Sportsman 700 Twin PARTS MANUAL PN 9918743

SPORTSMAN 700Model #A04CH68AKModel #A04CH68ALModel #A04CH68ANModel #A04CH68AO

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918743 and MICROFICHE PN 9918744 6/03

This page left blank intentionally.

TABLE OF CONTENTSSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

Parts 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. . . . . . . . . . . . . . . . . . . .

GGEARCASE 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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

5

6

1

910

16

15

1718

19

7

13

14

20

35

4

34

3331

30

12

3

32

2

2726

8

28

36

25

24

21


2221

23

29

11

A4

REAR CAB, SEAT and MAIN FRAMESPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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

5432117-3415432117-0535435164-455

1111

Cab, Rear, Camo Green Met (AK)Cab, Rear, Sonic Blue Met (AN)Cab, Rear, Med Yellow (AL)Cab, Rear, New Break-Up (AO)

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, Latch

19 2683197-0702682958-070

11

Asm., Seat, BlackCovering, Seat, Black

20 5431787 1 Cover, Tool Box21 7517377 4 Screw22 5432280 2 Spacer23 7542153 6 Nut24 7512283 6 Screw25 5244751-067 1 Brace, Frame26 1014461-067 1 Frame, Main27 7542122 8 Nut, Nylok28 7170509 1 Decal, Hitch29 7512232 22 Screw30 5811111 1 Foil, Rear Fender31 5811087 1 Foil32 5811106 2 Foil, Rear Cab, Front33 5434704-070

5434705-07011

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

34 7670057 22 Nut, U-Type Speed35 7517264

751737644

Screw (LH Side)Screw (RH Side)

36 5432221-0705433929-070

11

Footwell, Black, LHFootwell, Black, RH

6/03

A5

FRONT CABSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

5

7

6

11

18

23

15 14

21 20

22

6

1

12

4

10

17

12

10

98

13

14

19

16



1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5435322-177

2632471-1775435322-3822632471-3825435322-0702632471-0705435335-4552632819-455

11111111

Panel, Side, Black Met, LH (AK)Panel/Foil, Black Met, RH (AK)Panel, Side, Silver Vapor, LH (AN)Panel/Foil, Silver Vapor, RH (AN)Panel, Side, Black, LH (AL)Panel/Foil, Black, RH (AL)Panel, Side, New Break-Up, LH (AO)Panel/Foil, New Break-Up, RH (AO)

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

2632748-3412632748-0532632818-455

1111

Cab, Front, Camo Green Met (AK)Cab, Front, Sonic Blue Met (AN)Cab, Front, Med Yellow (AL)Cab, Front, New Break-Up (AO)

6 7670057 12 Nut, U-Type Speed7 5435110-400

5435110-3415435110-0535435166-455

1111

Cover, Front, Camo Green Met (AK)Cover, Front, Sonic Blue Met (AN)Cover, Front, Med Yellow (AL)Cover, Front, New Break-Up (AO)

8 7517867 2 Screw9 5246872 1 Guard, Splash, LH/Pump Mount10 7517386 3 Screw11 7670135 4 Nut, Push-on12 7517312 2 Screw13 7670156 2 Clip, Retaining14 7542122 2 Nut, Nylok15 7556034 2 Washer16 7555859 2 Washer, Flat17 5246021-067 1 Guard, Splash, RH18 5434702-070

5434703-07011

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

19 7515158 2 Screw20 7541925 2 Nut, Nylok21 7555792 2 Washer22 7512085 2 Screw

6/03

A6

REAR RACK MOUNTINGSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

1

2

4

7

86

9

10

5

1

6


3


1 7517983 2 Screw2 7517685 2 Screw3 7555916 2 Washer, Nylon4 2632836-070 1 Asm., Rack, Rear (Incl. Warning Decal)5 5334092 2 Spacer

6 7558402 8 Washer, Flat7 7512329 4 Bolt8 5241663 1 Bracket, Silencer, Frame9 7542324 4 Nut, Nylok10 1013724-067 1 Support, Rear Rack

6/03

A7

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

26

5

21

3

25

7

8

12

2

18

4

23

11

15

14

19

19

13

20

9

12

19

196

3

16

21

3

3

6

26

10

3

24

22

19

17

6


3

1

27

27

A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO


1 7517685 4 Screw2 5435240-070 1 Rack, Front, Black3 7558402 14 Washer, Flat4 7517208 4 Screw5 2431017

403005922

HeadlightBulb, Replacement, 27W

6 7542324 6 Nut, Nylok7 2632757-070 1 Asm., Bumper, Front, Black

(Incl. Warning Decal)8 7515306 4 Screw9 5434699-070 1 Panel10 7512094 2 Screw11 1014412-067 1 Guard, Brush12 5434314

543431511

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

13 5412504 4 Grommet

14 5435046 1 Cover, Radiator15 5247507-067 1 Grill, Brush Guard16 7518046 4 Screw17 7670094 6 Nut, U-Type18 7512097 6 Screw19 7515399 6 Screw20 5245767-067 1 Bracket, Bumper, Lower21 7512329 2 Screw22 7171474

717147511

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

23 1014020-067 1 Support, Front Rack24 5810467 1 Plug, Frame25 1014261-067

1014262-06711

Support, Front Rack, LHSupport, Front Rack, RH

26 7512232 6 Screw27 7555960 2 Washer, Flat

6/03

A9

DECALSSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

RH

LH

2 74 65

9

16

8

11

13

15

17

14

3

2

12

10

1

18


19


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

71710177171008717100971717997171801

111111

Decal, “4X4”, Side Panel, LH (AK)(AO)Decal, “4X4”, Side Panel, RH (AK)(AO)Decal, “4X4”, Side Panel, LH (AL)Decal, “4X4”, Side Panel, RH (AL)Decal, “4X4”, Side Panel, LH (AN)Decal, “4X4”, Side Panel, RH (AN)

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

717101911

Decal, Tank Side, LHDecal, Tank Side, RH

8 7078465 1 Logo, Polaris Star9 7079773

71718797079916

111

Decal, “POLARIS”, Front Cover (AK)(AN)Decal, “POLARIS”, Front Cover (AO)Decal, “POLARIS”, Front Cover (AL)

10 7079672 1 Decal, Foot Brake11 7079604 1 Decal, Override Switch, AWD12 7171014

71710157171797717179871710067171007

111111

Decal, Side Panel, LH (AK)(AO)Decal, Side Panel, RH (AK)(AO)Decal, Side Panel, LH (AN)Decal, Side Panel, RH (AN)Decal, Side Panel, LH (AL)Decal, Side Panel, RH (AL)

13 7077920 1 Decal, Passenger Warning14 7079959

707996011

Decal, “POLARIS”, Rear (AK)(AN)(AO)Decal, “POLARIS”, Rear (AL)

15 7079084 1 Decal, Tire Pressure/Load16 7171383 1 Decal, Discretionary Warning17 7079083 1 Decal, Warning, General, CPSC18 7171474

717147511

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

19 7171067 1 Decal, New Break-Up6/03

A10

COOLING SYSTEMSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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

543519611

Filler, Coolant (If built before 10/02/03)Filler, Coolant (If built after 10/02/03)

3 7512084 7 Screw4 5521644 1 Guard, Hose5 7042089 1 Retainer, Hose6 5412311 1 Hose, Filler Neck7 7080827 1 Clamp, 1 Inch8 7080003 4 Clamp, Hose

(Qty 2 if built after 10/02/03)9 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 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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

2511

16

9

4

1

13

2

19

6

5

3

10

1

2

34

5

10

9

15 24

21 22

14

14

17

20

20

20

19

23

2627

78

18

18


12

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 7555935 8 Washer8 7517615 4 Screw9 5410241 2 Dampener, Vibration10 7515316 2 Bolt, Carriage11 1261223-029 1 Silencer, Exhaust12 7556230 1 Washer13 7512666 1 Bolt14 3610047 2 Seal, Exhaust

15 7041804 2 Spring, Exhaust16 1261242-029 1 Pipe, Exhaust17 5244014 1 Shield, Heat18 7555935 5 Washer19 7515197 5 Screw20 7041789 3 Spring, Exhaust21 7542301 1 Nut22 3110064 1 Mount, Torque Stop23 7547101 1 Nutsert24 1261077-029 1 Manifold25 5245502 1 Shield, Heat, Exhaust26 7512329 4 Bolt27 7558402 4 Washer, Flat

6/03

A12

FUEL TANKSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

19

7

11

6

1514

1

2

3

18

10

13

4

9

5

10

12


8

20

23

22

21

16

17



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

A13

ENGINE MOUNTINGSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO


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

2202698

1

1

Kit, Short Block, ATV(If built before 10/02/03)Kit, Short Block, 700 ATV(If built after 10/02/03) NOTE: TheShort 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 Washer (If built before 10/02/03)14 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. 9)

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

5247368

1

1

Bracket, Mount, Top(If built before 10/02/03)Bracket, Mount, Top(If built after 10/02/03)

28 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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

4

3

21 E 2003 Polaris Sales Inc.



1380218 2 Asm., Drive Shaft1380186 2 Shaft (Incl. 4)

1 7670092 2 Circlip

2 1590358 2 Joint, CV3 2201015 2 Kit, Boot (Incl. Clamps and Grease)4 2202015 2 Kit, Cross and Bearing

12/02

B3

REAR DRIVE SHAFTSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

875 62

4

10

31

9

24




1380197 2 Asm., Drive Shaft, Rear (Incl. 1-8)1 1590362 1 CV Joint2 1350044 2 Clamp, Large3 1350046 1 Grease, 30g4 1350045 2 Boot5 1350043 2 Clamp, Small

6 1350047 1 Grease, 50g7 1590281 1 Joint, Plunging8 1350042 1 Ring, Spring9 2201374 1 Kit, Boot, Gear Side10 2201373 1 Kit, Boot, Wheel Side

5/03

B4

FRONT PROP SHAFTSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

7

1

2

34

35 6




1380221 1 Asm., Front Prop Shaft1 7661913 1 Pin, Spring2 3260133 1 Yoke, Gear Case, Front3 2202015 2 Kit, Cross and Bearing

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

12/02

B5

REAR PROP SHAFTSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

12

311




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

2 2202015 2 Kit, Cross and Bearing3 1380179 1 Shaft, Rear

12/02

B6

A-ARM/STRUT MOUNTINGSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 7042054-293

7042054-06722

Spring, Compression (AK)(AL)(AN)Spring, Compression (AO)

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 1520563-067

152058722

Rim, Front, Black (AK)(AO)Rim, Front, Chrome (AL)(AN)

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

11

12

8

9

3

10

4

56

7




1910681

1910682

1

1

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

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, .0946 5410780 1 Ring, Molded Square, .103 x .1347 5132294 1 Piston, Brake, Long8 2201398 1 Kit, Front Brake Pad9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder

12/02

B10

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

5

2

4

3

6

1E 2003 Polaris Sales Inc.



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

4 7081025 1 Cable, Throttle5 2010230 1 Asm., Throttle Control (Incl. 2,3,6)6 2010191 1 Asm., Throttle Clamp

6/03

B11

REAR CALIPERSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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




1910690 1 Asm., Caliper1 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 ------ -- -- -- -- 1 Line, Rear Brake, Foot(See Rear Master Cylinder/Foot PedalPg. B12, Ref. 16)

10 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 Pad

6/03

B12

REAR MASTER CYLINDER/FOOT PEDALSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 1910766 1 Line, Rear Brake, Foot

6/03

B13

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)9 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)

10 1910759 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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

23

47

28

2

1

5

3231

33

6

12

8

9

13

17

21 18

29

24

22

24

15

25

14

16

1011

26

19

27

3

30

20


C2

HANDLEBAR and HEADLIGHT PODSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO



1 5434380 1 Bezel2 3280431 1 Cluster3 5412138 1 Mount, Rubber4 7511881 3 Screw5 5434706-400

5434706-3415434706-0535435239-455

1111

Pod, Headlight, Upper (AK)Pod, Headlight, Upper (AN)Pod, Headlight, Upper (AL)Pod, Headlight, Upper (AO)

6 7517238 4 Screw7 5433903 1 Spacer, Switch, LH8 4010592 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 7081008 1 Cable, Choke19 4010638 1 Receptacle, Pod Mount, 12V20 2461045 1 Harness, Light, Pod/Accy.

21 7542122 4 Nut, Nylok22 5433762-177

5433762-3825433762-070

111

Pod, Headlight, Lower (AK)Pod, Headlight, Lower (AN)Pod, Headlight, Lower (AL)(AO)

23 7080631 1 Clip, Cable Retaining24 4011002

40102784010321

111

Switch, Key, 3 Position (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.

25 5433534 1 Cover, Key26 5132382 1 Cap27 4010298 1 Sensor28 7517658 1 Screw29 7080922 1 Nut, Choke30 7670127 1 Clip, Screw31 5242987-067 1 Tube, Handlebar32 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B10, Ref. 5)33 5631146

56311475631517

5631516

1

11

1

Block, Handlebar, Pegged(If built before 9/29/03)Block, Handlebar (If built before 9/29/03)Block, Handlebar, Pegged(If built after 9/29/03)Block, Handlebar (If built after 9/29/03)

6/03

C3

DRIVE CLUTCHSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

11

10

9

12

5

6

14

13

5

72

4

1615

31

17

8




1321971 1 Asm., Drive Clutch, EBS, Wide(Incl. All Less 12,16)

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, Jam

9 3576510 1 Cover, Bearing10 7552801 6 Washer, Spring Lock11 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 7556204 1 Washer, Thrust

4/01

C4

DRIVEN CLUTCHSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

9

2

67

8

12

14

15

16

18

2

1

17

13

11

10

543




1 7556120 2 Bushing2 1321973

1322407

1

1

Asm., Driven Clutch, EBS(Incl. 4-6,12-18)(If built before 7/01/03)Asm., Driven Clutch, EBS(Incl. 4-6,12-18)(If built after 7/01/03)

3 7556203 1 Washer4 7556010 1 Bushing5 7710461 1 Ring, Retaining6 5220646 1 Washer, Domed7 7552901 1 Washer, Spring Lock8 7515382 1 Bolt

9 3211091 1 Belt, Drive10 7517323 3 Screw11 1321977 3 Roller, Taper12 3585710 1 Bearing13 5211115 1 Washer14 3576511 1 Bearing, Moveable, 1 Inch15 7041635 1 Spring16 5132751 1 Ramp, Stationary17 5210753 1 Spacer18 7710448 1 Ring, Retaining

6/03

C5

CLUTCH COVERSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 1520564-067

152058822

Rim, Rear, Black (AK)(AO)Rim, Rear, Chrome (AN)(AL)

5 5133361 2 Hub, Rear Wheel6 5244635 2 Disc, Brake, Rear7 7710440 2 Ring, Retaining

8 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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO



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 1014320-067

1014321-0671014320-2931014321-293

1111

Arm, Control, Upper, LH (AO)Arm, Control, Upper, RH (AO)Arm, Control, Upper, LH (AK)(AN)(AL)Arm, Control, Upper, RH (AK)(AN)(AL)

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 7041453-067

7042311-067

7041453-293

7042311-293

2

2

2

2

Spring, Compression(If built before 6/16/03)(AO)Spring, Compression(If built after 6/16/03)(AO)Spring, Compression(If built before 6/16/03)(AK)(AN)(AL)Spring, Compression(If built after 6/16/03)(AK)(AN)(AL)

26 5433551 2 Sleeve, Shock Protector27 5631014 2 Cam, Adjusting, Spring28 7041959 2 Shock, Rear29 7515415 2 Screw30 5133806 2 Shaft, A-Arm31 1014174-067

1014175-0671014174-2931014175-293

1111

Control, Lower, LH (AO)Control, Lower, RH (AO)Control, Lower, LH (AK)(AN)(AL)Control, Lower, RH (AK)(AN)(AL)

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

1 2 4

7 865

1213

21

17

15

14

10

18

11

22

23

1916

25

20

2624

2

9

19

3




1 2461208 1 Harness, Main2 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, Speed

14 4010470 1 Cable15 2202099 1 Kit, Battery Bolt16 4010471 1 Cable, Battery/Solenoid17 5434037 1 Box, Battery18 5432077 AR Tube, Battery Vent19 7512024 6 Screw20 3087196 1 Switch, Magnetic21 4010376 1 Cable, Solenoid/Starter22 4010929 1 Rectifier, Regulator23 5133182 1 Sink, Heat24 4020139 3 Clip, Rosebud (Small)25 7080138 7 Cable Tie26 7512027 2 Screw

6/03

C10

GEAR SELECTORSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

2

14

56

78

9 1011

12

1315

1617

1819

20

2122

23

26

15

6

24

14

14

7


2

1

3 4

25



1341344

1341497

3233950

1

1

1

Asm., Front Gearcase(If built before 7/14/03)Asm., Front Gearcase(If built after 7/14/03)Asm., Gearcase (Incl. 13,19,20)

3233955 1 Kit, Bolt1 3234163 1 Screw, Set(1341497)2 3233998

3234159

1

1

Asm., Cover Plate (Incl. Output Cover,Insert and Coil)(1341344)Asm., Cover Plate (Incl. Output Cover,Insert and Coil)(1341497)

3 3234164 1 Button, Thrust (1341497)4 3234165 1 Plate, Thrust (1341497)5 3233925

323416111

Kit, Shim Set (Incl. Shims)(1341344)Shim, Armature Plate (1341497)

6 3233926 2 Bearing, Roller Ball7 3233953 1 Asm., Race/Output Hub (Incl. 23)8 3233928 1 Pin, Dowel9 3233932 1 Bearing, Roller Ball (1341344)10 3233933

323416611

Clutch Housing/Ring Gear (1341344)Clutch Housing/Ring Gear (1341497)

11 3234167

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

1

1

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

12 3233957 14 Kit, Roll13 ------ -- -- -- --

323416911

Bushing (1341344)Bushing (1341497)

14 3233956 1 Kit, Minor Repair(Incl. O-Rings and Seals)

15 3233918 11 Bolt16 3233947 1 Cover, Input17 3234112 1 Bearing, Roller Ball18 3233944 1 Shaft, Pinion, 11T19 ------ -- -- -- -- 1 Bushing20 ------ -- -- -- -- 1 Gearcase, LH21 3233942 1 Plug, Oil Fill22 3233951 1 Asm., Drain Plug

(Incl. Plug and Washer)23 3233929 1 Bearing, Needle, Roller Thrust24 3233954

323416811

Asm., Clutch (Incl. 9-12)(1341344)Asm., Clutch (Incl. 10-12)(1341497)

25 3234162 1 Ring, Retaining, Internal26 3233924

323416011

Plate, Armature (1341344)Plate, Armature (1341497)

6/03

C12

TRANSMISSION MOUNTINGSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

11

6

7

9

1312

14

10

6

1110

8

15

6

2

3

3 4

1

1

1

5

3

1




1 8450003-1525 AR Line, Fuel2 7052075 1 T-Fitting3 7080307 3 Clamp, Hose4 7080756 2 Clip5 7670102 1 Clip6 7547108 4 Nut, Flange, Lock7 7512377 2 Bolt, Carriage8 5247348 1 Bracket, Mount, Rear Transmission

9 7542321 2 Nut, Flange10 7555976 3 Washer, Flat11 7515417 2 Screw12 7552603 2 Washer, Spring Lock13 7515522 2 Bolt14 7517289 2 Screw15 1013134-067 1 Mount, Rear Engine

6/03

C13

GEARCASESPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

1

71

23

6

68

57

9

11

7069

676665

64 16

23

21

8

1547

48

57

49

16

505359

58

56

5152

54 55

15

8

4645

43 4241

40

12

2829

12

31323334

3536

3738 39

24

25

26

13

14

1718

31

29 2834

12

16

2524

12

15

2

2730

61

3432 30

44

60


4

22

6362

20

19

10

C14

GEARCASESPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO



1341471 1 Asm., Gearcase1 3233961 1 Nut2 3233826 8 Screw3 3234124 1 Cover4 3234123 1 Gasket5 3233869 1 O-Ring6 3233829 1 Pawl, Detent7 3233831 1 Shaft, Shift8 3233788 2 Seal9 3233832 1 Gear, 31T10 3234143 1 Lable, Oil Fill/Level Check11 3234128 1 Gearcase, Main12 3233018 4 Bearing13 3233036 1 Chain, Silent14 3233890 1 Shaft, Input15 3233019 4 Bearing16 3233794 2 Plug17 3234127 1 Cover, LH18 3233874 1 Seal19 3234042 2 Screw20 3234142 1 Bracket, Transmission Mount21 3233910 1 Drum, Shift22 3233548 1 O-Ring23 3233524 1 Tube, Vent24 3233858 2 Fork, Shift25 3233859 2 Pin, Dowel26 3233860 1 Rail, Shift Shaft27 3233915 1 Plate, Park28 3234040 1 Engagement Dog29 3234144 2 Spring, Wave30 3233875 3 Engagement Dog31 3233850 2 Ring, Retaining32 3233851 2 Washer33 3233852 1 Gear, 33T34 3233718 2 Bearing, Needle35 3233853 1 Shaft, Reverse

36 3233854 1 Sprocket, 24T37 3233855 1 Washer38 3233912 1 Gear, 28T39 3234136 1 Gear, 51T40 3234137 1 Gear, 56T41 3234086 4 Screw42 3234122 1 Cover, Bearing43 3233106 1 Ring44 3233357 1 Spacer45 3233607 1 Bearing, Ball46 3234140 1 Shaft, Pinion, 10T47 3233619 1 Washer, Thrust48 3233873 1 Sprocket, 22T/18T49 3233621 1 Gear, 31T50 3233911 1 Shaft, Output, Main, Rear51 3233582 1 Button, Thrust52 3233583 AR Shim53 3233611 AR Shim54 3234130 1 Cover, Output, Front55 3233846 15 Screw56 3233625 1 Shaft, Output, Front57 3233784 1 Chain, Silent58 3233844 1 Sprocket, 22T59 3233552 1 Bushing60 3234013 1 Clamp, Tie61 3233917 1 Lockout, Park62 3233247 4 Pin, Dowel63 3234043 2 Nut64 3233839 1 Gear, 16T65 3233838 1 Disc, Lockout66 3234082 1 Star, Detent67 3233076 1 O-Ring68 3233830 1 Spring, Compression69 3233835 1 Switch70 3233834 1 Ring, Retaining71 3233906 1 Bellcrank

6/03

D1

REAR GEARCASESPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

12 3

4 5

6

9

78

19

1718

16

17

6

54 2

1011 12 13 14

15




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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

5

14

15

2

23

1

26

8

20

3

22

21

12

19 18

16

17

25

8

11

15

15

7

29

13


9

10

2728

6

4

2423,



1 5412114 1 Seal, Flanged2 3514361 1 Bearing, Ball3 7556194 1 Bushing4 3514318 1 Bearing, Ball (If built after 10/02/03)5 7051530 1 Plug6 7661175 2 Dowel7 7518007 1 Plug8 1202658 1 Asm., Crankcase (Incl.18-26)9 7051531 1 Plug10 7052288 1 Plug11 5132753 2 Bearing12 5411184

541245511

Seal, Oil (If before 10/02/03)Seal, Oil (If after 10/02/03)

13 58123645812511

11

Gasket, Cover (If before 10/02/03)Gasket, Cover (If after 10/02/03)

14 1202384 1 Cover, Engine, Magneto

15 7517950 4 Screw16 5412048 1 Seal17 3585704 2 Bearing, Main Journal18 7052306 1 Plug, Magnetic19 5812232 1 Washer, Copper20 7517793 9 Screw21 7517792 6 Screw22 5211785 1 Plate, Baffle23 7518045 5 Screw (Qty 6 if built after 10/02/03)24 7516603 1 Bolt (If built after 10/02/03)25 1201970

120266311

Pickup, Oil (If before 10/02/03)Pickup, Oil (If after 10/02/03)

26 5812016 2 O-Ring27 3060004 1 Plug28 7710512 1 Ring, Retaining29 7663001 2 Pin, Dowel

6/03

D4

CRANKSHAFT and PISTONSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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

2202702

1

1

Kit, Crankshaft (Incl. 7, from Crank-case Pg. D3, Ref. 2,3,5,17)(If builtbefore 10/02/03)Kit, Crankshaft (Incl. 7, from Crank-case Pg. D3, Ref. 2,3,4,5,17)(If builtafter 10/02/03)

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

6/03

D5

CYLINDER and CYLINDER HEADSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

2

20

23

22

25

12

4

107

16

17

3

6

18

1

8

11

14

15

19

5

13

921

2624


27

D6

CYLINDER and CYLINDER HEADSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO



1 7517277 2 Screw2 5432533 1 Cover, Breather3 3021413 1 Valve, Breather4 7516822 7 Screw5 1201973 1 Cover, Rocker6 5411862 1 Seal7 7517883

751827466

Screw (If built before 10/02/03)Bolt, Head (If built after 10/02/03)

8 5811511 1 Gasket, Exhaust9 ------ -- -- -- -- 1 Manifold

(See Exhaust System Pg. A11, Ref. 24)10 7516730

751823444

Screw (If built before 10/02/03)Screw (If built after 10/02/03)

11 120165730214835131429

114

Head, Cylinder (If built before 10/02/03)Head, Cylinder (If built after 10/02/03)Guide, Valve

12 58121935247359

11

Gasket, Head (If built before 10/02/03)Gasket, Head (If built after 10/02/03)

13 2202158

2202696

1

1

Kit, Cylinder(Incl. 15)(If built before 10/02/03)Kit, Cylinder(Incl. 15)(If built after 10/02/03)

14 58114555247360

11

Gasket, Base (If built before 10/02/03)Gasket, Base (If built after 10/02/03)

15 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

5631390

1

1

Cover, Thermostat(If built before 10/02/03)Cover, Thermostat(If built after 10/02/03)

23 70523087052352

11

Thermostat (If built before 10/02/03)Thermostat (If built after 10/02/03)

24 5411521 1 O-Ring25 4010356 1 Switch, Temperature26 7052135

705214522

Fitting (If built before 10/02/03)Fitting (If built after 10/02/03)

27 7661175 2 Dowel (If built after 10/02/03)

6/03

D7

CARBURETORSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO



1 3130507 1 Ring2 3130508 1 E-Ring3 3131449

313122411

Needle, Jet (If built before 10/02/03)Needle, Jet (If built after 10/02/03)

4 3130752 1 Ring5 3130732 1 Diaphragm6 3131363 1 Jet, Needle, P-67 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130571

313057211

Jet, Main, #155 (If built before 10/02/03)Jet, Main, #157.5 (If built after 10/02/03)

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, #47.528 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, 10036 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, #16048 1253493

1253563

1

1

Asm., Carburetor(Incl. 1-12)(If built before 10/02/03)Asm., Carburetor(Incl. 1-12)(If built after 10/02/03)

49 3131451 1 Spring50 3130503 1 Asm., Cover51 3130592 4 Screw

6/03

D9

INTAKE and EXHAUSTSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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

2202693

1

1

Kit, Camshaft(Incl. 10)(If built before 10/02/03)Kit, Camshaft(Incl. 10)(If built after 10/02/03)

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

513415244

Lifter, Valve (If built before 10/02/03)Lifter, Valve (If built after 10/02/03)

11 51331415133363

22

Valve, Exhaust (If built before 10/02/03)Valve, Exhaust (If built after 10/02/03)

12 5132696 2 Valve, Intake13 5411895 4 Seal, Valve Guide14 7041565 4 Spring, Valve15 5131413 4 Retainer, Spring16 5910042 8 Lock, Valve Stem

6/03

D10

OIL DIPSTICKSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

4

5

3

1

2




1 1202109 1 Asm., Dipstick2 1202110

120262911

Tube, Oil Fill (If built before 10/02/03)Tube, Oil Fill (If built after 10/02/03)

3 7517795 2 Screw4 5245805 1 Clamp5 5812016 1 O-Ring

6/03

D11

WATER PUMPSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

12

7

42

1

8

10

11

6

5

9


3

(If built before 10/02/03)



1 5131419

5133948

1

1

Shaft, Oil/Water Pump(If built before 10/02/03)Shaft, Oil/Water Pump(If built after 10/02/03)

2 3584404 1 Bearing3 7710531 1 Ring, Retaining (If built after 10/02/03)4 ------ -- -- -- -- 1 Kit, Gear Set 680/780

(See Intake and Exhaust Pg. D9, Ref. 6)5 5433684 1 Impeller6 7555874 1 Washer, Flat

7 7546804 1 Nut, Nylok8 7516823

751682255

Screw (If built before 10/02/03)Screw (If built after 10/02/03)

9 7517950 2 Screw10 1202019

563138911

Cover (If built before 10/02/03)Cover (If built after 10/02/03)

11 58120485812508

11

O-Ring (If built before 10/02/03)O-Ring (If built after 10/02/03)

12 3610075 1 Seal, Water Pump

6/03

D12

OIL PUMPSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

5

2

7

3

6

4

8

9

1

10




1 25400062540086

11

Filter, Oil (If built before 10/02/03)Filter, Oil (If built after 10/02/03)

2 2540115 1 Nipple, Oil Filter3 7517807 4 Screw4 5131426

5433852

1

1

Housing, Oil Pump(If built before 10/02/03)Cover, Front (If built after 10/02/03)

5 12020791202588

11

Gerotor (If built before 10/02/03)Gerotor (If built after 10/02/03)

6 7661127 1 Pin, Dowel

7 70415637042203

11

Spring (If built before 10/02/03)Spring (If built after 10/02/03)

8 7556005 1 Washer9 7516824 1 Screw10 2202159

2202699

1

1

Kit, Oil Pump (Incl. 4,5 from WaterPump Pg. D11, Ref. 1,2,4)(If built be-fore 10/02/03)Kit, Oil Pump (Incl. 4,5 from WaterPump Pg. D11, Ref. 1,2,4)(If built after10/02/03)

6/03

D13

MAGNETOSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

54

7

89

12

14

3

6

12

13

1011

15

16




1 5245364 1 Holddown, Wire2 4010901 1 Asm., Stator3 7517847 2 Screw4 7517714 3 Screw5 4010899 1 Asm., Flywheel6 7555907 1 Washer7 7546909

754721311

Nut (If built before 10/02/03)Nut (If built after 10/02/03)

8 58123595412458

11

O-Ring (If built before 10/02/03)O-Ring (If built after 10/02/03)

9 12016841202641

11

Housing, Stator (If built before 10/02/03)Cover, Stator (If built after 10/02/03)

10 5812283 1 Cover, Sound11 5434310

543509911

Cover, Outer (If built before 10/02/03)Cover, Outer (If built after 10/02/03)

12 5411564 1 O-Ring (If built before 10/02/03)13 7517950 10 Screw14 5433820 1 Plug (If built before 10/02/03)15 4010897

401101711

Controller, Ignition (If built before 10/02/03)Controller, Ignition (If built after 10/02/03)

16 4010898 1 Coil, Ignition6/03

D14

STARTING MOTORSPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

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 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

2

7

1

83

4

5

69


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.


2873687 1 Kit, Tool (Incl. 1-7)1 2870725 1 Gauge, Tire Pressure2 ------ -- -- -- -- 1 Screwdriver3 ------ -- -- -- -- 1 Wrench, 8-10 Open4 ------ -- -- -- -- 1 Wrench, 9/16 x 1 1/2 Open5 ------ -- -- -- -- 1 Wrench, Plug

6 ------ -- -- -- -- 1 Puller, Spark Plug (Wrench Handle)7 2682572 1 Pouch, Tool Kit8 9918724

9919070

1

1

Owner’s Manual, ‘04.5 Sportsman400-700Supplement, Owner’s Manual, ’04Sportsman 700

9 2873647 1 Wrench, Torx6/03

This page left blank intentionally.

PRINTED IN THE USA PARTS MANUAL PN 9918743 and MICROFICHE PN 9918744 6/03

Sportsman 700 Twin PARTS MANUAL PN 9918743

Documents

Transcript of Sportsman 700 Twin PARTS MANUAL PN 9918743