7 7079902 1 Decal, 4 Stroke, Carb/Filter Information8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 4 Washer, Flat11 7556034 4 Washer12 7512085 2 Screw13 5431786 1 Box, Tool14 7517375 2 Screw15 7621403 2 Rivet16 5211033 2 Bracket, Lever Retainer17 1040387 1 Latch, Seat18 7041370 1 Spring, Latch19 2683197-070

2683419-070

2682958-070

11

1

Asm., Seat, BlackAsm., Seat, Black w/Gold Polaris(AT)(AV)Covering, Seat, Black

20 5412067 8 Bumper, Rubber21 5431787 1 Cover, Tool Box22 7517377 4 Screw23 5432280 2 Spacer24 7542153 6 Nut25 7512283 6 Screw26 5244751-067 1 Brace, Frame27 1014260-067 1 Frame, Main28 7542122 8 Nut, Nylok29 7170509 1 Decal, Hitch30 7512232 24 Screw31 5811111 1 Foil, Rear Fender32 5811087 1 Foil33 5811106 2 Foil, Rear Cab, Front34 5434704-070

5434705-07011

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

35 7670057 22 Nut, U-Type Speed36 7555832 2 Washer37 7517312 2 Screw38 7517264

751737644

Screw (LH Side)Screw (RH Side)

39 5432221-0705433929-070

11

Footwell, Black, LHFootwell, Black, RH

6/03

A5

FRONT CABSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


1

3

2

7

14

2120

11 10

17 16

18

219

8

22

6

13

8

65

4

9

10

15

12



1 2632748-4002632818-4552632748-0532632748-3412632818-456

11111

Cab, Front, Camo Green Met (AH)Cab, Front, New Break-Up (AC)(AT)Cab, Front, Yellow (AJ)Cab, Front, Sonic Blue Met (AF)Cab, Front, Shadowgrass (AV)

2 7670057 12 Nut, U-Type Speed3 5432088-400

5435110-400

5435166-4555432088-053

5435110-053

5432088-341

5435110-341

5435166-456

1

1

11

1

1

1

1

Cover, Front, Camo Green Met (AH)(If built before 5/01/03)Cover, Front, Camo Green Met (AH)(If built after 5/01/03)Cover, Front, New Break-Up (AC)(AT)Cover, Front, Yellow (AJ)(If built before 5/01/03)Cover, Front, Yellow (AJ)(If built after 5/01/03)Cover, Front, Sonic Blue Met (AF)(If built before 5/01/03)Cover, Front, Sonic Blue Met (AF)(If built after 5/01/03)Cover, Front, Shadowgrass (AV)

4 7517867 2 Screw5 5246872 1 Guard, Splash, LH/Pump Mount6 7517386 3 Screw7 7670135 4 Nut, Push-on8 7517312 2 Screw9 7670156 2 Clip, Retaining

10 7542122 2 Nut, Nylok11 7556034 2 Washer12 7555859 2 Washer, Flat13 5246021-067 1 Guard, Splash, RH14 5434702-070

5434703-07011

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

15 7515158 2 Screw16 7541925 2 Nut, Nylok17 7555792 2 Washer18 7512085 2 Screw19 5811491 1 Foil, Side Panel, Gen. IV, RH20 5812326 1 Foil, Side Panel, RH21 5433853-177

2632471-1775435167-4552632819-4555433853-0702632471-0705433853-3822632471-3825435335-4562632819-456

1111111111

Panel, Side, Black Met, LH (AH)Panel/Foil, Black Met, RH (AH)Panel, Side, New Break-Up, LH (AC)(AT)Panel/Foil, New Break-Up, RH (AC)(AT)Panel, Side, Black, LH (AJ)Panel/Foil, Black, RH (AJ)Panel, Side, Silver Vapor Met., LH (AF)Panel/Foil, Silver Vapor Met., RH (AF)Panel, Side, Shadowgrass, LH (AV)Panel/Foil, Shadowgrass, RH (AV)

22 7512232 14 Screw

7/03

A6

REAR RACK MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


1

2

3

5

7

8910

11

12

6

2

9


4


1 2871501 1 Kit, Extender, Rack, Rear(Incl. 12)(AC)(AT)(AV)

2 7517983 2 Screw3 7517685 2 Screw4 7555916 2 Washer, Nylon5 2632637-070

2632836-070

11

Asm., Rack, Rear (Incl. Warning Decal)(If built before 2/03/03)Asm., Rack, Rear (Incl. Warning Decal)(If built after 2/03/03)

6 5334092 2 Spacer7 7512329 4 Bolt8 5241663 1 Bracket, Silencer, Frame9 7558402 8 Washer, Flat10 7542324 4 Nut, Nylok11 1013724-067 1 Support, Rear Rack12 7517208 6 Screw (AC)(AT)(AV)

6/03

A7

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


28

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23

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27

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20

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6

25

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22

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11

14

21

218

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18

23

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5

8

28

12

5

26

24

21

19

8


5

A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 1013972-0671013972-418

11

Extender, Front Rack (AC)Extender, Front Rack (AT)(AV)

2 7517685 4 Screw3 7081085 2 Plug4 5434697-070

5435240-070

1

1

Rack, Front, Black(If built before 2/03/03)Rack, Front, Black (If built after 2/03/03)

5 7558402 14 Washer, Flat6 7517208 4 Screw7 2431017

403005922

HeadlightBulb, Replacement, 27W

8 7542324 6 Nut, Nylok9 2632757-070 1 Asm., Bumper, Front, Black

(Incl. Warning Decal)10 7515306 4 Screw11 5434699-070 1 Panel12 7512094 2 Screw13 1014412-067 1 Guard, Brush

14 54343145434315

11

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

15 5412504 4 Grommet, Rubber Mount16 5435046 1 Cover, Radiator17 5247507-067 1 Grill, Brush Guard18 7518046 4 Screw19 7670094 6 Nut, U-Type20 7512097 6 Screw21 7515399 6 Screw22 5245767-067 1 Bracket, Bumper, Lower23 7512329 2 Screw24 7171474

717147511

Decal, Reflector, Amber, LHDecal, Reflector, Amber, RH

25 1014020-067 1 Support, Front Rack26 5810467 1 Plug, Frame27 1014261-067

1014262-06711

Support, Front Rack, LHSupport, Front Rack, RH

28 7512232 6 Screw6/03

A9

DECALSSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


RH

LH

2 74 65

10

17

8

12

14

16

18

15

3

2

13

11

1

19

9



1 7079927 2 Decal, Reflector, Red2 7170912 2 Decal, Warning, Front/Rear Rack3 7171016

717101771714867171487220263471710087171009

1111111

Decal, “4X4”, Side Panel, LH (AH)Decal, “4X4”, Side Panel, RH (AH)Decal, “4X4”, Side Panel, LH (AC)(AT)(AV)Decal, “4X4”, Side Panel, RH (AC)AT)(AV)Kit, Side Panel Decals (AF)Decal, “4X4”, Side Panel, LH (AJ)Decal, “4X4”, Side Panel, RH (AJ)

4 7078253 1 Decal, Age Warning5 7079780 1 Decal, Warning AWD Switch6 7078003 1 Decal, Headlight Adjustment7 7171018

7171019717147671714772202635

11111

Decal, Tank Side, LH (AH)(AJ)Decal, Tank Side, RH (AH)(AJ)Decal, “Sprtmn 700”, LH (AC)(AT)(AV)Decal, “Sprtmn 700”, RH (AC)(AT)(AV)Kit, Tank Side Decals (AF)

8 7078465 1 Logo, Polaris Star9 7171067 1 Decal, Cover, Frt, New Break-Up (AC)(AT)10 7079916

70797737171879

111

Decal, “POLARIS”, Front Cover (AJ)Decal, “POLARIS”, Fr. Cvr. (AC)(AH)(AF)Decal, “POLARIS”, Fr. Cvr. (AT)(AV)

11 7079672 1 Decal, Foot Brake12 7079604 1 Decal, Override Switch, AWD13 7171014

717101571714827171483220263471710067171007

1111111

Decal, Side Panel, LH (AH)Decal, Side Panel, RH (AH)Decal, Side Panel, “700”, LH (AC)(AT)(AV)Decal, Side Panel, “700”, RH (AC)(AT)(AV)Kit, Side Panel Decals (AF)Decal, Side Panel, Top, LH (AJ)Decal, Side Panel, Top, RH (AJ)

14 7077920 1 Decal, Passenger Warning15 7079959

70799607172066

111

Decal, “POLARIS”, Rear (AC)(AF)(AH)Decal, “POLARIS”, Rear (AJ)Decal, “POLARIS”, Rear (AT)(AV)

16 7079084 1 Decal, Tire Pressure/Load17 7171383 1 Decal, Discretionary Warning18 7079083 1 Decal, Warning, General, CPSC19 7171474

717147511

Decal, Reflector, Amber, LHDecal, Reflector, Amber, RH

6/03

A10

COOLING SYSTEMSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 7081174 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 2410413 1 Asm., Fan36 7517975 4 Screw37 5412313 1 Hose, Engine, Lower38 7052282 1 Connector, Tee39 7081047 2 Clamp40 5412312 1 Hose

6/03

A11

EXHAUST SYSTEMSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


2713

18

9

4

1

15

2

21

6

5

3

10

1

2

34

5

10

9

17 26

23 24

16

16

19

22

22

22

21

25

12 11

78

20

20


14


1 7542324 2 Nut, Nylok2 7555716 2 Washer, Flat3 5010192 2 Bushing4 5410436 2 Washer, Rubber5 7555863 2 Washer6 5241663 1 Bracket, Silencer, Frame7 7555935 8 Washer8 7517615 4 Screw9 5410241 2 Dampener, Vibration10 7515316 2 Bolt, Carriage11 7558402 4 Washer, Flat12 7512329 4 Bolt13 1261223-029 1 Silencer, Exhaust14 7556230 1 Washer, Clean Out

15 7512666 1 Bolt16 3610047 2 Seal, Exhaust17 7041804 2 Spring, Exhaust18 1261242-029 1 Pipe, Exhaust19 5244014 1 Shield, Heat20 7555935 5 Washer21 7515197 5 Screw22 7041789 3 Spring, Exhaust23 7542301 1 Nut24 3110064 1 Mount, Torque Stop25 7547101 1 Nutsert26 1261077-029 1 Manifold27 5245502 1 Shield, Heat, Exhaust

6/03

A12

FUEL TANKSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ

4

19

14

13

17

9

10

1

20

5

3

6

7

11

2

8

18

8

7

12

16

15


(Before 2/21/03)

(After 2/21/03)

1314

(See Fuel Tank Pg. E3 for AT and AV Fuel Tank)


1 5433687 1 Cap, Gas Tank (Incl. 20)2 8360009-600 AR Line, Fuel3 5812265 1 Seal, Foam4 2520203

2520363

1

1

Asm., Fuel Tank (Incl. 13,14,19)(If built before 2/21/03)Asm., Fuel Tank (Incl. 13,14,19)(If built after 2/21/03)

5 5812004 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 Valve11 7517505 1 Screw12 8450080-65 2 Sheath, Foil

13 7052150

7052347

1

1

Fitting, Fuel Outlet, Main(If built before 2/21/03)Fitting, Fuel Outlet, Main(If built after 2/21/03)

14 7052149

7052346

1

1

Fitting, Fuel Outlet, Reserve(If built before 2/21/03)Fitting, Fuel Outlet, Reserve(If built after 2/21/03)

15 7052028 2 Grommet16 5812005 1 Foil, Fuel Tank17 5247184

524718511

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

18 7517685 2 Bolt19 5431053 1 Vent, Tank20 5812123 1 Gasket

7/03

A13

ENGINE MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


30

39

2827

10

40 38

34

41

15

43

8 9

4

14

37

26

3

24

23

3536

29

32 31

16

8

8

8

9

25

26

33

28

26

26

8

811

42

13

12

6

12

7

517

18 19

22

44

10

20

21E 2003 Polaris Sales Inc.

A14

ENGINE MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-



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 7542105 2 Nut19 7558301 2 Washer, Flat20 ------ -- -- -- -- 1 Guard, Splash, LH/Pump Mount

(See Front Cab Pg. A5, Ref. 5)

21 3110050 2 Mount, Carb22 7558203 2 Washer23 7051011 1 Valve, Check24 7516714 2 Screw25 7552901 2 Washer, Spring Lock26 7547108 6 Nut, Flange Lock27 5244622--067 1 Bracket, Mount, Top28 7555823 3 Washer, Flat29 7517868 1 Screw30 4010470 1 Cable, Black31 5411944 1 Boot, Intake32 7080451 1 Clamp, Hose33 3021119 2 Mount, Rubber34 7518197 1 Screw35 7575202 1 Washer, Interlock36 5210748 1 Washer, Flat37 5430261 1 Bushing38 7552603 2 Washer, Spring Lock39 7512492 2 Screw40 3110044 2 Mount, Rubber, Top41 5244771--067 1 Mount, Lower, Front42 7555823 AR Washer, Flat43 5245043--067 1 Bracket, Torque Stop44 7516734 2 Screw

9/02

B1

AIR BOXSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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. 31)

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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


5

6

4

32

1




1 1380218 2 Asm., Drive Shaft2 7670092 2 Circlip3 1590358 2 Joint, CV

4 2201015 2 Kit, Boot (Incl. Clamps and Grease)5 1380186 2 Shaft (Incl. 6)6 2202015 2 Kit, Cross and Bearing

12/02

B3

REAR DRIVE SHAFTSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


986 73

5

11

42

10

35




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)

5/03

B4

FRONT PROP SHAFTSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


8

2

3

45

46 7

1




1 1380221 1 Asm., Front Prop Shaft2 7661913 1 Pin, Spring3 3260133 1 Yoke, Gear Case, Front4 2202015 2 Kit, Cross and Bearing

5 1350089 1 Shaft, Bar6 3260131 1 Yoke, Prop Shaft, Transmission7 7080424 1 Fitting, Lubrication8 5411092 1 O-Ring

12/02

B5

REAR PROP SHAFTSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


23

422




1 1380208 1 Asm, Prop Shaft, Rear2 1350039 3 Yoke, Prop Shaft, Rear

3 2202015 2 Kit, Cross and Bearing4 1380179 1 Shaft, Rear

12/02

B6

A-ARM/STRUT MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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, Cotter

15 7080927 2 Joint, Ball16 5211121 2 Bracket, Ball Joint17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 7512084 6 Screw21 5435028-070

5435029-07011

Shield, CV Joint, LHShield, CV Joint, RH

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

12/02

B7

FRONT STRUTSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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

7041985-06722

Spring, CompressionSpring, Compression (AT)(AV)

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

6/03

B8

FRONT WHEELSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 1520587

1520563-0671520696-4551520696-456

2222

Rim, Front, Chrome (AF)(AJ)Rim, Front, Black (AC)(AH)Rim, Front, Break-Up (AT)Rim, Front, Shadowgrass (AV)

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

6/03

B9

FRONT BRAKESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


12

23

9

10

4

11

5

67

8

1




1 1910681

1910682

1

1

Asm., Brake Caliper, LH(Incl. 2-8,10,11)Asm., Brake Caliper, RH(Incl. 2-8,10,11)

2 7515489 1 Screw, Socket Set3 5132960

51329611930642

111

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

4 5410494 1 Boot, Pin Seal

5 1930665 1 Kit, Piston and Seal (Incl. 6-8)6 5410779 1 Ring, Molded Square (.094)7 5410780 1 Ring, Molded Square (.103 x .134)8 5132294 1 Piston, Brake, Long9 2201398 1 Kit, Front Brake Pad10 1910411 1 Mount, Caliper11 5410495 1 Boot, Bushing12 7080352 1 Screw, Bleeder

12/02

B10

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


5

2

4

3

7


6



1 5410193 1 O-Ring2 5434113 1 Cover, Throttle Control3 5411439 1 O-Ring4 7081025 1 Cable, Throttle

5 20102302010234

11

Asm., Throttle Control (Incl. 7)Asm., Throttle Control, Thumb(Incl. 6,7)(AT)(AV)

6 2410420 1 Asm., Thumb Warmer (AT)(AV)7 2010191 1 Asm., Throttle Clamp

7/03

B11

REAR CALIPERSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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

18




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. 10)

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 2202414 1 Kit, Brake Pad18 1910690 1 Asm., Caliper

12/02

B12

REAR MASTER CYLINDER/FOOT PEDALSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 1910438 1 Hose, Reservoir6 1013414-067 1 Mount, Brake7 7517386 3 Screw8 7661401 1 Pin, Cotter

9 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

12/02

B13

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


16

19

10

13

14

15

1718

3

1112

20

2

1

9

8

6

5

4

4

7




1 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 2010196 1 Asm., Master Cylinder8 2201833

7518304

1

2

Kit, Master Cylinder Clamp(Incl. Clamp, Screws)Screw (AT)(AV)

9 2201835 1 Kit, Master Cylinder Lever(Incl. Pin, Lever, Clip)

10 1910430 1 Line, Brake, Hand, Rear11 7621462 1 Rivet12 7080539 1 Clamp, Nylon13 8360031-34 1 Conduit14 1910474 1 Line, Brake, Left Front15 7080138 4 Cable Tie16 7512024 2 Screw17 1910475 1 Line, Brake, Right Front18 7052292 1 Fitting, Cross19 1910470 1 Line, Brake, Pod20 1910499 1 Bolt, Banjo

6/03

B14

STEERING POSTSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 7517428 2 Bolt, Carriage

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

2/03

C1

HANDLEBAR and HEADLIGHT PODSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


29

510

34

2

1

6

3837

39

9

17

11

12

18

22

27 24

35

30

28

30

20

2331

19

21

1415

32

25

33

3

36

26


4

7

16

138

C2

HANDLEBAR and HEADLIGHT PODSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-




1 5434380 1 Bezel2 3280431 1 Cluster3 5412138 1 Mount, Rubber4 4010964 1 Switch, Thumb Warmer, Hi/Lo (AT)(AV)5 7511881 3 Screw6 5434706-400

5435239-4555435330-4555434706-0535434706-3415435330-456

111111

Pod, Headlight, Upper (AH)Pod, Headlight, Upper (AC)Pod, Headlight, Upper (AT)Pod, Headlight, Upper (AJ)Pod, Headlight, Upper (AF)Pod, Headlight, Upper (AV)

7 4010963 1 Switch, Hand Warmer, Hi/Lo (AT)(AV)8 4010970 1 Module, Load Shed (AT)(AV)9 7517238 4 Screw10 5433903 1 Spacer, Switch, LH11 4010592 1 Switch, Handlebar12 5433834-070 2 Grip, Handlebar13 2461213 1 Harness, Wire, Warmers (AT)(AV)14 5432952 1 Plug15 7517625 1 Screw, Set16 2410418 2 Asm., Hand Warmer (AT)(AV)17 ------ -- -- -- -- 1 Asm., Master Cylinder

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

18 5244969-067 1 Bracket, Pod Mounting19 7517317 2 Screw20 4032079 1 Knob, Adjusting21 4032078 1 Rod, Adjusting

22 24102684010253

11

Asm., HeadlampBulb, Headlight

23 5410163 2 O-Ring24 7081008 1 Cable, Choke25 4010638 1 Receptacle, Pod Mount, 12V26 2461045 1 Harness, Light, Pod/Accy.27 7542122 4 Nut, Nylok28 5433762-070

5433762-1775433762-382

1

11

Pod, Headlight, Lower(AC)(AJ)(AT)(AV)Pod, Headlight, Lower (AH)Pod, Headlight, Lower (AF)

29 7080631 1 Clip, Cable Retaining30 4010390

40102784010321

111

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800Blank, 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.

31 5433534 1 Cover, Key32 5132382 1 Cap33 4010298 1 Sensor34 7517658 1 Screw35 7080922 1 Nut, Choke36 7670127 1 Clip, Screw37 5242987-067 1 Tube, Handlebar38 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B10, Ref. 5)39 5631146

563114711

Block, Handlebar, PeggedBlock, Handlebar

6/03

C3

DRIVE CLUTCHSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


9

2

67

8

12

14

15

16

18

2

1

17

13

11

10

543




1 7556120 2 Bushing2 1321973 1 Asm., Driven Clutch, EBS

(Incl. 4-6,12-18)3 7556203 1 Washer4 7556010 1 Bushing5 7710461 1 Ring, Retaining6 5220646 1 Washer, Domed7 7552901 1 Washer, Spring Lock8 7515382 1 Bolt9 3211091 1 Belt, Drive

10 7517323 3 Screw11 1321977 3 Roller, Taper12 3585710 1 Bearing13 5211115 1 Washer14 3576511 1 Bearing, Moveable, 1 Inch15 7041636 1 Spring16 5132751 1 Ramp, Stationary17 5210753 1 Spacer18 7710448 1 Ring, Retaining

12/02

C5

CLUTCH COVERSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


11

13

3

15

2

1

12

4

14

5

7

9

8

6

10




1 54111645412489

22

Cover, Dust, Hub (If built before 7/21/03)Cover, Dust, Hub (If built after 7/21/03)

2 7661404 2 Pin, Cotter3 7555796 4 Washer, Cone4 1520588

1520564-0671520695-4551520695-456

2222

Rim, Rear, Chrome (AF)(AJ)Rim, Rear, Black (AC)(AH)Rim, Rear, Break-Up (AT)Rim, Rear, Shadowgrass (AV)

5 51333615134311

22

Hub, Rear Wheel (If built before 9/29/03)Hub, Rear Wheel (If built after 9/29/03)

6 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

6/03

C7

REAR SUSPENSIONSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-




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 1014320-293

1014321-2931014320-0671014321-067

1111

Arm, Control, Upper, LHArm, Control, Upper, RHArm, Control, Upper, LH (AT)(AV)Arm, Control, Upper, RH (AT)(AV)

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, Long23 7515433 2 Screw

24 5630885 2 Retainer, Spring25 7041453-293

7041453-067

7042311-293

7042311-067

2

2

2

2

Spring, Compression(If built before 6/16/03)Spring, Compression(AT)(AV)(If built before 6/16/03)Spring, Compression(If built after 6/16/03)Spring, Compression(AT)(AV)(If built after 6/16/03)

26 5433551 2 Sleeve, Shock Protector27 5631014 2 Cam, Adjusting, Spring28 7041959 2 Shock, Rear29 7515415 2 Screw30 5133806 2 Shaft, A-Arm31 1014174-293

1014175-2931014174-0671014175-067

1111

Control, Lower, LHControl, Lower, RHControl, Lower, LH (AT)(AV)Control, Lower, RH (AT)(AV)

32 5631142 4 Bushing, Bearing Carrier33 7552614 4 Washer, Lock34 7517873 4 Screw35 7555740 4 Washer, Flat36 5434550 8 Bushing, Control, Lower37 5434890-1038

5434891-103811

Shield, LHShield, RH

38 7512084 4 Screw39 5133663

513366411

Carrier, Wheel Bearing, LHCarrier, Wheel Bearing (RH)

6/03

C9

ELECTRICAL/TAILLIGHTSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


1 2 4

7 865

1213

21

17

15

14

10

18

11

23

24

1916

26

20

2725

2

9

19

3

22




1 24609762461177

11

Harness, Main (If built before 2/24/03)Harness, Main (If built after 2/24/03)

2 2200593 2 Kit, Circuit Breaker, 20 AMP3 4010924 1 Module, Resistor4 2410320 1 Asm., Taillight, 12V (Incl. 7-13)5 4032045 1 Gasket, Taillight6 4030043 1 Bulb, Taillight7 4032046 1 Lens, Taillight8 4032029 2 Screw, Taillight9 7517386 1 Screw10 5247376 1 Strap, Battery Holddown11 4010630 1 Battery, 30 AMP12 4032064 1 Backing, Taillight/Brake Light13 7670054 2 Nut, Speed14 4010470 1 Cable15 2202099 1 Kit, Battery Bolt

16 4010471 1 Cable, Battery/Solenoid(AC)(AF)(AH)(AJ)

17 5434037 1 Box, Battery18 5432077 AR Tube, Battery Vent19 7512024 6 Screw20 3087196

401093011

Switch, Magnetic (If built before 6/26/03)Switch, Magnetic (If built after 6/26/03)

21 4010376 1 Cable, Solenoid/Starter22 2410411 1 Jumper, Harness

(If built 2/03/03 to 3/05/03)23 4010796

4010929

1

1

Rectifier, Regulator(If built before 2/17/03)Rectifier, Regulator(If built after 2/17/03)

24 5133182 1 Sink, Heat25 4020139 3 Clip, Rosebud (Small)26 7080138 7 Cable Tie27 7512027 2 Screw

6/03

C10

GEAR SELECTORSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


2

1

34

56

7 89

10

11

1213

1415

161718

1920

21

23

13

11

4

24

22

1

1

1

5




1 3233956 1 Kit, Minor Repair(Incl. O-Rings and Seals)

2 3233998 1 Asm., Cover Plate(Incl. Output Cover, Insert and Coil)

3 3233925 1 Kit, Shim Set (Incl. Shims)4 3233926 2 Bearing, Roller Ball5 3233953 1 Asm., Race/Output Hub (Incl. 21)6 3233928 1 Pin, Dowel7 3233932 1 Bearing, Roller Ball8 3233933 1 Clutch Housing/Ring Gear9 3233949

------ -- -- -- --

1

1

Asm., Roll Cage(Incl. Spring and Roll Cage)Spring

10 3233957 14 Kit, Roll11 3233934 2 Ring, Retaining, Wire Form

12 ------ -- -- -- -- 1 Bushing13 3233955 11 Kit, Bolt14 3233947 1 Cover, Input15 3233945 1 Bearing, Roller Ball16 3233944 1 Shaft, Pinion, 11T17 ------ -- -- -- -- 1 Bushing18 ------ -- -- -- -- 1 Gearcase, LH19 3233942 1 Plug, Oil Fill20 3233951 1 Asm., Drain Plug

(Incl. Plug and Washer21 3233929 1 Bearing, Needle, Roller Thrust22 3233954 1 Asm., Clutch (Incl. 7-11)23 3233924 1 Plate Armature24 1341344 1 Asm., Front Gearcase

(Incl. 2-12,16-19,20-23)7/03

C12

TRANSMISSION MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


12

7

10

8

1413

15

11

7

1211

9

16

7

2

3

3 4

1

1

1

6

5

3




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 4 Nut, Flange, Lock8 7542321 2 Nut, Flange

9 5244599-067 1 Mount, Rear Transmission10 7515398 2 Screw11 7555976 3 Washer, Flat12 7515417 2 Screw13 7552603 2 Washer, Spring Lock14 7515522 2 Bolt15 7517289 2 Screw16 1013134-067 1 Mount, Rear Engine

6/03

C13

GEARCASESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


1

69

2 34

66

5 68

59

6867

656463

6261

9

6015

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

2019

11

14

2

2225

58

2927 25

39

70

57


C14

GEARCASESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-




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 3234040 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 3233873 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 3234013 1 Clamp, Tie58 3233917 1 Lockout, Park59 3233867 1 Gearcase, Main60 3233324 1 Washer61 3233548 1 O-Ring62 3233839 1 Gear, 16T63 3233838 1 Disc, Lockout64 3233909 1 Star, Detent65 3233076 1 O-Ring66 3233830 1 Spring, Compression67 3233835 1 Switch68 3233834 1 Ring, Retaining69 3233906 1 Bellcrank70 1341343 1 Asm., Main Gearcase

11/02

D1

REAR GEARCASESPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


12 3

4 5

6

9

78

19

1718

16

17

6

54 2

1011 12 13 14

15

20




1 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, Knock10 3233577 1 Bushing

11 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 Shim20 1341352 1 Asm., Gearcase, Rear

4/01

D2

REAR GEARCASE MOUNTINGSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 1201658

771051211

Asm., Engine (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 7518045 6 Screw21 1201970 1 Pickup, Oil22 5812016 2 O-Ring

6/03

D4

CRANKSHAFT and PISTONSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


6

10

5

98

3

11

21

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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-




1 7517277 2 Screw2 5432533 1 Cover, Breather3 3021413 1 Valve, Breather4 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. 26)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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-




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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


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 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


11

6

32

1

7

9

10

5

4

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 7516823 5 Screw8 7517950 2 Screw9 1202019 1 Cover10 5812048 1 O-Ring11 3610075 1 Seal, Water Pump

12/02

D12

OIL PUMPSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


5

2

7

3

6

4

8

9

1

10




1 2540006 1 Filter, Oil2 2540115 1 Nipple, Oil Filter3 7517807 4 Screw4 5131426 1 Housing, Oil Pump5 1202079 1 Gerotor6 7661127 1 Pin, Dowel

7 7041563 1 Spring8 7556005 1 Washer9 7516824 1 Screw10 2202159 1 Kit, Oil Pump (Incl. 4,5 from Water

Pump Pg. D11, Ref. 1,2,3)

4/03

D13

MAGNETOSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


54

7

89

12

1417

3

6

12

1813

1011

19

15

16




1 5245364 1 Holddown, Wire2 4010709

40109012202602

111

Asm., Stator (If built before 2/23/03)Asm., Stator (If built after 2/23/03)Kit, Ignition (Incl. Jumper)

3 7517847 2 Screw4 7517848

751771433

Screw (If built before 2/23/03)Screw (If built after 2/23/03)

5 40601524010899

11

Asm., Flywheel (If built before 2/23/03)Asm., Flywheel (If built after 2/23/03)

6 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 4010897 1 Controller, Ignition (If built after 2/23/03)16 4010898 1 Coil, Ignition (If built after 2/23/03)17 4010124-66 2 Wire, Ignition (If built before 2/23/03)18 4010526 2 Boot, Spark Plug (If built before 2/23/03)19 4010696 1 Asm., Controller, Ingition

(Incl. 17,18)(If built before 2/23/03)

2/03

D14

STARTING MOTORSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


1

4

3

2

56




1 7516823 2 Screw2 4010417 1 Starter3 7555908 1 Washer, Thrust

4 4010418 1 Bendix5 7552616 1 Washer, Lock6 7546705 1 Nut

9/01

E1

TOOL KITSPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-


1

3

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94

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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 9918540

9918983

1

1

Owner’s Manual, ‘04 Sportsman400-700Instruction, Hand/Thumb Warmer Op-eration (AT)(AV)

10 2873647 1 Wrench, Torx6/03

E2

WINCH ASM.SPORTSMAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc. 6

26 19

24

19

19

19

25

16

20

2312

16

6

6

66

6

21

11

17

22

10

13

14

15

1

3

2

4

18

8

5

9

7


1 2410423 1 Asm., Winch Switch2 7518304 2 Screw3 5247139 1 Plate, Switch Mount4 5133010 2 Spacer, Master Cylinder Clamp5 7512247 2 Bolt6 7558402 10 Washer, Flat7 7512329 1 Bolt8 5247570 1 Bracket, Contractor9 7542122 2 Nut, Nylok10 2202253 1 Asm., Hook, Warn Winch11 2202643 1 Asm., Winch, Warn w/Cable12 5247568 1 Plate, Fairlead Mount13 2871462 1 Roller, Fairlead, Warn Winch

14 7515494 2 Screw15 7542451 2 Nut, Nylok16 7512392 4 Screw17 2461220 1 Harness, Front18 2461218 1 Harness, Main19 7542324 10 Nut, Nylok20 5434698-070 1 Bumper, Front21 2431017 2 Asm., Headlight, Bottom Mount22 1014020-067 1 Support, Rack, Front23 5247569 1 Plate Winch Mount24 7515321 4 Bolt25 7515317 4 Screw26 7552901 4 Washer, Spring Lock

6/03

E3

FUEL TANKSPORTSMAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV


(See Fuel Tank Pg. A12 for other Fuel Tank)

1

2

3 4 5

6

7

8

9

10

11

13

1415

18

19

20

21

22

23

12

16

17

10


1 54336875435324

11

Cap, Gas Tank (If built before 7/01/03)Cap, Gas Tank (If built after 7/01/03)

2 5812123 1 Gasket, Fuel Cap3 5812265 1 Seal, Foam4 8360009-600 AR Line, Fuel5 7517685 2 Screw6 5247184

524718511

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

7 5431053 1 Vent, Tank8 5812004 1 Foil, Tank9 8450103 AR Hose, Fuel10 7080003 4 Clamp, Hose, Red11 7052346 1 Fitting, Fuel Outlet, Reserve

12 7052028 1 Grommet13 7517505 1 Screw14 5432559 1 Knob, Fuel Valve15 5432733 1 Nut, Fuel Valve16 5247585 1 Bracket, Fuel Valve17 7661637 2 Rivet18 7052159 1 Valve, On/Off19 2520339 1 Asm., Fuel Tank w/Sender

(Incl. 7,8,11,12,20-23)20 5812005 1 Foil, Tank21 5810858 1 Gasket22 2410289 1 Sender, Fuel23 7512056 5 Screw

6/03

PRINTED IN THE USA PARTS MANUAL PN 9918612 and MICROFICHE PN 9918613 6/03

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Sportsman 700 Twin Parts Manual Pn 9918612

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Transcript of Sportsman 700 Twin Parts Manual Pn 9918612