PARTS MANUAL PN 9918743 and MICROFICHE PN 9918744 6/03

SPORTSMAN 700
Model #A04CH68AK
Model #A04CH68AL
Model #A04CH68AN
Model #A04CH68AO
E 2003 Polaris Sales Inc.

This page left blank intentionally.

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

Parts Manual

A-- ARM/STRUT MOUNTING . . . . . . . . . . . . . B6

AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1

BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . B13

BRAKE, FRONT . . . . . . . . . . . . . . . . . . . . . B9
BUMPER MOUNTING . . . . . . . . . . . . . . . . . A7-8

CAB, FRONT . . . . . . . . . . . . . . . . . . . . . . . .
CAB, REAR . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIPER, REAR . . . . . . . . . . . . . . . . . . . . .
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . .
CONTROLS - MASTER
CYLINDER/BRAKE LINE . . . . . . . . . . . .
CONTROLS - THROTTLE ASM./CABLE . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . .

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT, FRONT . . . . . . . . . . . . . . . . .
DRIVE SHAFT, REAR . . . . . . . . . . . . . . . . .
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MOUNTING . . . . . . . . . . . . . . . . . .
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . .

FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . .
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HOUSING . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .

A5
A3-4
B10
B11
D7-8
C5
B13
B10
A10
D3
D4
D5-6
D5-6
A9
D10
C3
B2
B3
C4
C9
A13-14
D9
A11
B12
A3-4
C11
A12

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C10

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C13-14
GEARCASE, REAR . . . . . . . . . . . . . . . . . . . D1
GEARCASE MOUNTING, REAR . . . . . . . . . . D2

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2

INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9

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

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D12

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

RACK MOUNTING, FRONT . . . . . . . . . . . . . A7-8

REAR RACK MOUNTING . . . . . . . . . . . . . . . A6
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . C6

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . . . . .
STRUT, FRONT . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION, REAR . . . . . . . . . . . . . . . . .

TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE ASM. . . . . . . . . . . . . . . . . . . . . .
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION MOUNTING . . . . . . . . . . . .

A3-4
D14
B14
B7
C7-8
C9
B10
E1
C12

WATER 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.

REAR CAB, SEAT and MAIN FRAME

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

19

E 2003 Polaris Sales Inc.

17

6
5

18

16
7

14

10

15

13
11

1
32
33

30

12

20

2
21 22

31

23
24

29

34

25
35

28

36

26
27

A3

REAR CAB, SEAT and MAIN FRAME

SPORTSMAN 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.

1
2
3
4

5
6
7
8
9
10
11
12
13
14
15
16
17
18

7541925
7555792
5811107
5432117-400
5432117-341
5432117-053
5435164-455
7511930
5246076
7079902
5811308
7512242
7555859
7556034
7512085
5431786
7517375
7621403
5211033
1040387
7041370

Qty. Description

4
4
1
1
1
1
1
2
1
1
1
4
4
4
2
1
2
2
2
1
1

Nut, Nylok
Washer
Foil, Rear Cab, Rear
Cab, Rear, Camo Green Met (AK)
Cab, Rear, Sonic Blue Met (AN)
Cab, Rear, Med Yellow (AL)
Cab, Rear, New Break-Up (AO)
Bolt
Retainer, Seat Latch
Decal, 4 Stroke, Carb/Filter Information
Foil, Tape, Rear Cab
Screw
Washer, Flat
Washer
Screw
Box, Tool
Screw
Rivet
Bracket, Lever Retainer
Latch, Seat
Spring, Latch

Ref. Part No.

Qty. Description

19 2683197-070
2682958-070
20 5431787
21 7517377
22 5432280
23 7542153
24 7512283
25 5244751-067
26 1014461-067
27 7542122
28 7170509
29 7512232
30 5811111
31 5811087
32 5811106
33 5434704-070
5434705-070
34 7670057
35 7517264
7517376
36 5432221-070
5433929-070

1
1
1
4
2
6
6
1
1
8
1
22
1
1
2
1
1
22
4
4
1
1

Asm., Seat, Black

Covering, Seat, Black
Cover, Tool Box
Screw
Spacer
Nut
Screw
Brace, Frame
Frame, Main
Nut, Nylok
Decal, Hitch
Screw
Foil, Rear Fender
Foil
Foil, Rear Cab, Front
Guard, Mud, Rear, Black, LH
Guard, Mud, Rear, Black, RH
Nut, U-Type Speed
Screw (LH Side)
Screw (RH Side)
Footwell, Black, LH
Footwell, Black, RH
6/03

A4

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

E 2003 Polaris Sales Inc.

5

1
2

22
21 20
9
12

11

10

13
6
19

12

15

18
17

16

14

14

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1 5811491
2 5435322-177
2632471-177
5435322-382
2632471-382
5435322-070
2632471-070
5435335-455
2632819-455
3 5812326
4 7512232
5 2632748-400
2632748-341
2632748-053
2632818-455
6 7670057
7 5435110-400
5435110-341
5435110-053
5435166-455

Qty. Description

Ref. Part No.

1
1
1
1
1
1
1
1
1
1
14
1
1
1
1
12
1
1
1
1

8
9
10
11
12
13
14
15
16
17
18

Foil, Side Panel, Gen. IV, RH

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)
Foil, Side Panel, RH
Screw
Cab, Front, Camo Green Met (AK)
Cab, Front, Sonic Blue Met (AN)
Cab, Front, Med Yellow (AL)
Cab, Front, New Break-Up (AO)
Nut, U-Type Speed
Cover, Front, Camo Green Met (AK)
Cover, Front, Sonic Blue Met (AN)
Cover, Front, Med Yellow (AL)
Cover, Front, New Break-Up (AO)

19
20
21
22

7517867
5246872
7517386
7670135
7517312
7670156
7542122
7556034
7555859
5246021-067
5434702-070
5434703-070
7515158
7541925
7555792
7512085

Qty. Description

2
1
3
4
2
2
2
2
2
1
1
1
2
2
2
2

Screw
Guard, Splash, LH/Pump Mount
Screw
Nut, Push-on
Screw
Clip, Retaining
Nut, Nylok
Washer
Washer, Flat
Guard, Splash, RH
Guard, Mud, Front, Black, LH
Guard, Mud, Front, Black, RH
Screw
Nut, Nylok
Washer
Screw
6/03

A5

REAR RACK MOUNTING

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

2
3
4
E 2003 Polaris Sales Inc.
10

1
5

8
7

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.

1
2
3
4
5

7517983
7517685
7555916
2632836-070
5334092

Qty. Description

2
2
2
1
2

Screw
Screw
Washer, Nylon
Asm., Rack, Rear (Incl. Warning Decal)
Spacer

Ref. Part No.

6
7
8
9
10

7558402
7512329
5241663
7542324
1013724-067

Qty. Description

8
4
1
4
1

Washer, Flat
Bolt
Bracket, Silencer, Frame
Nut, Nylok
Support, Rear Rack
6/03

A6

FRONT RACK and BUMPER MOUNTING

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

E 2003 Polaris Sales Inc.

26

27

26

27
3

25

19

19
6

24

3
3

23

19
9

22

10
3
3

6
11

12

21

19
19

21

20
13
14
15

12

18

16

17

A7

FRONT RACK and BUMPER MOUNTING

SPORTSMAN 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.

7517685
5435240-070
7558402
7517208
2431017
4030059
6 7542324
7 2632757-070

Qty. Description

1
2
3
4
5

4
1
14
4
2
2
6
1

8
9
10
11
12

4
1
2
1
1
1
4

7515306
5434699-070
7512094
1014412-067
5434314
5434315
13 5412504

Screw
Rack, Front, Black
Washer, Flat
Screw
Headlight
Bulb, Replacement, 27W
Nut, Nylok
Asm., Bumper, Front, Black
(Incl. Warning Decal)
Screw
Panel
Screw
Guard, Brush
Shield, Side, Radiator, LH
Shield, Side, Radiator, RH
Grommet

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25
26
27

5435046
5247507-067
7518046
7670094
7512097
7515399
5245767-067
7512329
7171474
7171475
1014020-067
5810467
1014261-067
1014262-067
7512232
7555960

Qty. Description

1
1
4
6
6
6
1
2
1
1
1
1
1
1
6
2

Cover, Radiator
Grill, Brush Guard
Screw
Nut, U-Type
Screw
Screw
Bracket, Bumper, Lower
Screw
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
Support, Front Rack
Plug, Frame
Support, Front Rack, LH
Support, Front Rack, RH
Screw
Washer, Flat
6/03

A8

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

5 6

7
8
19
E 2003 Polaris Sales Inc.

10

RH

11

12

13

14

9
2

15

17

18

16

LH

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.

1 7079927
2 7170912
3 7171016
7171017
7171008
7171009
7171799
7171801
4 7078253
5 7079780
6 7078003
7 7171018
7171019
8 7078465
9 7079773
7171879
7079916

Qty. Description

2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Decal, Reflector, Red

Decal, Warning, Front/Rear Rack
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)
Decal, Age Warning
Decal, Warning AWD Switch
Decal, Headlight Adjustment
Decal, Tank Side, LH
Decal, Tank Side, RH
Logo, Polaris Star
Decal, POLARIS, Front Cover (AK)(AN)
Decal, POLARIS, Front Cover (AO)
Decal, POLARIS, Front Cover (AL)

Ref. Part No.

10 7079672
11 7079604
12 7171014
7171015
7171797
7171798
7171006
7171007
13 7077920
14 7079959
7079960
15 7079084
16 7171383
17 7079083
18 7171474
7171475
19 7171067

Qty. Description

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Decal, Foot Brake

Decal, Override Switch, AWD
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)
Decal, Passenger Warning
Decal, POLARIS, Rear (AK)(AN)(AO)
Decal, POLARIS, Rear (AL)
Decal, Tire Pressure/Load
Decal, Discretionary Warning
Decal, Warning, General, CPSC
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
Decal, New Break-Up
6/03

A9

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

1
3
5

40

11
12
13

2
19

4
6

14

18

3
15

16

17

3
19

10

20
21

20
39 38

17

22
37

23

25

24

17

24
E 2003 Polaris Sales Inc.

36

26
27

28

34

35

29
33
24

31
32

30

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.

1 1240044
2 5434325
5435196
3 7512084
4 5521644
5 7042089
6 5412311
7 7080827
8 7080003
9
10
11
12
13
14
15
16
17
18
19
20

8450040-150
5430743
5810279
5433774
5431673
7052065
8450003-1525
7080307
7080826
5412030
7080614
5521597

Qty. Description

1
1
1
7
1
1
1
1
4
AR
1
1
1
1
1
1
1
3
1
2
2

Cap, Pressure
Filler, Coolant (If built before 10/02/03)
Filler, Coolant (If built after 10/02/03)
Screw
Guard, Hose
Retainer, Hose
Hose, Filler Neck
Clamp, 1 Inch
Clamp, Hose
(Qty 2 if built after 10/02/03)
Line, Fuel
Cap, Overflow, Drilled
Gasket, Overflow Cap
Plug, Cap
Tank, Surge
Fitting, Barbed, 90 Degree
Line, Fuel
Clamp, Hose
Clamp
Hose, Engine, Upper
Clamp, Hose
Hose, Guard

Ref. Part No.

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

5246656
7518014
7556196
7547197
4010161
1240103
5411975
7515179
7052296
5410584
5245773-067
7517386
5434171
4010631
2410413
7517975
5412313
7052282
7081047
5412312

Qty. Description

1
2
2
6
1
1
2
2
1
2
1
2
1
1
1
4
1
1
2
1

Bracket, Radiator Mount, Upper

Screw
Washer
U-Clip
Sensor, Thermal
Radiator
Grommet
Screw
Valve, Drain
Bushing, Mount
Bracket, Radiator, Lower
Screw
Shroud, Fan
Clip, Wiring
Asm., Fan
Screw
Hose, Engine, Lower
Connector, Tee
Clamp
Hose
6/03

A10

EXHAUST SYSTEM
SPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

2
4
5

3
4

E 2003 Polaris Sales Inc.

5
7

8
9

9
10

27 10
26
19

25

11
12

14

13

15

24

16

20
14
17
18

20

19

18
20
23
22

21

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.

1
2
3
4
5
6
7
8
9
10
11
12
13
14

7542324
7555716
5010192
5410436
7555863
5241663
7555935
7517615
5410241
7515316
1261223-029
7556230
7512666
3610047

Qty. Description

2
2
2
2
2
1
8
4
2
2
1
1
1
2

Nut, Nylok
Washer, Flat
Bushing
Washer, Rubber
Washer
Bracket, Silencer, Frame
Washer
Screw
Dampener, Vibration
Bolt, Carriage
Silencer, Exhaust
Washer
Bolt
Seal, Exhaust

Ref. Part No.

15
16
17
18
19
20
21
22
23
24
25
26
27

7041804
1261242-029
5244014
7555935
7515197
7041789
7542301
3110064
7547101
1261077-029
5245502
7512329
7558402

Qty. Description

2
1
1
5
5
3
1
1
1
1
1
4
4

Spring, Exhaust
Pipe, Exhaust
Shield, Heat
Washer
Screw
Spring, Exhaust
Nut
Mount, Torque Stop
Nutsert
Manifold
Shield, Heat, Exhaust
Bolt
Washer, Flat
6/03

A11

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

E 2003 Polaris Sales Inc.

3
23

22
6
21

7
8

17
20

18
16

19

15
14
10

13
12
11
10
9

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.

1 5433687
5435324
2 5812123
3 5812265
4 8360009-600
5 7517685
6 5247184
5247185
7 5431053
8 5812004
9 8450103
10 7080003
11 7052346

Qty. Description

1
1
1
1
AR
2
1
1
1
1
AR
4
1

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

Cap, Gas Tank (If built after 7/01/03)
Gasket, Fuel Cap
Seal, Foam
Line, Fuel
Screw
Bracket, Mounting, Rear, LH
Bracket, Mounting, Rear, RH
Vent, Tank
Foil, Tank
Hose, Fuel
Clamp, Hose, Red
Fitting, Fuel Outlet, Reserve

Ref. Part No.

Qty. Description

12
13
14
15
16
17
18
19

7052028
7517505
5432559
5432733
5247585
7661637
7052159
2520339

1
1
1
1
1
2
1
1

20
21
22
23

5812005
5810858
2410289
7512056

1
1
1
5

Grommet
Screw
Knob, Fuel Valve
Nut, Fuel Valve
Bracket, Fuel Valve
Rivet
Valve, On/Off
Asm., Fuel Tank w/Sender
(Incl. 7,8,11,12,20-23)
Foil, Tank
Gasket
Sender, Fuel
Screw
6/03

A12

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

7
6

20

E 2003 Polaris Sales Inc.

21

17

18 19

10

2
8

22
8
10

11

9 8
16

23

15
14

12

24
13

44
26

25

43
28

42

40

26

26
27

41

29

38
39
30
37

36
35
34

32

28
33
26

A13

31

ENGINE MOUNTING
SPORTSMAN 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.

1
2
3
4
5
6
7
8
9
10
11
12

7517867
7558301
2520227
7546601
7512329
5243829
7541923
7080003
8450040-- 600
2530009
8450080-50
2202082
2202698

13
14
15
16
17
18
19
20

7555770
4010132
7517386
8360009-- 600
5412287
7542105
7558301
-------

Qty. Description

2
2
1
2
4
1
2
8
AR
2
1
1
1

2
1
4
AR
1
2
2
1

Screw
Washer, Flat
Pump, Fuel
Nut, Nylok
Bolt
Strap, Fuel Pump Mounting
Nut, Well
Clamp, Hose
Line, Fuel
Filter
Sheath, Foil
Kit, Short Block, ATV
(If built before 10/02/03)
Kit, Short Block, 700 ATV
(If built after 10/02/03) NOTE: The
Short Block assembly contains a
crankcase assembly, cylinder & cylinder head assembly and a piston &
crankshaft assembly. Prior authorization is required for warranty consideration.
Washer (If built before 10/02/03)
Cable, Ground, Engine
Screw
Line, Fuel
Hose, Formed, Vent
Nut
Washer, Flat
Guard, Splash, LH/Pump Mount
(See Front Cab Pg. A5, Ref. 9)

Ref. Part No.

21
22
23
24
25
26
27

28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Qty. Description

3110050
7558203
7051011
7516714
7552901
7547108
5244622-- 067

2
2
1
2
2
6
1

5247368

7555823
7517868
4010470
5411944
7080451
3021119
7518197
7575202
5210748
5430261
7552603
7512492
3110044
5244771-- 067
7555823
5245043-- 067
7516734

3
1
1
1
1
2
1
1
1
1
2
2
2
1
AR
1
2

Mount, Carb
Washer
Valve, Check
Screw
Washer, Spring Lock
Nut, Flange Lock
Bracket, Mount, Top
(If built before 10/02/03)
Bracket, Mount, Top
(If built after 10/02/03)
Washer, Flat
Screw
Cable, Black
Boot, Intake
Clamp, Hose
Mount, Rubber
Screw
Washer, Interlock
Washer, Flat
Bushing
Washer, Spring Lock
Screw
Mount, Rubber, Top
Mount, Lower, Front
Washer, Flat
Bracket, Torque Stop
Screw
9/02

A14

AIR BOX
SPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

6
1

E 2003 Polaris Sales Inc.

2
5

13

12
31

9
11

30
29

14
10

15
14

28

17
27
26

16
18

17
17

24

19
23

25

22

21
20

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.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

5811633
7080595
7080413
5433847
5432868
7517317
5434013
5411422
5811482
5433678
5434044
7670102
5812316
7080451
-------

Qty. Description

1
1
1
1
1
4
1
1
1
1
1
1
1
2
1

Filter, Precleaner Sleeve

Filter, Air Intake
Clamp, Narrow Band
Sleeve
Cover, Air Box
Screw
Duct, Air Inlet
Gasket, Intake
Seal, Air Box Cover
Box, Air
Duct, Clutch Air Inlet
Clip
Seal, Foam
Clamp, Hose
Boot, Intake (See Engine Mounting
Pg. A14, Ref. 31)

Ref. Part No.

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

7080511
7080699
8450073-600
7080694
5411966
2530029
7080534
5433396
5242044
5432377
8450059-150
7080650
5811650
7558301
7515179
5412066

Qty. Description

1
3
AR
1
1
1
1
1
6
1
AR
1
1
2
2
1

Clamp, Narrow Band

Clamp, Hose
Line, Breather
Clamp
Hose, Breather, Formed
Filter, Breather
Clamp, Hose
Cap, End
Clip, Air Box
Plug, Trap
Line, Fuel
Clamp, Hose
Foil, Air Box
Washer, Flat
Screw
Boot, Carb
6/02

B1

FRONT DRIVE SHAFT

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

E 2003 Polaris Sales Inc.

4
3

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1380218
1380186
1 7670092

Qty. Description

Ref. Part No.

2 Asm., Drive Shaft

2 Shaft (Incl. 4)
2 Circlip

2 1590358
3 2201015
4 2202015

Qty. Description

2 Joint, CV
2 Kit, Boot (Incl. Clamps and Grease)
2 Kit, Cross and Bearing
12/02

B2

REAR DRIVE SHAFT

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

E 2003 Polaris Sales Inc.

1

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1
2
3
4
5

1380197
1590362
1350044
1350046
1350045
1350043

Qty. Description

2
1
2
1
2
2

Asm., Drive Shaft, Rear (Incl. 1-8)

CV Joint
Clamp, Large
Grease, 30g
Boot
Clamp, Small

Ref. Part No.

6
7
8
9
10

1350047
1590281
1350042
2201374
2201373

Qty. Description

1
1
1
1
1

Grease, 50g
Joint, Plunging
Ring, Spring
Kit, Boot, Gear Side
Kit, Boot, Wheel Side
5/03

B3

FRONT PROP SHAFT

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

E 2003 Polaris Sales Inc.

3

2
4

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1380221
1 7661913
2 3260133
3 2202015

Qty. Description

1
1
1
2

Ref. Part No.

Asm., Front Prop Shaft

Pin, Spring
Yoke, Gear Case, Front
Kit, Cross and Bearing

4
5
6
7

1350089
3260131
7080424
5411092

Qty. Description

1
1
1
1

Shaft, Bar
Yoke, Prop Shaft, Transmission
Fitting, Lubrication
O-Ring
12/02

B4

REAR PROP SHAFT

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

E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1380208
1 1350039

Qty. Description

Ref. Part No.

1 Asm, Prop Shaft, Rear

3 Yoke, Prop Shaft, Rear

2 2202015
3 1380179

Qty. Description

2 Kit, Cross and Bearing

1 Shaft, Rear
12/02

B5

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

E 2003 Polaris Sales Inc.

5
3

6
7
8

10

27

11
25
26

25

26

12

22

13

24
23

14
15
16

22

17
21
20

18
14

19

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.

1
2
3
4
5
6
7
8
9
10
11
12

7542439
1820805
7517909
5411291
7061034
7542711
5020926
7547028
7061054
5411920
7556099
-------

13 7547177
14 7661203

Qty. Description

2
2
2
2
2
2
2
2
2
1
4
1

Nut, Nylok
Asm., Tie Rod
Bolt
Boot, Seal, Rod End
Rod End
Nut
Tie Rod
Nut, LH
Rod End, LH
Boot, Seal, Rod End
Washer, Flat
Asm., Hubstrut
(See Front Strut Pg. B7 for Details)
2 Nut
4 Pin, Cotter

Ref. Part No.

15
16
17
18
19
20
21
22
23
24
25
26
27

7080927
5211121
7512284
5410548
7542438
7512084
5435028-070
5435029-070
5434551
5133806
2202274
2202275
7571611
7512492
7515415

Qty. Description

2
2
4
2
2
6
1
1
4
2
1
1
4
4
2

Joint, Ball
Bracket, Ball Joint
Screw
Boot, Rubber
Nut, Castle
Screw
Shield, CV Joint, LH
Shield, CV Joint, RH
Bushing, A-Arm, Long
Shaft, A-Arm
Kit, A-Frame, LH (Incl. 14,22,23,25,26)
Kit, A-Frame, RH (Incl. 14,22,23,25,26)
Washer, Dish Lock
Screw
Screw
12/02

B6

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

1
22

2
3

E 2003 Polaris Sales Inc.

21

5
19
6

18

20

17

16

10

10 18
8

15
14

9 10

11

12

13

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.

1
2
3
4
5
6
7
8

7547104
7555749
5810291
5432872
5132062
5432871
5243364
7042054-293
7042054-067
9 7515339
10 7558402
11 5132301
5132302

Qty. Description

2
2
2
2
2
2
2
2
2
4
10
1
1

Nut, Nylok
Washer
Spacer, Rubber
Ball, Pivot, Top
Spacer
Ball, Pivot, Bottom
Retainer, Spring
Spring, Compression (AK)(AL)(AN)
Spring, Compression (AO)
Bolt
Washer, Flat
Hubstrut, LH
Hubstrut, RH

Ref. Part No.

12 3514342
13 7710507
14 - - - - - - 15
16
17
18
19
20
21
22

7080306
7552901
7512365
7542324
7080367
5211115
7041761
5411608

Qty. Description

2 Bearing, Hubstrut
2 Ring, Retaining
1 Asm., Front Brake Caliper, LH
(See Front Brake Pg. B9 for Details)
2 Fitting, Lubrication
4 Washer, Spring Lock
4 Screw
4 Nut, Nylok
2 Clamp, Cable
2 Washer
2 Strut, Front
2 Bumper
6/03

B7

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

1
2

3
E 2003 Polaris Sales Inc.
4

5
6

7
8
9
10
12
11

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.

1
2
3
4
5

7512325
5244314
7515513
5133360
1520563-067
1520587
6 5411952

Qty. Description

8
2
8
2
2
2
2

Bolt
Disc, Brake
Stud
Hub, Wheel
Rim, Front, Black (AK)(AO)
Rim, Front, Chrome (AL)(AN)
Tire, 25x8-12

Ref. Part No.

7
8
9
10
11
12

7547237
7556004
7542810
5411164
7661401
1525017

Qty. Description

8
2
2
2
2
2

Nut, Flange
Washer
Nut, Slotted
Cover, Dust
Pin, Cotter
Valve, Rim
6/03

B8

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

4
11

5
6
7

10
E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1910681
1910682
1 7515489
2 5132960
5132961
1930642
3 5410494

Qty. Description

1 Asm., Brake Caliper, LH

(Incl. 1-7,9,10)
1 Asm., Brake Caliper, RH
(Incl. 1-7,9,10)
1 Screw, Socket Set
1 Caliper, Brake, LH
1 Caliper, Brake, RH
1 Kit, Front Brake Boot
1 Boot, Pin Seal

Ref. Part No.

4
5
6
7
8
9
10
11

1930665
5410779
5410780
5132294
2201398
1910411
5410495
7080352

Qty. Description

1
1
1
1
1
1
1
1

Kit, Piston and Seal (Incl. 5-7)

Ring, Molded Square, .094
Ring, Molded Square, .103 x .134
Piston, Brake, Long
Kit, Front Brake Pad
Mount, Caliper
Boot, Bushing
Screw, Bleeder
12/02

B9

CONTROLS - THROTTLE ASM./CABLE

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

E 2003 Polaris Sales Inc.

2
3

4
5

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.

1 5410193
2 5434113
3 5411439

Qty. Description

1 O-Ring
1 Cover, Throttle Control
1 O-Ring

Ref. Part No.

4 7081025
5 2010230
6 2010191

Qty. Description

1 Cable, Throttle
1 Asm., Throttle Control (Incl. 2,3,6)
1 Asm., Throttle Clamp
6/03

B10

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

12
13
12
14
15, 16

E 2003 Polaris Sales Inc.

14
16
16

4
1

14

15, 16
17
12, 14
12
9

12, 14, 17

10
11

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.

1
2
3
4
5
6
7
8

1910690
7512365
7552901
7558402
------1910529
7080960
7621462
-------

Qty. Description

1
2
2
2
2
1
1
1
1

Asm., Caliper
Screw
Washer, Spring Lock
Washer, Flat
Carrier, Bearing
Bracket, Caliper
Clamp, Nylon
Rivet
Line, Brake, Hand, Rear (See Controls
- Master Cylinder/Brake Line Pg. B13,
Ref. 10)

Ref. Part No.

9 ------10
11
12
13
14
15
16
17

7517756
7670126
2201873
1910538
2201870
2201872
2201869
2202414

Qty. Description

1 Line, Rear Brake, Foot

(See Rear Master Cylinder/Foot Pedal
Pg. B12, Ref. 16)
1 Screw
1 Clip, Retaining, Dual
1 Kit, Anvil Body
2 Fitting,Bleed, Compact
1 Kit, Slide Bolt
1 Kit, Seal
1 Kit, Piston and Seal
1 Kit, Brake Pad
6/03

B11

REAR MASTER CYLINDER/FOOT PEDAL

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

1
4

16

6
4
7

15
14

13
12
10

E 2003 Polaris Sales Inc.

11
9

10
7

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.

1
2
3
4
5
6
7
8

7512240
1930854
7542153
7080003
1910438
1013414-067
7517386
7661401

Qty. Description

1
1
1
2
1
1
3
1

Screw
Reservoir, Brake, Rear
Nut
Clamp, Hose
Hose, Reservoir
Mount, Brake
Screw
Pin, Cotter

Ref. Part No.

9
10
11
12
13
14
15
16

7555919
5433189
1013415-067
7041750
1910301
7515158
7042075
1910766

Qty. Description

2
2
1
1
1
2
1
1

Washer
Bushing, Pivot, Pedal
Rod, Brake
Spring
Master Cylinder, Brake, Rear
Screw
Spring, Gear Selector Lockout
Line, Rear Brake, Foot
6/03

B12

CONTROLS - MASTER CYLINDER/BRAKE LINE

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

4
4

20
8
19
3
17

18
10
9
11

13

12
E 2003 Polaris Sales Inc.
14

15

16

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.

1
2
3
4
5

Qty. Description

5411297
5410988
4110164
7517899
2201834

1
2
1
2
1

6 2201836

7 2010196
8 2201833

1
1

9 2201835

Boot, Brake Line, Rubber

Seal
Switch
Screw
Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)
Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)
Asm., Master Cylinder
Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)
Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)

Ref. Part No.

10
11
12
13
14
15
16
17
18
19
20

1910759
7621462
7080539
8360031-34
1910474
7080138
7512024
1910475
7052292
1910470
1910499

Qty. Description

1
1
1
1
1
4
2
1
1
1
1

Line, Brake, Hand, Rear

Rivet
Clamp, Nylon
Conduit
Line, Brake, Left Front
Cable Tie
Screw
Line, Brake, Right Front
Fitting, Cross
Line, Brake, Pod
Bolt, Banjo
6/03

B13

STEERING POST
SPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

2
4
5

E 2003 Polaris Sales Inc.

5
7
12

11
7
10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1
2
3
4
5
6

7542324
5433866
1013920-067
5246732
7512377
7517428

Qty.

4
2
1
1
2
2

Description

Ref. Part No.

Nut, Nylok
Bushing, Steering, Upper
Post, Steering
Bracket, Steering Post, Upper
Bolt, Carriage
Bolt, Carriage

7
8
9
10
11
12

7556162
5222393
3514352
7547158
7661633
7558402

Qty.

2
1
1
1
1
2

Description

Bushing
Flangette
Bearing
Nut
Pin, Cotter
Washer, Flat
2/03

B14

HANDLEBAR and HEADLIGHT POD

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

E 2003 Polaris Sales Inc.

1
2

3
8
7

11

10

12

33

31
32
30

13
14
15

28
27

29

16

26
25

17

24

22

18

21
19

23

24

20

C1

HANDLEBAR and HEADLIGHT POD

SPORTSMAN 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.

1
2
3
4
5

Qty. Description

5434380
3280431
5412138
7511881
5434706-400
5434706-341
5434706-053
5435239-455
7517238
5433903
4010592
5433834-070
5432952
7517625
-------

1
1
1
3
1
1
1
1
4
1
1
2
1
1
1

5244969-067
7517317
4032079
4032078
2410268
4010253
18 7081008
19 4010638
20 2461045

1
2
1
1
1
1
1
1
1

6
7
8
9
10
11
12
13
14
15
16
17

Bezel
Cluster
Mount, Rubber
Screw
Pod, Headlight, Upper (AK)
Pod, Headlight, Upper (AN)
Pod, Headlight, Upper (AL)
Pod, Headlight, Upper (AO)
Screw
Spacer, Switch, LH
Switch, Handlebar
Grip, Handlebar
Plug
Screw, Set
Asm., Master Cylinder
(See Controls - Master Cylinder/Brake
Line Pg. B13 for details)
Bracket, Pod Mounting
Screw
Knob, Adjusting
Rod, Adjusting
Asm., Headlamp
Bulb, Headlight
Cable, Choke
Receptacle, Pod Mount, 12V
Harness, Light, Pod/Accy.

Ref. Part No.

Qty. Description

21 7542122
22 5433762-177
5433762-382
5433762-070
23 7080631
24 4011002
4010278
4010321

4
1
1
1
1
1
1
1

25
26
27
28
29
30
31
32

1
1
1
1
1
1
1
1

5433534
5132382
4010298
7517658
7080922
7670127
5242987-067
-------

33 5631146

5631147
5631517

1
1

5631516

Nut, Nylok
Pod, Headlight, Lower (AK)
Pod, Headlight, Lower (AN)
Pod, Headlight, Lower (AL)(AO)
Clip, Cable Retaining
Switch, Key, 3 Position (Incl. Key)
Blank, Key, Series 2000, 6700, 6800
Blank, Key, Series 2200, 2300, 2700,
2800 NOTE: Your key can be duplicated only by obtaining a key blank
from Polaris and having it cut by mating it with your existing key.
Cover, Key
Cap
Sensor
Screw
Nut, Choke
Clip, Screw
Tube, Handlebar
Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B10, Ref. 5)
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

C2

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

5
E 2003 Polaris Sales Inc.
1

4
2

6
7

9
8
10

17
12
5

15 14
16

11

13

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.

1321971
1
2
3
4
5
6
7
8

1520231
7556202
5631119
7541906
5431936
5020422
3585712
7547130

Qty. Description

1 Asm., Drive Clutch, EBS, Wide

(Incl. All Less 12,16)
1 Clutch, One Way Drive
1 Washer, Brass
1 Spacer
3 Nut, FLEXLOC
6 Button, Clutch, Stemless
3 Pin, Roller
1 Bearing
1 Nut, Jam

Ref. Part No.

9
10
11
12
13
14
15
16
17

3576510
7552801
7512176
7041157
1321622
5430945
7512266
5631215
7556204

Qty. Description

1
6
6
1
3
6
3
3
1

Cover, Bearing
Washer, Spring Lock
Bolt
Spring, Clutch
Roller and Bushing
Washer, Multilube
Bolt, Shoulder
Weight, Shift, 20-56
Washer, Thrust
4/01

C3

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

1
E 2003 Polaris Sales Inc.

3
9
18

7
8

17

10
16

11
15
14

13

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.

1 7556120
2 1321973
1322407
3
4
5
6
7
8

7556203
7556010
7710461
5220646
7552901
7515382

Qty. Description

2 Bushing
1 Asm., Driven Clutch, EBS
(Incl. 4-6,12-18)(If built before 7/01/03)
1 Asm., Driven Clutch, EBS
(Incl. 4-6,12-18)(If built after 7/01/03)
1 Washer
1 Bushing
1 Ring, Retaining
1 Washer, Domed
1 Washer, Spring Lock
1 Bolt

Ref. Part No.

9
10
11
12
13
14
15
16
17
18

3211091
7517323
1321977
3585710
5211115
3576511
7041635
5132751
5210753
7710448

Qty. Description

1
3
3
1
1
1
1
1
1
1

Belt, Drive
Screw
Roller, Taper
Bearing
Washer
Bearing, Moveable, 1 Inch
Spring
Ramp, Stationary
Spacer
Ring, Retaining
6/03

C4

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

E 2003 Polaris Sales Inc.

4
5

15
14

13

12
11

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1 5434235
2201955
2 7517599
3 5434012
4 7080707
5 5411489
6 7512094
7 5434255-070

Qty. Description

1
1
5
1
2
1
9
1

Cover, Clutch, Inner

Kit, Inner Clutch Cover (Incl. 6,15)
Bolt/Washer
Duct, Clutch Outlet
Clamp, Narrow Band
Boot, Duct
Screw
Cover, Clutch, Outer

Ref. Part No.

8
9
10
11
12
13
14
15

5410542
5434264
7077666
7078689
5521578
7517867
5244527-067
5411918

Qty. Description

1
1
1
1
1
3
1
1

O-Ring
Plug
Decal, Automatic/EBS, Clutch
Decal, Warning, Clutch Cover
Seal, Cover, Clutch, Outer
Screw
Bracket, Retainer, Seal
Seal, Cover, Inner
6/02

C5

REAR WHEEL DRIVE

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

9
8
E 2003 Polaris Sales Inc.

5
4
10
11
12

2
3
1

15

14
13
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.

1
2
3
4

5411164
7661404
7555796
1520564-067
1520588
5 5133361
6 5244635
7 7710440

Qty. Description

2
2
4
2
2
2
2
2

Cover, Dust, Hub

Pin, Cotter
Washer, Cone
Rim, Rear, Black (AK)(AO)
Rim, Rear, Chrome (AN)(AL)
Hub, Rear Wheel
Disc, Brake, Rear
Ring, Retaining

Ref. Part No.

8
9
10
11
12
13
14
15

3585502
5631142
7512325
5411949
7515513
1525017
7547237
7543005

Qty. Description

2
2
8
2
8
2
8
2

Bearing
Bushing, Bearing Carrier
Screw
Tire, 25x11-12
Stud
Valve, Rim
Nut, Flange
Nut, Castle
6/03

C6

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

4
10
12

11

14

13

4
5
6

11

13

10
2

15
16

18

17

18
13

14

2
19

18

22

21

16

19

15

22

13
13

37
31
33
36

25

30

36
26

35
34
27
E 2003 Polaris Sales Inc.
28

19
29

C7

23

24

38

32

39

20

19

REAR SUSPENSION
SPORTSMAN 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.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

18
19
20
21
22
23

7517231
7555761
5432598
7512329
1580107-067
7542324
5020827
5334114-067
5434549
7555939
7558402
1541801-067
5434548
7515472
7512492
7552603
1014320-067
1014321-067
1014320-293
1014321-293
5020826
7542439
5245140-067
7555806
5434551
7515433

Qty. Description

4
8
8
6
2
6
2
1
2
2
8
1
12
6
4
4
1
1
1
1
6
10
1
2
4
2

Screw
Washer, Flat
Bushing, Stabilizer
Bolt
Arm, Stabilizer Bar
Nut, Nylok
Rod, Linkage, Stabilizer
Bar, Stabilizer Tube
Bushing, Stabilizer Tube
Washer
Washer, Flat
Support, Stabilizer
Bushing, A-Arm, Short
Screw
Screw
Washer, Spring Lock
Arm, Control, Upper, LH (AO)
Arm, Control, Upper, RH (AO)
Arm, Control, Upper, LH (AK)(AN)(AL)
Arm, Control, Upper, RH (AK)(AN)(AL)
Shaft, A-Arm, Short
Nut, Nylok
Strap, Rear Skid Plate
Washer, Flat
Bushing, A-Arm, Long
Screw

Ref. Part No.

24 5630885
25 7041453-067
7042311-067
7041453-293
7042311-293
26
27
28
29
30
31

32
33
34
35
36
37
38
39

5433551
5631014
7041959
7515415
5133806
1014174-067
1014175-067
1014174-293
1014175-293
5631142
7552614
7517873
7555740
5434550
5434890-1038
5434891-1038
7512084
5133663
5133664

Qty. Description

2 Retainer, Spring
2 Spring, Compression
(If built before 6/16/03)(AO)
2 Spring, Compression
(If built after 6/16/03)(AO)
2 Spring, Compression
(If built before 6/16/03)(AK)(AN)(AL)
2 Spring, Compression
(If built after 6/16/03)(AK)(AN)(AL)
2 Sleeve, Shock Protector
2 Cam, Adjusting, Spring
2 Shock, Rear
2 Screw
2 Shaft, A-Arm
1 Control, Lower, LH (AO)
1 Control, Lower, RH (AO)
1 Control, Lower, LH (AK)(AN)(AL)
1 Control, Lower, RH (AK)(AN)(AL)
4 Bushing, Bearing Carrier
4 Washer, Lock
4 Screw
4 Washer, Flat
8 Bushing, Control, Lower
1 Shield, LH
1 Shield, RH
4 Screw
1 Carrier, Wheel Bearing, LH
1 Carrier, Wheel Bearing (RH)
6/03

C8

ELECTRICAL/TAILLIGHT
SPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

3
2

4
5

10

11

2
12
13
25

24

14
15

26

19

16

17

23
22
20

19

18

21
E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13

2461208
2200593
4010924
2410320
4032045
4030043
4032046
4032029
7517386
5247376
4010630
4032064
7670054

Qty. Description

1
2
1
1
1
1
1
2
1
1
1
1
2

Harness, Main
Kit, Circuit Breaker, 20 AMP
Module, Resistor
Asm., Taillight, 12V (Incl. 7-13)
Gasket, Taillight
Bulb, Taillight
Lens, Taillight
Screw, Taillight
Screw
Strap, Battery Holddown
Battery, 30 AMP
Backing, Taillight/Brake Light
Nut, Speed

Ref. Part No.

14
15
16
17
18
19
20
21
22
23
24
25
26

4010470
2202099
4010471
5434037
5432077
7512024
3087196
4010376
4010929
5133182
4020139
7080138
7512027

Qty. Description

1
1
1
1
AR
6
1
1
1
1
3
7
2

Cable
Kit, Battery Bolt
Cable, Battery/Solenoid
Box, Battery
Tube, Battery Vent
Screw
Switch, Magnetic
Cable, Solenoid/Starter
Rectifier, Regulator
Sink, Heat
Clip, Rosebud (Small)
Cable Tie
Screw
6/03

C9

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

1
2

E 2003 Polaris Sales Inc.

11

4
10

6
6
7

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.

1
2
3
4
5
6

5412003
7512024
5411007
5435042
7515175
7542122

Qty. Description

1
1
1
2
2
2

Cover
Screw
Knob, Gear Selector
Mount, Gear Selector
Screw
Nut, Nylok

Ref. Part No.

7
8
9
10
11

1821055
7542324
7558402
1013315-067
7515306

Qty. Description

1
2
2
1
2

Asm., Linkage
Nut, Nylok
Washer, Flat
Selector, Gear
Screw
12/02

C10

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

1
2

3 4
E 2003 Polaris Sales Inc.

5
6
15
14

26

10

14

11

12

25

15

7
13
24

23

19

18

17

16

20

6
22

21

14

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.

1341344
1341497
3233950
3233955
1 3234163
2 3233998
3234159
3 3234164
4 3234165
5 3233925
3234161
6 3233926
7 3233953
8 3233928
9 3233932
10 3233933
3234166
11 3234167
-------

Qty. Description

1 Asm., Front Gearcase

(If built before 7/14/03)
1 Asm., Front Gearcase
(If built after 7/14/03)
1 Asm., Gearcase (Incl. 13,19,20)
1 Kit, Bolt
1 Screw, Set(1341497)
1 Asm., Cover Plate (Incl. Output Cover,
Insert and Coil)(1341344)
1 Asm., Cover Plate (Incl. Output Cover,
Insert and Coil)(1341497)
1 Button, Thrust (1341497)
1 Plate, Thrust (1341497)
1 Kit, Shim Set (Incl. Shims)(1341344)
1 Shim, Armature Plate (1341497)
2 Bearing, Roller Ball
1 Asm., Race/Output Hub (Incl. 23)
1 Pin, Dowel
1 Bearing, Roller Ball (1341344)
1 Clutch Housing/Ring Gear (1341344)
1 Clutch Housing/Ring Gear (1341497)
1 Asm., Roll Cage
(Incl. Spring and Roll Cage)
1 Spring

Ref. Part No.

Qty. Description

12 3233957
13 - - - - - - 3234169
14 3233956

14
1
1
1

15
16
17
18
19
20
21
22

3233918
3233947
3234112
3233944
------------3233942
3233951

11
1
1
1
1
1
1
1

23 3233929
24 3233954
3234168
25 3234162
26 3233924
3234160

1
1
1
1
1
1

Kit, Roll
Bushing (1341344)
Bushing (1341497)
Kit, Minor Repair
(Incl. O-Rings and Seals)
Bolt
Cover, Input
Bearing, Roller Ball
Shaft, Pinion, 11T
Bushing
Gearcase, LH
Plug, Oil Fill
Asm., Drain Plug
(Incl. Plug and Washer)
Bearing, Needle, Roller Thrust
Asm., Clutch (Incl. 9-12)(1341344)
Asm., Clutch (Incl. 10-12)(1341497)
Ring, Retaining, Internal
Plate, Armature (1341344)
Plate, Armature (1341497)

6/03

C11

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

E 2003 Polaris Sales Inc.

1

3
6
3

11

8
7
10
11

13

12

10

6
15
14

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.

1
2
3
4
5
6
7
8

8450003-1525
7052075
7080307
7080756
7670102
7547108
7512377
5247348

Qty. Description

AR
1
3
2
1
4
2
1

Line, Fuel
T-Fitting
Clamp, Hose
Clip
Clip
Nut, Flange, Lock
Bolt, Carriage
Bracket, Mount, Rear Transmission

Ref. Part No.

9
10
11
12
13
14
15

7542321
7555976
7515417
7552603
7515522
7517289
1013134-067

Qty. Description

2
3
2
2
2
2
1

Nut, Flange
Washer, Flat
Screw
Washer, Spring Lock
Bolt
Screw
Mount, Rear Engine
6/03

C12

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

18
16

E 2003 Polaris Sales Inc.

17
19

15
20

14
13

12

25
21

24

22

26

12
39
34 38
29 28 37
32 30
34 36 31

25
23
10

27

68 67

71

16 15

64

66
65

70

69

24

11

8
4

63

16 62
61

59
60

47

12
48

28

34
31 33
29 30 32

35
12

46

49
50

58

45

51

43 42 41

40

44
52
53 54

55

57
8

56
15

C13

GEARCASE
SPORTSMAN 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.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

1341471
3233961
3233826
3234124
3234123
3233869
3233829
3233831
3233788
3233832
3234143
3234128
3233018
3233036
3233890
3233019
3233794
3234127
3233874
3234042
3234142
3233910
3233548
3233524
3233858
3233859
3233860
3233915
3234040
3234144
3233875
3233850
3233851
3233852
3233718
3233853

Qty. Description

1
1
8
1
1
1
1
1
2
1
1
1
4
1
1
4
2
1
1
2
1
1
1
1
2
2
1
1
1
2
3
2
2
1
2
1

Asm., Gearcase
Nut
Screw
Cover
Gasket
O-Ring
Pawl, Detent
Shaft, Shift
Seal
Gear, 31T
Lable, Oil Fill/Level Check
Gearcase, Main
Bearing
Chain, Silent
Shaft, Input
Bearing
Plug
Cover, LH
Seal
Screw
Bracket, Transmission Mount
Drum, Shift
O-Ring
Tube, Vent
Fork, Shift
Pin, Dowel
Rail, Shift Shaft
Plate, Park
Engagement Dog
Spring, Wave
Engagement Dog
Ring, Retaining
Washer
Gear, 33T
Bearing, Needle
Shaft, Reverse

Ref. Part No.

36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71

3233854
3233855
3233912
3234136
3234137
3234086
3234122
3233106
3233357
3233607
3234140
3233619
3233873
3233621
3233911
3233582
3233583
3233611
3234130
3233846
3233625
3233784
3233844
3233552
3234013
3233917
3233247
3234043
3233839
3233838
3234082
3233076
3233830
3233835
3233834
3233906

Qty. Description

1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
AR
AR
1
15
1
1
1
1
1
1
4
2
1
1
1
1
1
1
1
1

Sprocket, 24T
Washer
Gear, 28T
Gear, 51T
Gear, 56T
Screw
Cover, Bearing
Ring
Spacer
Bearing, Ball
Shaft, Pinion, 10T
Washer, Thrust
Sprocket, 22T/18T
Gear, 31T
Shaft, Output, Main, Rear
Button, Thrust
Shim
Shim
Cover, Output, Front
Screw
Shaft, Output, Front
Chain, Silent
Sprocket, 22T
Bushing
Clamp, Tie
Lockout, Park
Pin, Dowel
Nut
Gear, 16T
Disc, Lockout
Star, Detent
O-Ring
Spring, Compression
Switch
Ring, Retaining
Bellcrank
6/03

C14

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

2
1

6
E 2003 Polaris Sales Inc.
19

18

17
8

9
17
16
10
6

11

12

13

14
15

2
5

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.

1
2
3
4
5
6
7
8
9
10

3233876
3233846
3233524
3233254
3233777
3233878
3233583
3233582
3233529
3233577

Qty. Description

1
8
1
2
2
2
AR
1
2
1

Cover, Output, LH
Screw
Tube, Vent
Washer
Plug
Seal
Shim
Button, Thrust
Pipe, Knock
Bushing

Ref. Part No.

11
12
13
14
15
16
17
18
19
20

3233881
3233714
3233588
3233882
3233785
3233880
3233268
3233879
3233581
1341352

Qty. Description

1
1
1
1
1
1
2
1
AR
1

Shaft, Pinion, 10T

Bearing, Ball
O-Ring
Cover, Input
Seal
Gearcase, Housing, Rear
Bearing, Ball
Gear, 31T
Shim
Asm., Gearcase, Rear
4/01

D1

REAR GEARCASE MOUNTING

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

E 2003 Polaris Sales Inc.

2

1
5

2
3

2
5
4

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1 7517878
2 7555806
3 7547008

Qty. Description

Ref. Part No.

5 Screw
12 Washer, Flat
5 Nut, FLEXLOC

4 7512492
5 7552603

Qty. Description

6 Screw
6 Washer, Spring Lock
4/01

D2

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

7
1

2
3

8
5

9
10
11

23, 24

12

25
26

13

14
15

29
27

28
15

17
16

15

23
19

18

20

E 2003 Polaris Sales Inc.

22
21

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.

1
2
3
4
5
6
7
8
9
10
11
12

5412114
3514361
7556194
3514318
7051530
7661175
7518007
1202658
7051531
7052288
5132753
5411184
5412455
13 5812364
5812511
14 1202384

Qty. Description

1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1

Seal, Flanged
Bearing, Ball
Bushing
Bearing, Ball (If built after 10/02/03)
Plug
Dowel
Plug
Asm., Crankcase (Incl.18-26)
Plug
Plug
Bearing
Seal, Oil (If before 10/02/03)
Seal, Oil (If after 10/02/03)
Gasket, Cover (If before 10/02/03)
Gasket, Cover (If after 10/02/03)
Cover, Engine, Magneto

Ref. Part No.

15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

7517950
5412048
3585704
7052306
5812232
7517793
7517792
5211785
7518045
7516603
1201970
1202663
5812016
3060004
7710512
7663001

Qty. Description

4
1
2
1
1
9
6
1
5
1
1
1
2
1
1
2

Screw
Seal
Bearing, Main Journal
Plug, Magnetic
Washer, Copper
Screw
Screw
Plate, Baffle
Screw (Qty 6 if built after 10/02/03)
Bolt (If built after 10/02/03)
Pickup, Oil (If before 10/02/03)
Pickup, Oil (If after 10/02/03)
O-Ring
Plug
Ring, Retaining
Pin, Dowel
6/03

D3

CRANKSHAFT and PISTON

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

1
2

E 2003 Polaris Sales Inc.

11

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1
2
3
4

2202107
3022996
------2202127

5 2202109
2202702

Qty. Description

2
4
2
1

Kit, Piston (Incl. 2,3,4)

Circlip, Piston
Pin, Piston
Kit, Piston Ring (Incl. Control,Iron, and
Chrome Rings)
1 Kit, Crankshaft (Incl. 7, from Crankcase Pg. D3, Ref. 2,3,5,17)(If built
before 10/02/03)
1 Kit, Crankshaft (Incl. 7, from Crankcase Pg. D3, Ref. 2,3,4,5,17)(If built
after 10/02/03)

Ref. Part No.

6
7
8
9
10
11

7721117
2202145
7517865
7555982
7721131
5132396

Qty. Description

1
1
1
1
1
1

Key, Woodruff
Kit, Gear Set
Screw
Washer
Key, Woodruff
Shaft, Balance

6/03

D4

CYLINDER and CYLINDER HEAD

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

6
E 2003 Polaris Sales Inc.

10

7
21

22

8
23 24

25 26

11
20

12

19
18

27

17
16

13

15

14

D5

CYLINDER and CYLINDER HEAD

SPORTSMAN 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.

1
2
3
4
5
6
7

Qty. Description

7517277
5432533
3021413
7516822
1201973
5411862
7517883
7518274
8 5811511
9 -------

2
1
1
7
1
1
6
6
1
1

10 7516730
7518234
11 1201657
3021483
5131429
12 5812193
5247359
13 2202158

4
4
1
1
4
1
1
1

2202696

Screw
Cover, Breather
Valve, Breather
Screw
Cover, Rocker
Seal
Screw (If built before 10/02/03)
Bolt, Head (If built after 10/02/03)
Gasket, Exhaust
Manifold
(See Exhaust System Pg. A11, Ref. 24)
Screw (If built before 10/02/03)
Screw (If built after 10/02/03)
Head, Cylinder (If built before 10/02/03)
Head, Cylinder (If built after 10/02/03)
Guide, Valve
Gasket, Head (If built before 10/02/03)
Gasket, Head (If built after 10/02/03)
Kit, Cylinder
(Incl. 15)(If built before 10/02/03)
Kit, Cylinder
(Incl. 15)(If built after 10/02/03)

Ref. Part No.

Qty. Description

14 5811455
5247360
15 7051534
16 - - - - - - -

1
1
1
1

17 7080681
18 7516734
19 1253415
20 3070195
21 7516822
22 5631196

1
2
1
2
2
1

5631390

23 7052308
7052352
24 5411521
25 4010356
26 7052135
7052145
27 7661175

1
1
1
1
2
2
2

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

Gasket, Base (If built after 10/02/03)
Plug
Asm., Carburetor
(See Carburetor Pg. D8, Ref. 48)
Clamp, Hose
Screw
Adapter, Carburetor
Spark Plug, RC7YC
Screw
Cover, Thermostat
(If built before 10/02/03)
Cover, Thermostat
(If built after 10/02/03)
Thermostat (If built before 10/02/03)
Thermostat (If built after 10/02/03)
O-Ring
Switch, Temperature
Fitting (If built before 10/02/03)
Fitting (If built after 10/02/03)
Dowel (If built after 10/02/03)
6/03

D6

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

51

4
50
5

E 2003 Polaris Sales Inc.

49
7
8

44
46

47

48

45
42

43

41
40

10
11

39
12

16

15 14

13

13

26

17

25

35

27
28
29
30

34
33
32

31

18

24

23

19

22
21
20

D7

36

37

38

CARBURETOR
SPORTSMAN 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.

1 3130507
2 3130508
3 3131449
3131224
4 3130752
5 3130732
6 3131363
7 3130541
8 3130540
9 3130504
10 3130014
11 3130571
3130572
12 3131393
13 3130515
14 3130517
15 3130518
16 3130519
17 3130361
18 3130594
19 3130532
20 3130520
21 3130590
22 3130521
23 3130529
24 3130591
25 3131360
26 3130533

Qty. Description

1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
1
1
4
1
1
1
1
1
1

Ring
E-Ring
Needle, Jet (If built before 10/02/03)
Needle, Jet (If built after 10/02/03)
Ring
Diaphragm
Jet, Needle, P-6
Screw
Washer, Spring
Asm., Jet Block
Washer
Jet, Main, #155 (If built before 10/02/03)
Jet, Main, #157.5 (If built after 10/02/03)
Cap
Seal
Packing
E-Ring
Cap
Pin, Float
Plate
O-Ring
Screw
Asm., Float Body
Screw
Asm., Float
Screw
Valve, Needle (1.5)
O-Ring

Ref. Part No.

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Qty. Description

3131226
3130522
3130523
3130525
3130524
3130546
3130545
3130544
3130502
3131398
3130514
3130501
------3130543
3130535
3130511
3130512
3131396
3130538
3131395
3130625
1253493

1
1
1
1
1
1
1
1
1
1
1
2
1
1
4
1
1
1
1
1
1
1

1253563

49 3131451
50 3130503
51 3130592

1
1
4

Jet, Pilot, #47.5

O-Ring
Washer
Spring
Adjuster
Screw, Adjust
Ring
Spring
Valve, Throttle, 100
Spring
Ring
Screw
Asm., Throttle Shaft
Guide, Cable
Screw
Cover
O-Ring
Holder, Guide
Spring
Asm., Plunger
Jet, Air, #160
Asm., Carburetor
(Incl. 1-12)(If built before 10/02/03)
Asm., Carburetor
(Incl. 1-12)(If built after 10/02/03)
Spring
Asm., Cover
Screw
6/03

D8

INTAKE and EXHAUST

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

E 2003 Polaris Sales Inc.

16
15

14
4
5

13

6
8

10

11
12

11

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.

1 1202169
2 5132402
3 2202110
2202693
4
5
6
7
8

5244286
7517598
2202145
7041999
7556183

Qty. Description

4 Asm., Rocker Arm

4 Pushrod
1 Kit, Camshaft
(Incl. 10)(If built before 10/02/03)
1 Kit, Camshaft
(Incl. 10)(If built after 10/02/03)
1 Plate, Thrust
3 Screw
1 Kit, Gear Set 680/780
3 Spring, Compression
1 Washer, Spring

Ref. Part No.

9 7517865
10 5131415
5134152
11 5133141
5133363
12 5132696
13 5411895
14 7041565
15 5131413
16 5910042

Qty. Description

1
4
4
2
2
2
4
4
4
8

Screw
Lifter, Valve (If built before 10/02/03)
Lifter, Valve (If built after 10/02/03)
Valve, Exhaust (If built before 10/02/03)
Valve, Exhaust (If built after 10/02/03)
Valve, Intake
Seal, Valve Guide
Spring, Valve
Retainer, Spring
Lock, Valve Stem
6/03

D9

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

1
E 2003 Polaris Sales Inc.

4
5

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.

1 1202109
2 1202110
1202629

Qty. Description

1 Asm., Dipstick
1 Tube, Oil Fill (If built before 10/02/03)
1 Tube, Oil Fill (If built after 10/02/03)

Ref. Part No.

3 7517795
4 5245805
5 5812016

Qty. Description

2 Screw
1 Clamp
1 O-Ring
6/03

D10

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

1
2
3

4
5
6

E 2003 Polaris Sales Inc.

12

11
10
(If built before 10/02/03)
9

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.

1 5131419
5133948
2 3584404
3 7710531
4 ------5 5433684
6 7555874

Qty. Description

1 Shaft, Oil/Water Pump

(If built before 10/02/03)
1 Shaft, Oil/Water Pump
(If built after 10/02/03)
1 Bearing
1 Ring, Retaining (If built after 10/02/03)
1 Kit, Gear Set 680/780
(See Intake and Exhaust Pg. D9, Ref. 6)
1 Impeller
1 Washer, Flat

Ref. Part No.

7 7546804
8 7516823
7516822
9 7517950
10 1202019
5631389
11 5812048
5812508
12 3610075

D11

Qty. Description

1
5
5
2
1
1
1
1
1

Nut, Nylok
Screw (If built before 10/02/03)
Screw (If built after 10/02/03)
Screw
Cover (If built before 10/02/03)
Cover (If built after 10/02/03)
O-Ring (If built before 10/02/03)
O-Ring (If built after 10/02/03)
Seal, Water Pump
6/03

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

1
2
9
8
7

E 2003 Polaris Sales Inc.

10

5
4

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

Qty. Description

1 2540006
2540086
2 2540115
3 7517807
4 5131426

1
1
1
4
1

5433852
5 1202079
1202588
6 7661127

1
1
1
1

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

Filter, Oil (If built after 10/02/03)
Nipple, Oil Filter
Screw
Housing, Oil Pump
(If built before 10/02/03)
Cover, Front (If built after 10/02/03)
Gerotor (If built before 10/02/03)
Gerotor (If built after 10/02/03)
Pin, Dowel

Ref. Part No.

7 7041563
7042203
8 7556005
9 7516824
10 2202159
2202699

Qty. Description

1
1
1
1
1

Spring (If built before 10/02/03)

Spring (If built after 10/02/03)
Washer
Screw
Kit, Oil Pump (Incl. 4,5 from Water
Pump Pg. D11, Ref. 1,2,4)(If built before 10/02/03)
1 Kit, Oil Pump (Incl. 4,5 from Water
Pump Pg. D11, Ref. 1,2,4)(If built after
10/02/03)
6/03

D12

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

2
3

E 2003 Polaris Sales Inc.

4

10

11
12

13

16
15
14

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.

1
2
3
4
5
6
7

5245364
4010901
7517847
7517714
4010899
7555907
7546909
7547213
8 5812359
5412458

Qty. Description

Ref. Part No.

1
1
2
3
1
1
1
1
1
1

9 1201684
1202641
10 5812283
11 5434310
5435099
12 5411564
13 7517950
14 5433820
15 4010897
4011017
16 4010898

Holddown, Wire
Asm., Stator
Screw
Screw
Asm., Flywheel
Washer
Nut (If built before 10/02/03)
Nut (If built after 10/02/03)
O-Ring (If built before 10/02/03)
O-Ring (If built after 10/02/03)

Qty. Description

1
1
1
1
1
1
10
1
1
1
1

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

Cover, Stator (If built after 10/02/03)
Cover, Sound
Cover, Outer (If built before 10/02/03)
Cover, Outer (If built after 10/02/03)
O-Ring (If built before 10/02/03)
Screw
Plug (If built before 10/02/03)
Controller, Ignition (If built before 10/02/03)
Controller, Ignition (If built after 10/02/03)
Coil, Ignition
6/03

D13

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

3
6

E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No.

1 7516823
2 4010417
3 7555908

Qty. Description

2 Screw
1 Starter
1 Washer, Thrust

Ref. Part No.

4 4010418
5 7552616
6 7546705

Qty. Description

1 Bendix
1 Washer, Lock
1 Nut
9/01

D14

TOOL KIT
SPORTSMAN 700 A04CH68AK and SPORTSMAN 700 A04CH68AL and SPORTSMAN 700 A04CH68AN and SPORTSMAN 700 A04CH68AO

1
E 2003 Polaris Sales Inc.
2

8
3

9
6

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.
Ref. Part No.

1
2
3
4
5

2873687
2870725
-------------------------

Qty. Description

1
1
1
1
1
1

Ref. Part No.

Kit, Tool (Incl. 1-7)

Gauge, Tire Pressure
Screwdriver
Wrench, 8-10 Open
Wrench, 9/16 x 1 1/2 Open
Wrench, Plug

6 ------7 2682572
8 9918724
9919070
9 2873647

Qty. Description

1 Puller, Spark Plug (Wrench Handle)

1 Pouch, Tool Kit
1 Owners Manual, 04.5 Sportsman
400-700
1 Supplement, Owners Manual, 04
Sportsman 700
1 Wrench, Torx
6/03

E1

This page left blank intentionally.

PRINTED IN THE USA

PARTS MANUAL PN 9918743 and MICROFICHE PN 9918744 6/03