PARTS MANUAL PN 9918612 and MICROFICHE PN 9918613 6/03

SPORTSMAN 700
Model #A04CH68AC
Model #A04CH68AF
Model #A04CH68AH
Model #A04CH68AJ
Model #A04CH68AT
Model #A04CH68AV
Rev. 02
E 2003 Polaris Sales Inc.
 TABLE OF CONTENTS
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700
A04CH68AJ and SPORTSMAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV
Parts Manual

A GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C13-14
A-- ARM/STRUT MOUNTING . . . . . . . . . . . . . B6 GEARCASE, REAR . . . . . . . . . . . . . . . . . . . D1
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B1 GEARCASE MOUNTING, REAR . . . . . . . . . . D2

B H
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . B13
BRAKE, FRONT . . . . . . . . . . . . . . . . . . . . . B9
BUMPER MOUNTING . . . . . . . . . . . . . . . . . A7-8
C INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
CAB, 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
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . C1-2
HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . C1-2
I
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D13
MASTER CYLINDER . . . . . . . . . . . . . . . . . . B13
MASTER CYLINDER, REAR . . . . . . . . . . . . B12
O
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D12
P
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
PROP SHAFT, FRONT . . . . . . . . . . . . . . . . . B4
PROP SHAFT, REAR . . . . . . . . . . . . . . . . . B5

D R
RACK MOUNTING, FRONT . . . . . . . . . . . . . A7-8
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A9
REAR RACK MOUNTING . . . . . . . . . . . . . . . A6
DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . D10
REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . C6
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . C3
DRIVE SHAFT, FRONT . . . . . . . . . . . . . . . . . B2
DRIVE SHAFT, REAR . . . . . . . . . . . . . . . . . B3
S
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . C4 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4
STARTING MOTOR . . . . . . . . . . . . . . . . . . . D14
E STEERING POST . . . . . . . . . . . . . . . . . . . . . B14
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . C9 STRUT, FRONT . . . . . . . . . . . . . . . . . . . . . . B7
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14 SUSPENSION, REAR . . . . . . . . . . . . . . . . . C7-8
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . D9
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A11 T
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . C9
F THROTTLE ASM. . . . . . . . . . . . . . . . . . . . . . B10
FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . B12 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E1
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-4 TRANSMISSION MOUNTING . . . . . . . . . . . . C12
FRONT HOUSING . . . . . . . . . . . . . . . . . . . . C11
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . A12 W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D11
G WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . B8
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . C10 WINCH ASM. . . . . . . . . . . . . . . . . . . . . . . . . E2

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
 REAR CAB, SEAT and MAIN FRAME
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

19
E 2003 Polaris Sales Inc.
6 17
18
16
5
7 8 15
4 9 14
3 10
2
1 13

12 20
11 21

1 2
33 22 23
32
34 31 24

30
25
35
26
36 37
38 29

39

27
28

A3
 REAR CAB, SEAT and MAIN FRAME
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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, Nylok 20 5412067 8 Bumper, Rubber
2 7555792 4 Washer 21 5431787 1 Cover, Tool Box
3 5811107 1 Foil, Rear Cab, Rear 22 7517377 4 Screw
4 5432117-400 1 Cab, Rear, Camo Green Met (AH) 23 5432280 2 Spacer
5435164-455 1 Cab, Rear, New Break-Up (AC)(AT) 24 7542153 6 Nut
5432117-341 1 Cab, Rear, Sonic Blue (AF)
5432117-053 1 Cab, Rear, Yellow (AJ) 25 7512283 6 Screw
5435164-456 1 Cab, Rear, Shadowgrass (AV) 26 5244751-067 1 Brace, Frame
5 7511930 2 Bolt 27 1014260-067 1 Frame, Main
6 5246076 1 Retainer, Seat Latch 28 7542122 8 Nut, Nylok
7 7079902 1 Decal, 4 Stroke, Carb/Filter Information 29 7170509 1 Decal, Hitch
8 5811308 1 Foil, Tape, Rear Cab 30 7512232 24 Screw
9 7512242 4 Screw 31 5811111 1 Foil, Rear Fender
10 7555859 4 Washer, Flat 32 5811087 1 Foil
11 7556034 4 Washer 33 5811106 2 Foil, Rear Cab, Front
12 7512085 2 Screw 34 5434704-070 1 Guard, Mud, Rear, Black, LH
13 5431786 1 Box, Tool 5434705-070 1 Guard, Mud, Rear, Black, RH
14 7517375 2 Screw 35 7670057 22 Nut, U-Type Speed
15 7621403 2 Rivet 36 7555832 2 Washer
16 5211033 2 Bracket, Lever Retainer 37 7517312 2 Screw
17 1040387 1 Latch, Seat 38 7517264 4 Screw (LH Side)
7517376 4 Screw (RH Side)
18 7041370 1 Spring, Latch
39 5432221-070 1 Footwell, Black, LH
19 2683197-070 1 Asm., Seat, Black 5433929-070 1 Footwell, Black, RH
2683419-070 1 Asm., Seat, Black w/Gold Polaris
(AT)(AV)
2682958-070 1 Covering, Seat, Black
6/03

A4
 FRONT CAB
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

1
19
21 22 2
20

18 3
17 16

5
8 7 4
6
9
2
15 8
11 10
14

13 12 10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2632748-400 1 Cab, Front, Camo Green Met (AH) 10 7542122 2 Nut, Nylok
2632818-455 1 Cab, Front, New Break-Up (AC)(AT) 11 7556034 2 Washer
2632748-053 1 Cab, Front, Yellow (AJ)
2632748-341 1 Cab, Front, Sonic Blue Met (AF) 12 7555859 2 Washer, Flat
2632818-456 1 Cab, Front, Shadowgrass (AV) 13 5246021-067 1 Guard, Splash, RH
2 7670057 12 Nut, U-Type Speed 14 5434702-070 1 Guard, Mud, Front, Black, LH
3 5432088-400 1 Cover, Front, Camo Green Met (AH) 5434703-070 1 Guard, Mud, Front, Black, RH
(If built before 5/01/03) 15 7515158 2 Screw
5435110-400 1 Cover, Front, Camo Green Met (AH) 16 7541925 2 Nut, Nylok
(If built after 5/01/03)
5435166-455 1 Cover, Front, New Break-Up (AC)(AT) 17 7555792 2 Washer
5432088-053 1 Cover, Front, Yellow (AJ) 18 7512085 2 Screw
(If built before 5/01/03) 19 5811491 1 Foil, Side Panel, Gen. IV, RH
5435110-053 1 Cover, Front, Yellow (AJ)
(If built after 5/01/03) 20 5812326 1 Foil, Side Panel, RH
5432088-341 1 Cover, Front, Sonic Blue Met (AF) 21 5433853-177 1 Panel, Side, Black Met, LH (AH)
(If built before 5/01/03) 2632471-177 1 Panel/Foil, Black Met, RH (AH)
5435110-341 1 Cover, Front, Sonic Blue Met (AF) 5435167-455 1 Panel, Side, New Break-Up, LH (AC)(AT)
(If built after 5/01/03) 2632819-455 1 Panel/Foil, New Break-Up, RH (AC)(AT)
5435166-456 1 Cover, Front, Shadowgrass (AV) 5433853-070 1 Panel, Side, Black, LH (AJ)
4 7517867 2 Screw 2632471-070 1 Panel/Foil, Black, RH (AJ)
5433853-382 1 Panel, Side, Silver Vapor Met., LH (AF)
5 5246872 1 Guard, Splash, LH/Pump Mount 2632471-382 1 Panel/Foil, Silver Vapor Met., RH (AF)
6 7517386 3 Screw 5435335-456 1 Panel, Side, Shadowgrass, LH (AV)
7 7670135 4 Nut, Push-on 2632819-456 1 Panel/Foil, Shadowgrass, RH (AV)
8 7517312 2 Screw 22 7512232 14 Screw
9 7670156 2 Clip, Retaining
7/03

A5
 REAR RACK MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

2 E 2003 Polaris Sales Inc.

3
4
5

12

11
2
6

10
9 9
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. Qty. Description Ref. Part No. Qty. Description
1 2871501 1 Kit, Extender, Rack, Rear 6 5334092 2 Spacer
(Incl. 12)(AC)(AT)(AV) 7 7512329 4 Bolt
2 7517983 2 Screw 8 5241663 1 Bracket, Silencer, Frame
3 7517685 2 Screw 9 7558402 8 Washer, Flat
4 7555916 2 Washer, Nylon 10 7542324 4 Nut, Nylok
5 2632637-070 1 Asm., Rack, Rear (Incl. Warning Decal) 11 1013724-067 1 Support, Rear Rack
1 (If built before 2/03/03)
2632836-070 Asm., Rack, Rear (Incl. Warning Decal) 12 7517208 6 Screw (AC)(AT)(AV)
(If built after 2/03/03)
6/03

A6
 FRONT RACK and BUMPER MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1 3
2

4
E 2003 Polaris Sales Inc.

5
28
6
7

27 5
28
8
21 9
21
8
5
26
5
25 10

21
11
24
12
5 23

8
5
13
14
21 23

22
21
15
16

14 17

19 18
20

A7
 FRONT RACK and BUMPER MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1013972-067 1 Extender, Front Rack (AC) 14 5434314 1 Shield, Side, Radiator, LH
1013972-418 1 Extender, Front Rack (AT)(AV) 5434315 1 Shield, Side, Radiator, RH
2 7517685 4 Screw 15 5412504 4 Grommet, Rubber Mount
3 7081085 2 Plug 16 5435046 1 Cover, Radiator
4 5434697-070 1 Rack, Front, Black 17 5247507-067 1 Grill, Brush Guard
(If built before 2/03/03) 18 7518046 4 Screw
5435240-070 1 Rack, Front, Black (If built after 2/03/03)
19 7670094 6 Nut, U-Type
5 7558402 14 Washer, Flat
20 7512097 6 Screw
6 7517208 4 Screw
21 7515399 6 Screw
7 2431017 2 Headlight
4030059 2 Bulb, Replacement, 27W 22 5245767-067 1 Bracket, Bumper, Lower
8 7542324 6 Nut, Nylok 23 7512329 2 Screw
9 2632757-070 1 Asm., Bumper, Front, Black 24 7171474 1 Decal, Reflector, Amber, LH
(Incl. Warning Decal) 7171475 1 Decal, Reflector, Amber, RH
10 7515306 4 Screw 25 1014020-067 1 Support, Front Rack
11 5434699-070 1 Panel 26 5810467 1 Plug, Frame
12 7512094 2 Screw 27 1014261-067 1 Support, Front Rack, LH
1014262-067 1 Support, Front Rack, RH
13 1014412-067 1 Guard, Brush
28 7512232 6 Screw
6/03

A8
 DECALS
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

4 5 6
2 3 7
1 8
9
E 2003 Polaris Sales Inc.

11 12
13
RH 14 15
10
2

16

17
18
19
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. Qty. Description Ref. Part No. Qty. Description
1 7079927 2 Decal, Reflector, Red 11 7079672 1 Decal, Foot Brake
2 7170912 2 Decal, Warning, Front/Rear Rack 12 7079604 1 Decal, Override Switch, AWD
3 7171016 1 Decal, “4X4”, Side Panel, LH (AH) 13 7171014 1 Decal, Side Panel, LH (AH)
7171017 1 Decal, “4X4”, Side Panel, RH (AH) 7171015 1 Decal, Side Panel, RH (AH)
7171486 1 Decal, “4X4”, Side Panel, LH (AC)(AT)(AV) 7171482 1 Decal, Side Panel, “700”, LH (AC)(AT)(AV)
7171487 1 Decal, “4X4”, Side Panel, RH (AC)AT)(AV) 7171483 1 Decal, Side Panel, “700”, RH (AC)(AT)(AV)
2202634 1 Kit, Side Panel Decals (AF) 2202634 1 Kit, Side Panel Decals (AF)
7171008 1 Decal, “4X4”, Side Panel, LH (AJ) 7171006 1 Decal, Side Panel, Top, LH (AJ)
7171009 1 Decal, “4X4”, Side Panel, RH (AJ) 7171007 1 Decal, Side Panel, Top, RH (AJ)
4 7078253 1 Decal, Age Warning 14 7077920 1 Decal, Passenger Warning
5 7079780 1 Decal, Warning AWD Switch 15 7079959 1 Decal, “POLARIS”, Rear (AC)(AF)(AH)
6 7078003 1 Decal, Headlight Adjustment 7079960 1 Decal, “POLARIS”, Rear (AJ)
7172066 1 Decal, “POLARIS”, Rear (AT)(AV)
7 7171018 1 Decal, Tank Side, LH (AH)(AJ)
7171019 1 Decal, Tank Side, RH (AH)(AJ) 16 7079084 1 Decal, Tire Pressure/Load
7171476 1 Decal, “Sprtmn 700”, LH (AC)(AT)(AV) 17 7171383 1 Decal, Discretionary Warning
7171477 1 Decal, “Sprtmn 700”, RH (AC)(AT)(AV) 18 7079083 1 Decal, Warning, General, CPSC
2202635 1 Kit, Tank Side Decals (AF)
19 7171474 1 Decal, Reflector, Amber, LH
8 7078465 1 Logo, Polaris Star 7171475 1 Decal, Reflector, Amber, RH
9 7171067 1 Decal, Cover, Frt, New Break-Up (AC)(AT)
10 7079916 1 Decal, “POLARIS”, Front Cover (AJ)
7079773 1 Decal, “POLARIS”, Fr. Cvr. (AC)(AH)(AF)
7171879 1 Decal, “POLARIS”, Fr. Cvr. (AT)(AV)
6/03

A9
 COOLING SYSTEM
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1 10 11
8
9 12
2 13
3 3
19
4 8 14
5 7 18 15
6 16
17
3
3
20
19 40
20 21
39 38
17 22
23
37 25
17 24

24 26
27
28
E 2003 Polaris Sales Inc. 36
35 34
29
33
24 30
31
32

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 1240044 1 Cap, Pressure 21 5246656 1 Bracket, Radiator Mount, Upper
2 5434325 1 Filler, Coolant 22 7518014 2 Screw
3 7512084 7 Screw 23 7556196 2 Washer
4 5521644 1 Guard, Hose 24 7547197 6 U-Clip
5 7042089 1 Retainer, Hose 25 4010161 1 Sensor, Thermal
6 5412311 1 Hose, Filler Neck 26 1240103 1 Radiator
7 7080827 1 Clamp, 1 Inch 27 5411975 2 Grommet
8 7080003 4 Clamp, Hose 28 7515179 2 Screw
9 8450040-150 AR Line, Fuel 29 7052296 1 Valve, Drain
10 5430743 1 Cap, Overflow, Drilled 30 5410584 2 Bushing, Mount
11 5810279 1 Gasket, Overflow Cap 31 5245773-067 1 Bracket, Radiator, Lower
12 5433774 1 Plug, Cap 32 7517386 2 Screw
13 5431673 1 Tank, Surge 33 5434171 1 Shroud, Fan
14 7052065 1 Fitting, Barbed, 90 Degree 34 4010631 1 Clip, Wiring
15 8450003-1525 1 Line, Fuel 35 2410413 1 Asm., Fan
16 7080307 1 Clamp, Hose 36 7517975 4 Screw
17 7080826 3 Clamp 37 5412313 1 Hose, Engine, Lower
18 5412030 1 Hose, Engine, Upper 38 7052282 1 Connector, Tee
19 7081174 2 Clamp, Hose 39 7081047 2 Clamp
20 5521597 2 Hose, Guard 40 5412312 1 Hose
6/03

A10
 EXHAUST SYSTEM
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV
1 1
2
2
3
3
4 E 2003 Polaris Sales Inc.
5 4
5
6
7
8
9 9
10 10
11
12
21

13 27

14
16
15
17 18 26
22
16
19
20 22

21 20
22
25
23 24

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, Nylok 15 7512666 1 Bolt
2 7555716 2 Washer, Flat 16 3610047 2 Seal, Exhaust
3 5010192 2 Bushing 17 7041804 2 Spring, Exhaust
4 5410436 2 Washer, Rubber 18 1261242-029 1 Pipe, Exhaust
5 7555863 2 Washer 19 5244014 1 Shield, Heat
6 5241663 1 Bracket, Silencer, Frame 20 7555935 5 Washer
7 7555935 8 Washer 21 7515197 5 Screw
8 7517615 4 Screw 22 7041789 3 Spring, Exhaust
9 5410241 2 Dampener, Vibration 23 7542301 1 Nut
10 7515316 2 Bolt, Carriage 24 3110064 1 Mount, Torque Stop
11 7558402 4 Washer, Flat 25 7547101 1 Nutsert
12 7512329 4 Bolt 26 1261077-029 1 Manifold
13 1261223-029 1 Silencer, Exhaust 27 5245502 1 Shield, Heat, Exhaust
14 7556230 1 Washer, Clean Out
6/03

A11
 FUEL TANK
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ

1
E 2003 Polaris Sales Inc.
20
2 19
18

3
17

4
5

16

15 (After 2/21/03)
6
14
(Before 2/21/03) 14
13
13
7
7

8
9
11 12
10
8
(See Fuel Tank Pg. E3 for AT and AV Fuel Tank)
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 5433687 1 Cap, Gas Tank (Incl. 20) 13 7052150 1 Fitting, Fuel Outlet, Main
2 8360009-600 AR Line, Fuel (If built before 2/21/03)
7052347 1 Fitting, Fuel Outlet, Main
3 5812265 1 Seal, Foam (If built after 2/21/03)
4 2520203 1 Asm., Fuel Tank (Incl. 13,14,19) 14 7052149 1 Fitting, Fuel Outlet, Reserve
(If built before 2/21/03) (If built before 2/21/03)
2520363 1 Asm., Fuel Tank (Incl. 13,14,19) 7052346 1 Fitting, Fuel Outlet, Reserve
(If built after 2/21/03) (If built after 2/21/03)
5 5812004 1 Foil, Fuel Tank 15 7052028 2 Grommet
6 7052161 1 Valve, 3-Way 16 5812005 1 Foil, Fuel Tank
7 7080003 4 Clamp, Hose, Red 17 5247184 1 Bracket, Mounting, Rear, LH
8 8450040-600 AR Line, Fuel 5247185 1 Bracket, Mounting, Rear, RH
9 5432733 1 Nut, Fuel Valve 18 7517685 2 Bolt
10 5432559 1 Knob, Fuel Valve 19 5431053 1 Vent, Tank
11 7517505 1 Screw 20 5812123 1 Gasket
12 8450080-65 2 Sheath, Foil
7/03

A12
 ENGINE MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

7
6 20
5 E 2003 Polaris Sales Inc.
17 21
3 4
18 19
10
2
1 8 9 22
8
10 8
11
8 9 8

16
23
8 15

12 14

24

13
44
43 25
26 26
27
28

41
26
42

40 29
38
39

30
37
36 32 31
28
35
34
33

26

A13
 ENGINE MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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 7517867 2 Screw 21 3110050 2 Mount, Carb
2 7558301 2 Washer, Flat 22 7558203 2 Washer
3 2520227 1 Pump, Fuel 23 7051011 1 Valve, Check
4 7546601 2 Nut, Nylok 24 7516714 2 Screw
5 7512329 4 Bolt 25 7552901 2 Washer, Spring Lock
6 5243829 1 Strap, Fuel Pump Mounting 26 7547108 6 Nut, Flange Lock
7 7541923 2 Nut, Well 27 5244622-- 067 1 Bracket, Mount, Top
8 7080003 8 Clamp, Hose 28 7555823 3 Washer, Flat
9 8450040-- 600 AR Line, Fuel 29 7517868 1 Screw
10 2530009 2 Filter 30 4010470 1 Cable, Black
11 8450080-50 1 Sheath, Foil 31 5411944 1 Boot, Intake
12 2202082 1 Kit, Short Block, ATV NOTE: The 32 7080451 1 Clamp, Hose
Short Block assembly contains a 33 3021119 2 Mount, Rubber
crankcase assembly, cylinder & cylin-
der head assembly and a piston & 34 7518197 1 Screw
crankshaft assembly. Prior authoriza- 35 7575202 1 Washer, Interlock
tion is required for warranty consider- 36 5210748 1 Washer, Flat
ation.
37 5430261 1 Bushing
13 7555770 2 Washer
38 7552603 2 Washer, Spring Lock
14 4010132 1 Cable, Ground, Engine
39 7512492 2 Screw
15 7517386 4 Screw
40 3110044 2 Mount, Rubber, Top
16 8360009-- 600 AR Line, Fuel
41 5244771-- 067 1 Mount, Lower, Front
17 5412287 1 Hose, Formed, Vent
42 7555823 AR Washer, Flat
18 7542105 2 Nut
43 5245043-- 067 1 Bracket, Torque Stop
19 7558301 2 Washer, Flat
44 7516734 2 Screw
20 ------- 1 Guard, Splash, LH/Pump Mount
(See Front Cab Pg. A5, Ref. 5)
9/02

A14
 AIR BOX
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV
6
1
E 2003 Polaris Sales Inc.
2
5 13
3 7
4
8

12
31 9

11

30
29 14
10
15

14
16
17
28 18
27
17

26 17
24
19
23 21
25 22
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. Qty. Description Ref. Part No. Qty. Description
1 5811633 1 Filter, Precleaner Sleeve 16 7080511 1 Clamp, Narrow Band
2 7080595 1 Filter, Air Intake 17 7080699 3 Clamp, Hose
3 7080413 1 Clamp, Narrow Band 18 8450073-600 AR Line, Breather
4 5433847 1 Sleeve 19 7080694 1 Clamp
5 5432868 1 Cover, Air Box 20 5411966 1 Hose, Breather, Formed
6 7517317 4 Screw 21 2530029 1 Filter, Breather
7 5434013 1 Duct, Air Inlet 22 7080534 1 Clamp, Hose
8 5411422 1 Gasket, Intake 23 5433396 1 Cap, End
9 5811482 1 Seal, Air Box Cover 24 5242044 6 Clip, Air Box
10 5433678 1 Box, Air 25 5432377 1 Plug, Trap
11 5434044 1 Duct, Clutch Air Inlet 26 8450059-150 AR Line, Fuel
12 7670102 1 Clip 27 7080650 1 Clamp, Hose
13 5812316 1 Seal, Foam 28 5811650 1 Foil, Air Box
14 7080451 2 Clamp, Hose 29 7558301 2 Washer, Flat
15 ------- 1 Boot, Intake (See Engine Mounting 30 7515179 2 Screw
Pg. A14, Ref. 31) 31 5412066 1 Boot, Carb
6/02

B1
 FRONT DRIVE SHAFT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

2 E 2003 Polaris Sales Inc.

3

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 Ref. Part No. Qty. Description
1 1380218 2 Asm., Drive Shaft 4 2201015 2 Kit, Boot (Incl. Clamps and Grease)
2 7670092 2 Circlip 5 1380186 2 Shaft (Incl. 6)
3 1590358 2 Joint, CV 6 2202015 2 Kit, Cross and Bearing
12/02

B2
 REAR DRIVE SHAFT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
E 2003 Polaris Sales Inc.

2 3 4 5 5 7 3
6 8 9

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. Qty. Description Ref. Part No. Qty. Description
1 1380197 2 Asm., Drive Shaft, Rear (Incl. 2-9) 7 1350047 1 Grease, 50g
2 1590362 1 CV Joint 8 1590281 1 Joint, Plunging
3 1350044 2 Clamp, Large 9 1350042 1 Ring, Spring
4 1350046 1 Grease, 30g 10 2201374 1 Kit, Boot (Gear Side)
5 1350045 2 Boot 11 2201373 1 Kit, Boot (Wheel Side)
6 1350043 2 Clamp, Small
5/03

B3
 FRONT PROP SHAFT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

2 E 2003 Polaris Sales Inc.

3 4
6 8
5 7
4

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1380221 1 Asm., Front Prop Shaft 5 1350089 1 Shaft, Bar
2 7661913 1 Pin, Spring 6 3260131 1 Yoke, Prop Shaft, Transmission
3 3260133 1 Yoke, Gear Case, Front 7 7080424 1 Fitting, Lubrication
4 2202015 2 Kit, Cross and Bearing 8 5411092 1 O-Ring
12/02

B4
 REAR PROP SHAFT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
E 2003 Polaris Sales Inc.

4
2
3 2
2

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1380208 1 Asm, Prop Shaft, Rear 3 2202015 2 Kit, Cross and Bearing
2 1350039 3 Yoke, Prop Shaft, Rear 4 1380179 1 Shaft, Rear
12/02

B5
 A-ARM/STRUT MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

4
E 2003 Polaris Sales Inc. 1 5
6
3
7
8
2
9
10

27

11

26 22 12
25

25 24 13
26
23 14

15
16

22
17
21 18
20 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. Qty. Description Ref. Part No. Qty. Description
1 7542439 2 Nut, Nylok 15 7080927 2 Joint, Ball
2 1820805 2 Asm., Tie Rod 16 5211121 2 Bracket, Ball Joint
3 7517909 2 Bolt 17 7512284 4 Screw
4 5411291 2 Boot, Seal, Rod End 18 5410548 2 Boot, Rubber
5 7061034 2 Rod End 19 7542438 2 Nut, Castle
6 7542711 2 Nut 20 7512084 6 Screw
7 5020926 2 Tie Rod 21 5435028-070 1 Shield, CV Joint, LH
8 7547028 2 Nut, LH 5435029-070 1 Shield, CV Joint, RH
9 7061054 2 Rod End, LH 22 5434551 4 Bushing, A-Arm, Long
10 5411920 1 Boot, Seal, Rod End 23 5133806 2 Shaft, A-Arm
11 7556099 4 Washer, Flat 24 2202274 1 Kit, A-Frame, LH (Incl. 14,22,23,25,26)
2202275 1 Kit, A-Frame, RH (Incl. 14,22,23,25,26)
12 ------- 1 Asm., Hubstrut
(See Front Strut Pg. B7 for Details) 25 7571611 4 Washer, Dish Lock
13 7547177 2 Nut 26 7512492 4 Screw
14 7661203 4 Pin, Cotter 27 7515415 2 Screw
12/02

B6
 FRONT STRUT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
22
2

E 2003 Polaris Sales Inc.

4

21

5
19
18
6 20
17
16
10
7
10 18

8
15

9 10 14

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. Qty. Description Ref. Part No. Qty. Description
1 7547104 2 Nut, Nylok 12 3514342 2 Bearing, Hubstrut
2 7555749 2 Washer 13 7710507 2 Ring, Retaining
3 5810291 2 Spacer, Rubber 14 - - - - - - - 1 Asm., Front Brake Caliper, LH
4 5432872 2 Ball, Pivot, Top (See Front Brake Pg. B9 for Details)
5 5132062 2 Spacer 15 7080306 2 Fitting, Lubrication
6 5432871 2 Ball, Pivot, Bottom 16 7552901 4 Washer, Spring Lock
7 5243364 2 Retainer, Spring 17 7512365 4 Screw
8 7042054-067 2 Spring, Compression 18 7542324 4 Nut, Nylok
7041985-067 2 Spring, Compression (AT)(AV) 19 7080367 2 Clamp, Cable
9 7515339 4 Bolt 20 5211115 2 Washer
10 7558402 10 Washer, Flat 21 7041761 2 Strut, Front
11 5132301 1 Hubstrut, LH 22 5411608 2 Bumper
5132302 1 Hubstrut, RH
6/03

B7
 FRONT WHEEL
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2 3

E 2003 Polaris Sales Inc.

4

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. Qty. Description Ref. Part No. Qty. Description
1 7512325 8 Bolt 6 5411952 2 Tire (25x8-12)
2 5244314 2 Disc, Brake 7 7547237 8 Nut, Flange
3 7515513 8 Stud 8 7556004 2 Washer
4 5133360 2 Hub, Wheel 9 7542810 2 Nut, Slotted
5 1520587 2 Rim, Front, Chrome (AF)(AJ) 10 5411164 2 Cover, Dust
1520563-067 2 Rim, Front, Black (AC)(AH) 11 7661401 2 Pin, Cotter
1520696-455 2 Rim, Front, Break-Up (AT)
1520696-456 2 Rim, Front, Shadowgrass (AV) 12 1525017 2 Valve, Rim
6/03

B8
 FRONT BRAKE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2
3 4

5
12
6
7
8 9

11

E 2003 Polaris Sales Inc.

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1910681 1 Asm., Brake Caliper, LH 5 1930665 1 Kit, Piston and Seal (Incl. 6-8)
(Incl. 2-8,10,11) 6 5410779 1 Ring, Molded Square (.094)
1910682 1 Asm., Brake Caliper, RH
(Incl. 2-8,10,11) 7 5410780 1 Ring, Molded Square (.103 x .134)
2 7515489 1 Screw, Socket Set 8 5132294 1 Piston, Brake, Long
3 5132960 1 Caliper, Brake, LH 9 2201398 1 Kit, Front Brake Pad
5132961 1 Caliper, Brake, RH 10 1910411 1 Mount, Caliper
1930642 1 Kit, Front Brake Boot 11 5410495 1 Boot, Bushing
4 5410494 1 Boot, Pin Seal 12 7080352 1 Screw, Bleeder
12/02

B9
 CONTROLS - THROTTLE ASM./CABLE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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. Qty. Description Ref. Part No. Qty. Description
1 5410193 1 O-Ring 5 2010230 1 Asm., Throttle Control (Incl. 7)
2 5434113 1 Cover, Throttle Control 2010234 1 Asm., Throttle Control, Thumb
(Incl. 6,7)(AT)(AV)
3 5411439 1 O-Ring
6 2410420 1 Asm., Thumb Warmer (AT)(AV)
4 7081025 1 Cable, Throttle
7 2010191 1 Asm., Throttle Clamp
7/03

B10
 REAR CALIPER
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

12

13

12
14

15, 16
E 2003 Polaris Sales Inc.
14

16

4 16
14
1 2 18
3 15, 16

17

12, 14

12
9 12, 14, 17
5

10 7

11 8
6

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512365 2 Screw 9 1910429 1 Line, Brake, Rear, Foot
2 7552901 2 Washer, Spring Lock 10 7517756 1 Screw
3 7558402 2 Washer, Flat 11 7670126 1 Clip, Retaining, Dual
4 ------- 2 Carrier, Bearing 12 2201873 1 Kit, Anvil Body
5 1910529 1 Bracket, Caliper 13 1910538 2 Fitting,Bleed, Compact
6 7080960 1 Clamp, Nylon 14 2201870 1 Kit, Slide Bolt
7 7621462 1 Rivet 15 2201872 1 Kit, Seal
8 ------- 1 Line, Brake, Hand, Rear (See Controls 16 2201869 1 Kit, Piston and Seal
- Master Cylinder/Brake Line Pg. B13, 17 2202414 1 Kit, Brake Pad
Ref. 10)
18 1910690 1 Asm., Caliper
12/02

B11
 REAR MASTER CYLINDER/FOOT PEDAL
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

2 3
1

5
16
6

15
14
13
E 2003 Polaris Sales Inc.
12 7
9
10
11
10
9
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. Qty. Description Ref. Part No. Qty. Description
1 7512240 1 Screw 9 7555919 2 Washer
2 1930854 1 Reservoir, Brake, Rear 10 5433189 2 Bushing, Pivot, Pedal
3 7542153 1 Nut 11 1013415-067 1 Rod, Brake
4 7080003 2 Clamp, Hose 12 7041750 1 Spring
5 1910438 1 Hose, Reservoir 13 1910301 1 Master Cylinder, Brake, Rear
6 1013414-067 1 Mount, Brake 14 7515158 2 Screw
7 7517386 3 Screw 15 7042075 1 Spring, Gear Selector Lockout
8 7661401 1 Pin, Cotter 16 1910429 1 Line, Rear Brake, Foot
12/02

B12
 CONTROLS - MASTER CYLINDER/BRAKE LINE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1 4
4 5

2
7
6

20
8
19

3
18
17
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. Qty. Description Ref. Part No. Qty. Description
1 5411297 1 Boot, Brake Line, Rubber 10 1910430 1 Line, Brake, Hand, Rear
2 5410988 2 Seal 11 7621462 1 Rivet
3 4110164 1 Switch 12 7080539 1 Clamp, Nylon
4 7517899 2 Screw 13 8360031-34 1 Conduit
5 2201834 1 Kit, Master Cylinder Cap 14 1910474 1 Line, Brake, Left Front
(Incl. Cap, Screws, Sight, Gasket) 15 7080138 4 Cable Tie
6 2201836 1 Kit, Master Cylinder Park Brake Lever 16 7512024 2 Screw
(Incl. Lever, Spring)
17 1910475 1 Line, Brake, Right Front
7 2010196 1 Asm., Master Cylinder
18 7052292 1 Fitting, Cross
8 2201833 1 Kit, Master Cylinder Clamp
(Incl. Clamp, Screws) 19 1910470 1 Line, Brake, Pod
7518304 2 Screw (AT)(AV) 20 1910499 1 Bolt, Banjo
9 2201835 1 Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
6/03

B13
 STEERING POST
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

3
1
2
4
5

2 6

E 2003 Polaris Sales Inc.

5
7
12
1 8
9

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. Qty. Description Ref. Part No. Qty. Description
1 7542324 4 Nut, Nylok 7 7556162 2 Bushing
2 5433866 2 Bushing, Steering, Upper 8 5222393 1 Flangette
3 1013920-067 1 Post, Steering 9 3514352 1 Bearing
4 5246732 1 Bracket, Steering Post, Upper 10 7547158 1 Nut
5 7512377 2 Bolt, Carriage 11 7661633 1 Pin, Cotter
6 7517428 2 Bolt, Carriage 12 7558402 2 Washer, Flat
2/03

B14
 HANDLEBAR and HEADLIGHT POD
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

1 7

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

17 16
39

37
38
36
18
19

34 20 22
35
33 21
32

31
30 23

24
27
28
25
29
30
26

C1
 HANDLEBAR and HEADLIGHT POD
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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 5434380 1 Bezel 22 2410268 1 Asm., Headlamp
2 3280431 1 Cluster 4010253 1 Bulb, Headlight
3 5412138 1 Mount, Rubber 23 5410163 2 O-Ring
4 4010964 1 Switch, Thumb Warmer, Hi/Lo (AT)(AV) 24 7081008 1 Cable, Choke
5 7511881 3 Screw 25 4010638 1 Receptacle, Pod Mount, 12V
6 5434706-400 1 Pod, Headlight, Upper (AH) 26 2461045 1 Harness, Light, Pod/Accy.
5435239-455 1 Pod, Headlight, Upper (AC) 27 7542122 4 Nut, Nylok
5435330-455 1 Pod, Headlight, Upper (AT) 28 5433762-070 1 Pod, Headlight, Lower
5434706-053 1 Pod, Headlight, Upper (AJ) (AC)(AJ)(AT)(AV)
5434706-341 1 Pod, Headlight, Upper (AF) 5433762-177 1 Pod, Headlight, Lower (AH)
5435330-456 1 Pod, Headlight, Upper (AV) 5433762-382 1 Pod, Headlight, Lower (AF)
7 4010963 1 Switch, Hand Warmer, Hi/Lo (AT)(AV) 29 7080631 1 Clip, Cable Retaining
8 4010970 1 Module, Load Shed (AT)(AV) 30 4010390 1 Switch, Ignition (Incl. Key)
9 7517238 4 Screw 4010278 1 Blank, Key, Series 2000, 6700, 6800
10 5433903 1 Spacer, Switch, LH 4010321 1 Blank, Key, Series 2200, 2300, 2700,
2800 NOTE: Your key can be dupli-
11 4010592 1 Switch, Handlebar cated only by obtaining a key blank
12 5433834-070 2 Grip, Handlebar from Polaris and having it cut by mat-
13 2461213 1 Harness, Wire, Warmers (AT)(AV) ing it with your existing key.
14 5432952 1 Plug 31 5433534 1 Cover, Key
15 7517625 1 Screw, Set 32 5132382 1 Cap
16 2410418 2 Asm., Hand Warmer (AT)(AV) 33 4010298 1 Sensor
17 ------- 1 Asm., Master Cylinder 34 7517658 1 Screw
(See Controls - Master Cylinder/Brake 35 7080922 1 Nut, Choke
Line Pg. B13 for details) 36 7670127 1 Clip, Screw
18 5244969-067 1 Bracket, Pod Mounting 37 5242987-067 1 Tube, Handlebar
19 7517317 2 Screw 38 ------- 1 Asm., Throttle Control (See Controls -
20 4032079 1 Knob, Adjusting Throttle Asm./Cable Pg. B10, Ref. 5)
21 4032078 1 Rod, Adjusting 39 5631146 1 Block, Handlebar, Pegged
5631147 1 Block, Handlebar
6/03

C2
 DRIVE CLUTCH
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

5
E 2003 Polaris Sales Inc. 4 6

7
1 2 3 9
8

10

18
12
11

5
15 14
16 13

17

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1520231 1 Clutch, One Way Drive 11 7512176 6 Bolt
2 7556202 1 Washer, Brass 12 7041157 1 Spring, Clutch
3 5631119 1 Spacer 13 1321622 3 Roller and Bushing
4 7541906 3 Nut, FLEXLOC 14 5430945 6 Washer, Multilube
5 5431936 6 Button, Clutch, Stemless 15 7512266 3 Bolt, Shoulder
6 5020422 3 Pin, Roller 16 5631215 3 Weight, Shift, 20-56
7 3585712 1 Bearing 17 1321971 1 Asm., Drive Clutch, EBS, Wide
8 7547130 1 Nut, Jam (Incl. All Less 12,16)
9 3576510 1 Cover, Bearing 18 7556204 1 Washer, Thrust
10 7552801 6 Washer, Spring Lock
4/01

C3
 DRIVEN CLUTCH
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

2
1

E 2003 Polaris Sales Inc.

3
4
9 5
6
7
8
18
17
10
16 11

15
14
13

2 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 7556120 2 Bushing 10 7517323 3 Screw
2 1321973 1 Asm., Driven Clutch, EBS 11 1321977 3 Roller, Taper
(Incl. 4-6,12-18) 12 3585710 1 Bearing
3 7556203 1 Washer 13 5211115 1 Washer
4 7556010 1 Bushing 14 3576511 1 Bearing, Moveable, 1 Inch
5 7710461 1 Ring, Retaining 15 7041636 1 Spring
6 5220646 1 Washer, Domed 16 5132751 1 Ramp, Stationary
7 7552901 1 Washer, Spring Lock 17 5210753 1 Spacer
8 7515382 1 Bolt 18 7710448 1 Ring, Retaining
9 3211091 1 Belt, Drive
12/02

C4
 CLUTCH COVER
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

1
4

2 5

7
15
14 8
13 9
12
11

10
6

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434235 1 Cover, Clutch, Inner 8 5410542 1 O-Ring
2201955 1 Kit, Inner Clutch Cover (Incl. 6,15) 9 5434264 1 Plug
2 7517599 5 Bolt/Washer 10 7077666 1 Decal, “Automatic/EBS”, Clutch
3 5434012 1 Duct, Clutch Outlet 11 7078689 1 Decal, Warning, Clutch Cover
4 7080707 2 Clamp, Narrow Band 12 5521578 1 Seal, Cover, Clutch, Outer
5 5411489 1 Boot, Duct 13 7517867 3 Screw
6 7512094 9 Screw 14 5244527-067 1 Bracket, Retainer, Seal
7 5434255-070 1 Cover, Clutch, Outer 15 5411918 1 Seal, Cover, Inner
6/02

C5
 REAR WHEEL DRIVE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

8
E 2003 Polaris Sales Inc. 7
6

4
10

11
2 12
3

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. Qty. Description Ref. Part No. Qty. Description
1 5411164 2 Cover, Dust, Hub (If built before 7/21/03) 7 7710440 2 Ring, Retaining
5412489 2 Cover, Dust, Hub (If built after 7/21/03) 8 3585502 2 Bearing
2 7661404 2 Pin, Cotter 9 5631142 2 Bushing, Bearing Carrier
3 7555796 4 Washer, Cone 10 7512325 8 Screw
4 1520588 2 Rim, Rear, Chrome (AF)(AJ) 11 5411949 2 Tire, 25x11-12
1520564-067 2 Rim, Rear, Black (AC)(AH)
1520695-455 2 Rim, Rear, Break-Up (AT) 12 7515513 8 Stud
1520695-456 2 Rim, Rear, Shadowgrass (AV) 13 1525017 2 Valve, Rim
5 5133361 2 Hub, Rear Wheel (If built before 9/29/03) 14 7547237 8 Nut, Flange
5134311 2 Hub, Rear Wheel (If built after 9/29/03) 15 7543005 2 Nut, Castle
6 5244635 2 Disc, Brake, Rear
6/03

C6
 REAR SUSPENSION
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

4
11
9
10
12
1 11
6
2 14
3 13
13
4
10
9
5 8 2 15
18 16
6 3
3
17
2 18
13 20
7
3 19
14
2
22
19 21
16 19
4 15 23

18 22
13 24
38
13
37
31 25
32 30
33

36 36
39
35 26

34
27
E 2003 Polaris Sales Inc.

19 28

29

C7
 REAR SUSPENSION
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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 7517231 4 Screw 24 5630885 2 Retainer, Spring
2 7555761 8 Washer, Flat 25 7041453-293 2 Spring, Compression
3 5432598 8 Bushing, Stabilizer (If built before 6/16/03)
7041453-067 2 Spring, Compression
4 7512329 6 Bolt (AT)(AV)(If built before 6/16/03)
5 1580107-067 2 Arm, Stabilizer Bar 7042311-293 2 Spring, Compression
6 7542324 6 Nut, Nylok (If built after 6/16/03)
7042311-067 2 Spring, Compression
7 5020827 2 Rod, Linkage, Stabilizer (AT)(AV)(If built after 6/16/03)
8 5334114-067 1 Bar, Stabilizer Tube 26 5433551 2 Sleeve, Shock Protector
9 5434549 2 Bushing, Stabilizer Tube 27 5631014 2 Cam, Adjusting, Spring
10 7555939 2 Washer 28 7041959 2 Shock, Rear
11 7558402 8 Washer, Flat 29 7515415 2 Screw
12 1541801-067 1 Support, Stabilizer 30 5133806 2 Shaft, A-Arm
13 5434548 12 Bushing, A-Arm, Short 31 1014174-293 1 Control, Lower, LH
14 7515472 6 Screw 1014175-293 1 Control, Lower, RH
15 7512492 4 Screw 1014174-067 1 Control, Lower, LH (AT)(AV)
1014175-067 1 Control, Lower, RH (AT)(AV)
16 7552603 4 Washer, Spring Lock
32 5631142 4 Bushing, Bearing Carrier
17 1014320-293 1 Arm, Control, Upper, LH
1014321-293 1 Arm, Control, Upper, RH 33 7552614 4 Washer, Lock
1014320-067 1 Arm, Control, Upper, LH (AT)(AV) 34 7517873 4 Screw
1014321-067 1 Arm, Control, Upper, RH (AT)(AV) 35 7555740 4 Washer, Flat
18 5020826 6 Shaft, A-Arm, Short 36 5434550 8 Bushing, Control, Lower
19 7542439 10 Nut, Nylok 37 5434890-1038 1 Shield, LH
20 5245140-067 1 Strap, Rear Skid Plate 5434891-1038 1 Shield, RH
21 7555806 2 Washer, Flat 38 7512084 4 Screw
22 5434551 4 Bushing, A-Arm, Long 39 5133663 1 Carrier, Wheel Bearing, LH
23 7515433 2 Screw 5133664 1 Carrier, Wheel Bearing (RH)
6/03

C8
 ELECTRICAL/TAILLIGHT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

3
1 2
4
7 8 9 10
5 6

2 11

12
13
14
25 26 15
27
16
19

24 17

23

19 18
20
21
22
E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2460976 1 Harness, Main (If built before 2/24/03) 16 4010471 1 Cable, Battery/Solenoid
2461177 1 Harness, Main (If built after 2/24/03) (AC)(AF)(AH)(AJ)
2 2200593 2 Kit, Circuit Breaker, 20 AMP 17 5434037 1 Box, Battery
3 4010924 1 Module, Resistor 18 5432077 AR Tube, Battery Vent
4 2410320 1 Asm., Taillight, 12V (Incl. 7-13) 19 7512024 6 Screw
5 4032045 1 Gasket, Taillight 20 3087196 1 Switch, Magnetic (If built before 6/26/03)
6 4030043 1 Bulb, Taillight 4010930 1 Switch, Magnetic (If built after 6/26/03)
7 4032046 1 Lens, Taillight 21 4010376 1 Cable, Solenoid/Starter
8 4032029 2 Screw, Taillight 22 2410411 1 Jumper, Harness
(If built 2/03/03 to 3/05/03)
9 7517386 1 Screw
23 4010796 1 Rectifier, Regulator
10 5247376 1 Strap, Battery Holddown (If built before 2/17/03)
11 4010630 1 Battery, 30 AMP 4010929 1 Rectifier, Regulator
12 4032064 1 Backing, Taillight/Brake Light (If built after 2/17/03)
13 7670054 2 Nut, Speed 24 5133182 1 Sink, Heat
14 4010470 1 Cable 25 4020139 3 Clip, Rosebud (Small)
15 2202099 1 Kit, Battery Bolt 26 7080138 7 Cable Tie
27 7512027 2 Screw
6/03

C9
 GEAR SELECTOR
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

11

5 10

6 9
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. Qty. Description Ref. Part No. Qty. Description
1 5412003 1 Cover 7 1821055 1 Asm., Linkage
2 7512024 1 Screw 8 7542324 2 Nut, Nylok
3 5411007 1 Knob, Gear Selector 9 7558402 2 Washer, Flat
4 5435042 2 Mount, Gear Selector 10 1013315-067 1 Selector, Gear
5 7515175 2 Screw 11 7515306 2 Screw
6 7542122 2 Nut, Nylok
12/02

C10
 FRONT HOUSING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2
E 2003 Polaris Sales Inc.
3
4
5 7 8
13 6 1
9
1 10
23 11
5 13
12 14
11 15
16
22 21 17
4 18
1
19
20

24

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 3233956 1 Kit, Minor Repair 12 ------- 1 Bushing
(Incl. O-Rings and Seals) 13 3233955 11 Kit, Bolt
2 3233998 1 Asm., Cover Plate 14 3233947 1 Cover, Input
(Incl. Output Cover, Insert and Coil)
15 3233945 1 Bearing, Roller Ball
3 3233925 1 Kit, Shim Set (Incl. Shims)
16 3233944 1 Shaft, Pinion, 11T
4 3233926 2 Bearing, Roller Ball
17 ------- 1 Bushing
5 3233953 1 Asm., Race/Output Hub (Incl. 21)
18 ------- 1 Gearcase, LH
6 3233928 1 Pin, Dowel
19 3233942 1 Plug, Oil Fill
7 3233932 1 Bearing, Roller Ball
20 3233951 1 Asm., Drain Plug
8 3233933 1 Clutch Housing/Ring Gear (Incl. Plug and Washer
9 3233949 1 Asm., Roll Cage 21 3233929 1 Bearing, Needle, Roller Thrust
(Incl. Spring and Roll Cage)
------- 1 Spring 22 3233954 1 Asm., Clutch (Incl. 7-11)
10 3233957 14 Kit, Roll 23 3233924 1 Plate Armature
11 3233934 2 Ring, Retaining, Wire Form 24 1341344 1 Asm., Front Gearcase
(Incl. 2-12,16-19,20-23)
7/03

C11
 TRANSMISSION MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

3 4
1
5
2
1
E 2003 Polaris Sales Inc.

1 6

3 10
7 9
8
3
12
11
12
7

11
13
14

16

15

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 8450003-1525 AR Line, Fuel 9 5244599-067 1 Mount, Rear Transmission
2 7052075 1 T-Fitting 10 7515398 2 Screw
3 7080307 3 Clamp, Hose 11 7555976 3 Washer, Flat
4 7080756 2 Clip 12 7515417 2 Screw
5 7670102 1 Clip 13 7552603 2 Washer, Spring Lock
6 8450003-1525 AR Line, Fuel 14 7515522 2 Bolt
7 7547108 4 Nut, Flange, Lock 15 7517289 2 Screw
8 7542321 2 Nut, Flange 16 1013134-067 1 Mount, Rear Engine
6/03

C12
 GEARCASE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

17
16
15
E 2003 Polaris Sales Inc.

14

13

12
11 20
18 19
21
11
20 34
19 29 33
2 24 23 32
27 25
10 29 31 26
7 30
8 9 29
5 6 11
26 28
4 22 24 25 27 35
3 15 14 23 38 37 36
2 11
1 42 40
43 41 39
44
66 65 61
69 59 47
64 62 15 45 46
63 60 56 48 49
58 55 50
67 57
68 54

53 7

14

52
51

70

C13
 GEARCASE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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 3233961 1 Nut 36 3233608 4 Screw
2 3233826 8 Screw 37 3233609 1 Cover, Bearing
3 3233827 1 Cover 38 3233106 1 Ring
4 3233829 1 Pawl, Detent 39 3233357 1 Spacer
5 3233869 1 O-Ring 40 3233607 1 Bearing, Ball
6 3233831 1 Shaft, Shift 41 3233606 1 Shaft, Pinion, 10T
7 3233788 2 Seal 42 3233619 1 Washer, Thrust
8 3233832 1 Gear, 31T 43 3233873 1 Sprocket, 22T/18T
9 3233711 1 Plug, Oil Fill 44 3233621 1 Gear, 31T
10 3233524 1 Tube, Vent 45 3233911 1 Shaft, Output, Main, Rear
11 3233018 4 Bearing 46 3233582 1 Button, Thrust
12 3233036 1 Chain, Silent 47 3233583 AR Shim
13 3233890 1 Shaft, Input 48 3233611 AR Shim
14 3233019 4 Bearing 49 3233781 1 Cover, Output, Front
15 3233529 4 Pipe, Knock 50 3233846 17 Screw
16 3233865 1 Cover, LH 51 3233777 1 Plug
17 3233874 1 Seal 52 3233254 1 Washer
18 3233910 1 Drum, Shift 53 3233625 1 Shaft, Output, Front
19 3233858 2 Fork, Shift 54 3233784 1 Chain, Silent
20 3233859 2 Pin, Dowel 55 3233844 1 Sprocket, 22T
21 3233860 1 Rail, Shift Shaft 56 3233552 1 Bushing
22 3233915 1 Plate, Park 57 3234013 1 Clamp, Tie
23 3234040 1 Engagement Dog 58 3233917 1 Lockout, Park
24 3233849 2 Spring, Wave 59 3233867 1 Gearcase, Main
25 3233875 3 Engagement Dog 60 3233324 1 Washer
26 3233850 2 Ring, Retaining 61 3233548 1 O-Ring
27 3233851 2 Washer 62 3233839 1 Gear, 16T
28 3233852 1 Gear, 33T 63 3233838 1 Disc, Lockout
29 3233718 2 Bearing, Needle 64 3233909 1 Star, Detent
30 3233853 1 Shaft, Reverse 65 3233076 1 O-Ring
31 3233854 1 Sprocket, 24T 66 3233830 1 Spring, Compression
32 3233855 1 Washer 67 3233835 1 Switch
33 3233912 1 Gear, 28T 68 3233834 1 Ring, Retaining
34 3233913 1 Gear, 40T 69 3233906 1 Bellcrank
35 3234039 1 Gear, 44T 70 1341343 1 Asm., Main Gearcase
11/02

C14
 REAR GEARCASE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

4 5
2 3
1

6
E 2003 Polaris Sales Inc.

19

17
7
18
8

9
17 20

16

10
11 12 13 14
6
15
4 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. Qty. Description Ref. Part No. Qty. Description
1 3233876 1 Cover, Output, LH 11 3233881 1 Shaft, Pinion, 10T
2 3233846 8 Screw 12 3233714 1 Bearing, Ball
3 3233524 1 Tube, Vent 13 3233588 1 O-Ring
4 3233254 2 Washer 14 3233882 1 Cover, Input
5 3233777 2 Plug 15 3233785 1 Seal
6 3233878 2 Seal 16 3233880 1 Gearcase, Housing, Rear
7 3233583 AR Shim 17 3233268 2 Bearing, Ball
8 3233582 1 Button, Thrust 18 3233879 1 Gear, 31T
9 3233529 2 Pipe, Knock 19 3233581 AR Shim
10 3233577 1 Bushing 20 1341352 1 Asm., Gearcase, Rear
4/01

D1
 REAR GEARCASE MOUNTING
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

1
2 4
5

1
2

2
2 5
3 4 5
4

2
3

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517878 5 Screw 4 7512492 6 Screw
2 7555806 12 Washer, Flat 5 7552603 6 Washer, Spring Lock
3 7547008 5 Nut, FLEXLOC
4/01

D2
 CRANKCASE
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

5
1
2
6
3
4

8 9
10
11

20 21
22 13 11
18
12
11
20

15 14

6
18

19 E 2003 Polaris Sales Inc.

16

17

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5412114 1 Seal, Flanged 12 5412048 1 Seal
2 3514361 1 Bearing, Ball 13 3585704 4 Bearing, Main Journal
3 7556194 1 Bushing 14 7052306 1 Plug, Magnetic
4 3514318 1 Bearing, Ball 15 5812232 1 Washer, Copper
5 7518007 1 Plug 16 7517793 9 Screw
6 1201658 1 Asm., Engine (Incl.14-22) 17 7517792 6 Screw
7710512 1 Ring, Retaining 18 7663001 2 Pin, Dowel
7 5132753 4 Bearing 19 5211785 1 Plate, Baffle
8 5411184 1 Seal, Oil 20 7518045 6 Screw
9 5812364 1 Gasket, Cover 21 1201970 1 Pickup, Oil
10 1202384 1 Cover, Engine, Magneto 22 5812016 2 O-Ring
11 7517950 4 Screw
6/03

D3
 CRANKSHAFT and PISTON
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2
3 4

3
2

E 2003 Polaris Sales Inc.

5
6

11
10

9
8
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2202107 2 Kit, Piston (Incl. 2,3,4) 6 7721117 1 Key, Woodruff
2 3022996 4 Circlip, Piston 7 2202145 1 Kit, Gear Set
3 ------- 2 Pin, Piston 8 7517865 1 Screw
4 2202127 1 Kit, Piston Ring (Incl. Control,Iron, and 9 7555982 1 Washer
Chrome Rings) 10 7721131 1 Key, Woodruff
5 2202109 1 Kit, Crankshaft (Incl. 7, from Crank- 11 5132396 1 Shaft, Balance
case Pg. D3, Ref. 2,3,4,13)
9/02

D4
 CYLINDER and CYLINDER HEAD
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

3
2
1

E 2003 Polaris Sales Inc.

10
7

9
21 22
8

23 24 25 26

11
20

19 12
18
17

16 15 13

14

D5
 CYLINDER and CYLINDER HEAD
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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 7517277 2 Screw 14 5811455 1 Gasket, Base
2 5432533 1 Cover, Breather 15 7051534 1 Plug
3 3021413 1 Valve, Breather 16 - - - - - - - 1 Asm., Carburetor
4 7516822 7 Screw (See Carburetor Pg. D8, Ref. 48)
5 1201973 1 Cover, Rocker 17 7080681 1 Clamp, Hose
6 5411862 1 Seal 18 7516734 2 Screw
19 1253415 1 Adapter, Carburetor
7 7517883 6 Screw
8 5811511 1 Gasket, Exhaust 20 3070195 2 Spark Plug, RC7YC
9 ------- 1 Manifold 21 7516822 2 Screw
(See Exhaust System Pg. A11, Ref. 26) 22 5631196 1 Cover, Thermostat
10 7516730 4 Screw 23 7052308 1 Thermostat
11 1201657 1 Head, Cylinder 24 5411521 1 O-Ring
5131429 4 Guide, Valve 25 4010356 1 Switch, Temperature
12 5812193 1 Gasket, Head 26 7052135 2 Fitting
13 2202158 1 Kit, Cylinder (Incl. 15)
5/02

D6
 CARBURETOR
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2
3 51

4
50

5
E 2003 Polaris Sales Inc.
49

6 7
8
44
45
46
47
9 42
48 43
41

10 40
11
39
12
37
36 38
13 13
15 14
16
35
27
34
28
17 26 33
29
30
25 32
31

18
24 23

19

22

21

20

D7
 CARBURETOR
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

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 3130507 1 Ring 27 3131226 1 Jet, Pilot (#47.5)
2 3130508 1 E-Ring 28 3130522 1 O-Ring
3 3131449 1 Needle, Jet 29 3130523 1 Washer
4 3130752 1 Ring 30 3130525 1 Spring
5 3130732 1 Diaphragm 31 3130524 1 Adjuster
6 3131363 1 Needle, Jet (P-6) 32 3130546 1 Screw, Adjust
7 3130541 2 Screw 33 3130545 1 Ring
8 3130540 2 Washer, Spring 34 3130544 1 Spring
9 3130504 1 Asm., Jet Block 35 3130502 1 Valve, Throttle (100)
10 3130014 1 Washer 36 3131398 1 Spring
11 3130571 1 Jet, Main (#155) 37 3130514 1 Ring
12 3131393 2 Cap 38 3130501 2 Screw
13 3130515 2 Seal 39 ------- 1 Asm., Throttle Shaft
14 3130517 1 Packing 40 3130543 1 Guide, Cable
15 3130518 1 E-Ring 41 3130535 4 Screw
16 3130519 1 Cap 42 3130511 1 Cover
17 3130361 1 Pin, Float 43 3130512 1 O-Ring
18 3130594 1 Plate 44 3131396 1 Holder, Guide
19 3130532 1 O-Ring 45 3130538 1 Spring
20 3130520 4 Screw 46 3131395 1 Asm., Plunger
21 3130590 1 Asm., Float Body 47 3130625 1 Jet, Air (#160)
22 3130521 1 Screw 48 1253493 1 Asm., Carburetor (Incl. 1-12)
23 3130529 1 Asm., Float 49 3131451 1 Spring
24 3130591 1 Screw 50 3130503 1 Asm., Cover
25 3131360 1 Valve, Needle (1.5) 51 3130592 4 Screw
26 3130533 1 O-Ring
9/02

D8
 INTAKE and EXHAUST
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

16
15
2
3
14
4
13 5
6
7
6
8

10

11

11
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 1202169 4 Asm., Rocker Arm 9 7517865 1 Screw
2 5132402 4 Pushrod 10 5131415 4 Lifter, Valve
3 2202110 1 Kit, Camshaft (Incl. 7) 11 5133141 2 Valve, Exhaust
4 5244286 1 Plate, Thrust 12 5132696 2 Valve, Intake
5 7517598 3 Screw 13 5411895 4 Seal, Valve Guide
6 2202145 1 Kit, Gear Set 680/780 14 7041565 4 Spring, Valve
7 7041999 3 Spring, Compression 15 5131413 4 Retainer, Spring
8 7556183 1 Washer, Spring 16 5910042 8 Lock, Valve Stem
6/02

D9
 OIL DIPSTICK
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1202109 1 Asm., Dipstick 4 5245805 1 Clamp
2 1202110 1 Tube, Oil Fill 5 5812016 1 O-Ring
3 7517795 2 Screw
4/01

D10
 WATER PUMP
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2 3

5
6

E 2003 Polaris Sales Inc.

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. Qty. Description Ref. Part No. Qty. Description
1 5131419 1 Shaft, Oil/Water Pump 6 7546804 1 Nut, Nylok
2 3584404 1 Bearing 7 7516823 5 Screw
3 ------- 1 Kit, Gear Set 680/780 (See Intake and 8 7517950 2 Screw
Exhaust Pg. D9, Ref. 6) 9 1202019 1 Cover
4 5433684 1 Impeller 10 5812048 1 O-Ring
5 7555874 1 Washer, Flat 11 3610075 1 Seal, Water Pump
12/02

D11
 OIL PUMP
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

7
E 2003 Polaris Sales Inc.
6
10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2540006 1 Filter, Oil 7 7041563 1 Spring
2 2540115 1 Nipple, Oil Filter 8 7556005 1 Washer
3 7517807 4 Screw 9 7516824 1 Screw
4 5131426 1 Housing, Oil Pump 10 2202159 1 Kit, Oil Pump (Incl. 4,5 from Water
5 1202079 1 Gerotor Pump Pg. D11, Ref. 1,2,3)
6 7661127 1 Pin, Dowel
4/03

D12
 MAGNETO
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2
3 E 2003 Polaris Sales Inc.
4
5

8
6 9
7

10
11

12
13
18

19 16

15

14
17

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5245364 1 Holddown, Wire 10 5812283 1 Cover, Sound
2 4010709 1 Asm., Stator (If built before 2/23/03) 11 5434310 1 Cover, Outer
4010901 1 Asm., Stator (If built after 2/23/03) 12 5411564 1 O-Ring
2202602 1 Kit, Ignition (Incl. Jumper)
13 7517950 10 Screw
3 7517847 2 Screw
14 5433820 1 Plug
4 7517848 3 Screw (If built before 2/23/03)
7517714 3 Screw (If built after 2/23/03) 15 4010897 1 Controller, Ignition (If built after 2/23/03)
5 4060152 1 Asm., Flywheel (If built before 2/23/03) 16 4010898 1 Coil, Ignition (If built after 2/23/03)
4010899 1 Asm., Flywheel (If built after 2/23/03) 17 4010124-66 2 Wire, Ignition (If built before 2/23/03)
6 7555907 1 Washer 18 4010526 2 Boot, Spark Plug (If built before 2/23/03)
7 7546909 1 Nut 19 4010696 1 Asm., Controller, Ingition
8 5812359 1 O-Ring (Incl. 17,18)(If built before 2/23/03)
9 1201684 1 Housing, Stator
2/03

D13
 STARTING MOTOR
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1
2

3
5 4
6

E 2003 Polaris Sales Inc.

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7516823 2 Screw 4 4010418 1 Bendix
2 4010417 1 Starter 5 7552616 1 Washer, Lock
3 7555908 1 Washer, Thrust 6 7546705 1 Nut
9/01

D14
 TOOL KIT
SPORTSMAN 700 A04CH68AC and SPORTSMAN 700 A04CH68AF and SPORTSMAN 700 A04CH68AH and SPORTSMAN 700 A04CH68AJ and SPORTS-
MAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc.

9
4

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2873687 1 Kit, Tool (Incl. 2-8) 7 ------- 1 Puller, Spark Plug (Wrench Handle)
2 2870725 1 Gauge, Tire Pressure 8 2682572 1 Pouch, Tool Kit
3 ------- 1 Screwdriver 9 9918540 1 Owner’s Manual, ‘04 Sportsman
4 ------- 1 Wrench, 8-10 Open 400-700
9918983 1 Instruction, Hand/Thumb Warmer Op-
5 ------- 1 Wrench, 9/16 x 1 1/2 Open eration (AT)(AV)
6 ------- 1 Wrench, Plug 10 2873647 1 Wrench, Torx
6/03
E1
 WINCH ASM.
SPORTSMAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

1 5

3
E 2003 Polaris Sales Inc. 6
7
4

8
9
10

25 26 19 6 11

6 16
24

22 12
23 19 13
6 19
21 14
20
15
6 16
6
19
18 17

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2410423 1 Asm., Winch Switch 14 7515494 2 Screw
2 7518304 2 Screw 15 7542451 2 Nut, Nylok
3 5247139 1 Plate, Switch Mount 16 7512392 4 Screw
4 5133010 2 Spacer, Master Cylinder Clamp 17 2461220 1 Harness, Front
5 7512247 2 Bolt 18 2461218 1 Harness, Main
6 7558402 10 Washer, Flat 19 7542324 10 Nut, Nylok
7 7512329 1 Bolt 20 5434698-070 1 Bumper, Front
8 5247570 1 Bracket, Contractor 21 2431017 2 Asm., Headlight, Bottom Mount
9 7542122 2 Nut, Nylok 22 1014020-067 1 Support, Rack, Front
10 2202253 1 Asm., Hook, Warn Winch 23 5247569 1 Plate Winch Mount
11 2202643 1 Asm., Winch, Warn w/Cable 24 7515321 4 Bolt
12 5247568 1 Plate, Fairlead Mount 25 7515317 4 Screw
13 2871462 1 Roller, Fairlead, Warn Winch 26 7552901 4 Washer, Spring Lock
6/03

E2
 FUEL TANK
SPORTSMAN 700 A04CH68AT and SPORTSMAN 700 A04CH68AV

E 2003 Polaris Sales Inc. 2

3 5
4
23

22

21
7

8
17
18 20
16
19
15
14

10 13

12

11

10

9
(See Fuel Tank Pg. A12 for other Fuel Tank)

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 5433687 1 Cap, Gas Tank (If built before 7/01/03) 12 7052028 1 Grommet
5435324 1 Cap, Gas Tank (If built after 7/01/03) 13 7517505 1 Screw
2 5812123 1 Gasket, Fuel Cap 14 5432559 1 Knob, Fuel Valve
3 5812265 1 Seal, Foam 15 5432733 1 Nut, Fuel Valve
4 8360009-600 AR Line, Fuel 16 5247585 1 Bracket, Fuel Valve
5 7517685 2 Screw 17 7661637 2 Rivet
6 5247184 1 Bracket, Mounting, Rear, LH 18 7052159 1 Valve, On/Off
5247185 1 Bracket, Mounting, Rear, RH
19 2520339 1 Asm., Fuel Tank w/Sender
7 5431053 1 Vent, Tank (Incl. 7,8,11,12,20-23)
8 5812004 1 Foil, Tank 20 5812005 1 Foil, Tank
9 8450103 AR Hose, Fuel 21 5810858 1 Gasket
10 7080003 4 Clamp, Hose, Red 22 2410289 1 Sender, Fuel
11 7052346 1 Fitting, Fuel Outlet, Reserve 23 7512056 5 Screw
6/03

E3
PRINTED IN THE USA PARTS MANUAL PN 9918612 and MICROFICHE PN 9918613 6/03
Changed pages in 9918612
1 2 3 4 5 6 7 8 9 10 11 12 13 14

A cover toc x x x x x x x x x x

B x x x x x

C x x x x x x

D x

E x x x

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