I have a 2004 Sportsman 700 (Carb) and need to repair the front housing. The left axle is hanging up in reverse. I suspect a bearing is bad. I took the house out to the dealer and they informed me it was better to replace the entire unit ($1031) as none of the repairs will hold. I found that hard to believe and I plan to do the repair myself. Is the dealer correct, I hope not.

Also, any suggestions on the repair itself or where could I find the service or repair manual?

 

here is a link with a parts breakdown...I just went under 2004 sp700 not sure if yours is an 2004.5 model. Didnt see anything as high priced as 1031 but there could be markup in that price.

http://www.partsland.com/index...SMAN-700-FRONT-HOUSING

 

Appreciate the feedback. The part I needed is now absolute (#12) in the picture you attached. I bought the entire housing for a little over $800 new at the polaris dealer this afternoon. It figures the one part I needed was now discontinued. O well, I figure the rest of it was wore as well. I just hated to sink that much into an 04 model.

While there I also bought the heavier springs. I'm hoping that will stiffen up the frontend a little. After adding the winch it got a little soft.

Thanks again,

Jim