sportsman 600 model #a04ch59af model …pi54.com/corp/manuals/parts/9918610.pdf · sportsman 600...

SPORTSMAN 600Model #A04CH59AFModel #A04CH59AHModel #A04CH59AJ

E 2003 Polaris Sales Inc.

PARTS MANUAL PN 9918610 and MICROFICHE PN 9918611 12/02

TABLE OF CONTENTSSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

Parts Manual

AA--ARM/STRUT MOUNTING B12. . . . . . . . . . . . .AIR BOX B1. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBRAKE LINE B10. . . . . . . . . . . . . . . . . . . . . . . .BRAKE, FRONT B8. . . . . . . . . . . . . . . . . . . . .BUMPER MOUNTING A7-8. . . . . . . . . . . . . . . . .

CCAB, FRONT A5. . . . . . . . . . . . . . . . . . . . . . . .CAB,REAR A3-4. . . . . . . . . . . . . . . . . . . . . . . . .CABLE B9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .CALIPER, REAR C9. . . . . . . . . . . . . . . . . . . . .CARBURETOR D7-8. . . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER C3. . . . . . . . . . . . . . . . . . . . .CONTROLS -- MASTER

CYLINDER/BRAKE LINE B10. . . . . . . . . . . .CONTROLS -- THROTTLE ASM./CABLE B9. . . .COOLING SYSTEM A10. . . . . . . . . . . . . . . . . . .CRANKCASE D3. . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT D4. . . . . . . . . . . . . . . . . . . . . . .CYLINDER D5-6. . . . . . . . . . . . . . . . . . . . . . . . . .CYLINDER HEAD D5-6. . . . . . . . . . . . . . . . . . . . .

DDECALS A9. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C1. . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT, FRONT B2. . . . . . . . . . . . . . . . .DRIVE SHAFT, REAR B3. . . . . . . . . . . . . . . . .DRIVEN CLUTCH C2. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL C7. . . . . . . . . . . . . . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST D9. . . . . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A11. . . . . . . . . . . . . . . . . . .

FFRAME A3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C11. . . . . . . . . . . . . . . . . . . .FUEL TANK A12. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C10. . . . . . . . . . . . . . . . . . . .

GGEARCASE (Cases and Snorkel) D1-2. . . . . . . . . .GEARCASE (INTERNAL COMPONENTS) C13-14. . .

HHANDLEBAR B13-14. . . . . . . . . . . . . . . . . . . . . . . .HEADLIGHT POD B13-14. . . . . . . . . . . . . . . . . . . . .

IINTAKE D9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MMAGNETO D13. . . . . . . . . . . . . . . . . . . . . . . . . .MASTER CYLINDER B10. . . . . . . . . . . . . . . . . .MASTER CYLINDER, REAR C8. . . . . . . . . . . .

OOIL PUMP D12. . . . . . . . . . . . . . . . . . . . . . . . . .

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

RRACK MOUNTING, FRONT A7-8. . . . . . . . . . . . .RACK MOUNTING, REAR A6. . . . . . . . . . . . . .REAR WHEEL DRIVE C4. . . . . . . . . . . . . . . . . .

SSEAT A3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D14. . . . . . . . . . . . . . . . . . .STEERING POST B11. . . . . . . . . . . . . . . . . . . . .STRUT, FRONT B6. . . . . . . . . . . . . . . . . . . . . .SUSPENSION, REAR C5-6. . . . . . . . . . . . . . . . .

TTAILLIGHT C7. . . . . . . . . . . . . . . . . . . . . . . . . .THROTTLE ASM. B9. . . . . . . . . . . . . . . . . . . . .TOOL KIT E1. . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING C12. . . . . . . . . . . .

WWATER PUMP D11. . . . . . . . . . . . . . . . . . . . . . .WHEEL, FRONT B7. . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

A3

REAR CAB, SEAT and MAIN FRAMESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

5

6

1

910

16

15

1718

19

7

13

14

21

36

4

3035

34

3231

12

3

33

20

2

2428

8

29

37

27

26

21


2523

24

22

11

A4

REAR CAB, SEAT and MAIN FRAMESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

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

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

5432117-0535432117-341

111

Cab, Rear (AH)Cab, Rear (AJ)Cab, Rear (AF)

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

2682958-07011

Asm., Seat, BlackCovering, Seat, Black

20 5412067 8 Bumper, Rubber21 5431787 1 Cover, Tool Box22 7517377 4 Screw23 5432280 2 Spacer (LH Only)24 7542122 8 Nut, Nylok25 7542153 6 Nut, Nylok, Flanged26 7512283 6 Screw27 5244751-067 1 Brace, Frame28 1014260-067 1 Frame, Main29 7170509 1 Decal, Hitch30 7512232 24 Screw31 5811111 1 Foil, Rear Fender32 5811087 1 Foil33 5811106 2 Foil, Rear Cab, Front34 5434704-070

5434705-07011

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

35 7670057 22 Nut, U-Type Speed36 7517377

751737644

Screw (LH Side)Screw (RH Side)

37 5432221-0705433929-070

11

Footwell, Black, LHFootwell, Black, RH

2/03

A5

FRONT CABSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

5

7

6

11

18

23

15 14

21 20

22

6

1

12

4

10 17

12

10

98

13

14

19

16


1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5433853-400

2632471-4005433853-3822632471-3825433853-0702632471-070

111111

Panel, Side, LH (AH)Panel/Foil, RH (AH)Panel, Side, LH (AF)Panel/Foil, RH (AF)Panel, Side, LH (AJ)Panel/Foil, RH (AJ)

3 5812326 1 Foil, Side Panel, RH4 7512232 10 Screw5 2632748-400

2632748-0532632748-341

111

Cab, Front (AH)Cab, Front (AJ)Cab, Front (AF)

6 7670057 10 Nut, U-Type Speed7 5432088-400

5432088-0535432088-341

111

Cover, Front (AH)Cover, Front (AJ)Cover, Front (AF)

8 7517861 2 Screw

9 5246872 1 Guard, Splash, LH/Pump Mount10 7517386 3 Screw11 7670135 2 Nut, Push-on12 7517312 2 Screw13 7670156 2 Clip, Retainer14 7542122 2 Nut, Nylok15 7556034 2 Washer16 7555859 2 Washer, Flat17 5246021-067 1 Guard, Splash, RH18 5434702-070

5434703-07011

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

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

2/03

A6

REAR RACK MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

2

3

4

67

89

10

11

5

1

8


1 7517983 2 Screw2 7517685 2 Screw3 2632637-070

2632836-070

1

1

Asm., Rack, Rear (Incl. Ref. 4 andWarning Decal)(If built before 2/03/03)Asm., Rack, Rear (Incl. Ref. 4 andWarning Decal)(If built after 2/03/03)

4 ------ -- -- -- -- 2 Decal, Reflector, Red(See Decals Pg. A9, Ref. 1)

5 5334092 2 Spacer6 7512329 4 Bolt7 5241663 1 Bracket, Silencer, Frame8 7558402 8 Washer, Flat9 7542324 4 Nut, Nylok10 1013724-067 1 Support, Rear Rack11 7517208 6 Screw

2/03

A7

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

27

5

22

3

26

8

9

13

2

19

1

4

24

12

16

15

20

20

14

21

10

13

20

207

3

17

22

3

3

7

27

11

3

6

25

23

20

18

7

A8

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ


1 7517685 4 Screw2 5434697-070

5435240-070

1

1

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

3 7558402 12 Washer, Flat4 7517208 4 Screw5 2431017

403005922

HeadlightBulb, Replacement, 27W

6 7555843 2 Washer, Flat7 7542324 8 Nut, Nylok8 2632757-070 1 Asm., Bumper, Front, Black

(Incl. Warning Decal)9 7515306 4 Screw10 5434699-070 1 Panel11 7512094 2 Screw12 1014412-067 1 Guard, Brush13 5434314

543431511

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

14 5410774 4 Grommet15 5435046 1 Cover, Radiator16 5247137-067 1 Grill17 7518046 4 Screw18 7670094 6 Nut, U-Type19 7512097 6 Screw20 7515399 6 Screw21 5245767-067 1 Bracket, Bumper, Lower22 7512329 2 Screw23 7171474

717147511

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

24 1014020-067 1 Support, Front Rack25 5810467 1 Plug, Frame26 1014261-067

1014262-06711

Support, Front Rack, LHSupport, Front Rack, RH

27 7512232 6 Screw

2/03

A9

DECALSSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

RH

LH

2 3 4 65

8

17

7

11

16

18

12

15

2

1310

149

1


1 7179927 2 Decal, Reflector, Red2 7170912 2 Decal, Warning, Front/Rear Rack3 7171012

71710137171016717101771710087171009

111111

Decal, “4X4”, Side Panel, LH (AF)Decal, “4X4”, Side Panel, RH (AF)Decal, “4X4”, Side Panel, LH (AH)Decal, “4X4”, Side Panel, RH (AH)Decal, “4X4”, Side Panel, LH (AJ)Decal, “4X4”, Side Panel, RH (AJ)

4 7078253 1 Decal, Age Warning5 7079780 1 Decal, Warning AWD Switch6 7078003 1 Decal, Headlight Adjustment7 7078465 1 Logo, Polaris Star8 7079773

707991611

Decal, “POLARIS”, Front Cover (AF)(AH)Decal, “POLARIS”, Front Cover (AJ)

9 71714747171475

11

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

10 7079672 1 Decal, Foot Brake

11 7079604 1 Decal, Override Switch, AWD12 7171315

717131671710047171005

1111

Decal, Tank Side, “600”, LH (AF)Decal, Tank Side, “600”, RH (AF)Decal, Tank Side, LH (AH)(AJ)Decal, Tank Side, RH (AH)(AJ)

13 717101071710117171014717101571710067171007

111111

Decal, Side Panel, Top, LH (AF)Decal, Side Panel, Top, RH (AF)Decal, Side Panel, Top, LH (AH)Decal, Side Panel, Top, RH (AH)Decal, Side Panel, Top, LH (AJ)Decal, Side Panel, Top, RH (AJ)

14 7077920 1 Decal, Passenger Warning15 7079959

707996011

Decal, “POLARIS”, Rear (AF)(AH)Decal, “POLARIS”, Rear (AJ)

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

1/03

A10

COOLING SYSTEMSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

101

3536

2037

33

13

17

11

1514

5

122

25

26

30

6

29

3124

24

17187

19

32

5

4

2140

38

34

2728

16

89

8

3922

2317

5

19

20

24

3


1 1240044 1 Cap, Pressure2 5434325 1 Filler, Coolant3 5521644 1 Guard, Hose4 7042089 1 Retainer, Hose5 7512084 5 Screw6 5412311 1 Hose, Filler Neck7 7080827 1 Clamp, 1 Inch8 7080003 4 Clamp, Hose9 8450040-150 AR Line, Fuel10 5430743 1 Cap, Overflow, Drilled11 5810279 1 Gasket, Overflow Cap12 5433774 1 Plug, Cap13 5431673 1 Tank, Surge14 7052065 1 Fitting, Barbed, 90 Degree15 8450003-1525 1 Line, Fuel16 7080307 1 Clamp, Hose17 7080826 3 Clamp18 5412030 1 Hose, Engine, Upper19 7080844 2 Clamp, Springband20 5521597 2 Hose, Guard

21 5246656 1 Bracket, Radiator Mount, Upper22 7518014 2 Screw23 7556196 2 Washer24 7547197 6 U-Clip25 4010161 1 Sensor, Thermal26 1240103 1 Radiator27 5411975 2 Grommet28 7515179 2 Screw29 7052296 1 Valve, Drain30 5410584 2 Bushing, Mount31 5245773-067 1 Bracket, Radiator, Lower32 7517386 2 Screw33 5434171 1 Shroud, Fan34 4010631 1 Clip, Wiring35 2410288 1 Asm., Fan and Motor36 7517975 4 Screw37 5412312 1 Hose, Radiator, Lower38 7052282 1 Connector, Tee39 7081047 2 Clamp40 5412313 1 Hose, Engine, Lower

9/02

A11

EXHAUST SYSTEMSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

2411

15

9

4

1

12

2

17

6

5

3

10

1

2

34

5

10

9

14 23

20 21

13

13

16

19

19

19

17

22

78

18

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7542324 2 Nut, Nylok2 7555716 2 Washer, Flat3 5010192 2 Bushing4 5410436 2 Washer, Rubber5 7555863 2 Washer6 5241663 1 Bracket, Silencer, Frame7 7555935 8 Washer8 7517615 4 Screw9 5410241 2 Dampener, Vibration10 7515316 2 Bolt, Carriage11 1261223-029 1 Silencer, Exhaust12 7512666 1 Bolt

13 3610047 2 Seal, Exhaust14 7041804 2 Spring, Exhaust15 1261242-029 1 Pipe, Exhaust16 5244014 1 Shield, Heat17 7515197 5 Screw18 7555935 5 Washer19 7041789 3 Spring, Exhaust20 7542301 1 Nut21 3110064 1 Mount, Torque Stop22 7547101 1 Nutsert23 1261077-029 1 Manifold24 5245502 1 Shield, Heat, Exhaust

12/02

A12

FUEL TANKSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

4

19

14

13

17

9

10

1

20

5

3

6

7

11

2

8

18

8

7

12

16

15


1 5433687 1 Cap, Gas Tank (Incl. 20)2 8360009-600 AR Line, Fuel3 5812265 1 Seal, Foam4 2520203 1 Asm., Fuel Tank (Incl. 13,14,19)5 5182004 1 Foil, Fuel Tank6 7052161 1 Valve, 3-Way7 7080003 4 Clamp, Hose, Red8 8450103-600 AR Hose, Fuel9 5432733 1 Nut, Fuel Valve10 5432559 1 Knob, Fuel Valve11 7517505 1 Screw

12 8450080-65 2 Sheath, Foil13 7052150 1 Fitting, Fuel Outlet, Main14 7052149 1 Fitting, Fuel Outlet, Reserve15 7052028 2 Grommet16 5812005 1 Foil, Fuel Tank17 5247184

524718511

Bracket, Fuel Cover Mount, LHBracket, Fuel Cover Mount, RH

18 7517685 2 Screw19 5431053 1 Vent, Tank20 5812123 1 Gasket

12/02

A13

ENGINE MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

30

39

2827

10

40 38

34

41

15

43

89

4

14

37

26

1

24

23

3536

29

32 31

168

8

8

9

25

26

33

28

26

26

8

811

42

13

12

17

5

6723

10 18 19

20

2122

A14

ENGINE MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ


1 2520227 1 Pump, Fuel2 7517867 2 Screw3 7558301 2 Washer, Flat4 7546601 2 Nut, Nylok5 7541923 2 Nut, Well6 5243829 1 Strap, Fuel Pump Mounting7 7512329 4 Bolt8 7080003 8 Clamp, Hose9 8450103--600 AR Line, Fuel10 2530009 1 Filter11 8450080-50 1 Sheath, Foil12 2202361 1 Kit, Short Block, ATV 680 03 NOTE:

The Short Block assembly contains acrankcase assembly, cylinder & cylin-der head assembly and a piston &crankshaft assembly. Prior authoriza-tion is required for warranty consider-ation.

13 7555770 2 Washer14 4010132 1 Cable, Ground, Engine15 7517386 1 Screw16 8360009--600 AR Line, Fuel17 5412287 1 Hose, Formed18 7542105 2 Nut19 7558301 2 Washer, Flat20 ------ -- -- -- -- 1 Guard, Splash, LH/Pump Mount (See

Front Cab Pg. A5, Ref. 9)

21 3110050 2 Mount, Carb22 7558203 2 Washer23 7051011 1 Valve, Check24 7516714 2 Screw25 7552901 2 Washer, Spring Lock26 7547108 6 Nut, Flange Lock27 5244622--067 1 Bracket, Mount, Top28 7555815 3 Washer29 7517868 1 Screw30 4010470 1 Cable, Black31 5411944 1 Boot, Intake32 7080451 1 Clamp, Hose33 3021119 2 Mount, Rubber34 7518197 1 Bolt35 7575202 1 Washer, Interlock36 5210748 1 Washer, Flat37 5430261 1 Bushing38 7552603 2 Washer, Spring Lock39 7512492 2 Screw40 3110044 2 Mount, Rubber, Top41 5244771--067 1 Mount, Lower, Front42 7555823 AR Washer, Flat43 5245043--067 1 Bracket, Torque Stop

12/02

B1

AIR BOXSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

4

9

5

25

27

10

28

7

8

2

26

11

3

30

24

6

21

17

29

20

17

17

18

15

14

23

31

1416

19

12

13

22



1 5811633 1 Filter, Precleaner Sleeve2 7080595 1 Filter, Air Intake3 7080413 1 Clamp, Narrow Band4 5433847 1 Sleeve5 5432868 1 Cover, Air Box6 7527317 4 Screw7 5434013 1 Duct, Air Inlet8 5411422 1 Gasket, Intake9 5811482 1 Seal, Air Box Cover10 5433678 1 Box, Air11 5434044 1 Duct, Clutch Air Inlet12 7670102 1 Clip13 5812316 1 Seal, Foam14 7080451 2 Clamp, Hose15 5411944 1 Boot16 7080511 1 Clamp, Narrow Band

17 7080699 3 Clamp, Hose18 8450073-600 AR Line, Breather19 7080694 1 Clamp20 5411966 1 Hose, Breather, Formed21 2530029 1 Filter, Breather22 7080534 1 Clamp, Hose23 5433396 1 Cap, End24 5242044 6 Clip, Air Box25 5432377 1 Plug, Trap26 8450059-150 AR Line, Fuel27 7080650 1 Clamp, Hose28 5811650 1 Foil, Air Box29 7558301 2 Washer, Flat30 7515179 2 Screw31 5412066 1 Boot, Carb

6/02

B2

FRONT DRIVE SHAFTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

5

6

4

32

1



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

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

12/02

B3

REAR DRIVE SHAFTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

986 73

5

11

42

10

35

1



1 1380197 2 Asm., Drive Shaft, Rear (Incl. 2-9)2 1590325 1 CV Joint3 1350044 2 Clamp, Large4 1350046 1 Grease, 30g5 1350045 2 Boot6 1350043 2 Clamp, Small

7 1350047 1 Grease, 50g8 1590281 1 Joint, Plunging9 1350042 1 Ring, Spring10 2201374 1 Kit, Boot (Gear Side)11 2201373 1 Kit, Boot (Wheel Side)

12/02

B4

FRONT PROP SHAFTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

8

2

3

45

46 7

1



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

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

12/02

B5

REAR PROP SHAFTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

2 3

1

42 2

5



1 7661913 1 Pin, Spring2 1350039 3 Yoke, Prop Shaft, Rear3 2202015 2 Kit, Cross and Bearing

4 1380209 1 Shaft, Prop, Rear5 1380208 1 Asm, Prop Shaft, Rear

12/02

B6

FRONT STRUTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

22

21

20

1918

17

14

1211

16

158

7

6

5

9

4

3

2

1

10 18

10

10

13



1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7042054-067 2 Spring, Compression9 7515339 4 Bolt10 7558402 10 Washer, Flat11 5132301

513230211

Hubstrut, LHHubstrut, RH

12 3514342 2 Bearing, Hubstrut13 7710507 2 Ring, Retaining14 ------ -- -- -- -- 1 Asm., Front Brake Caliper, LH

(See Front Brake Pg. B8 for Details)15 7080306 2 Fitting, Lubrication16 7552901 4 Washer, Spring Lock17 7512365 4 Screw18 7542324 4 Nut, Nylok19 7080367 2 Clamp, Cable20 5211115 2 Washer21 7041761 2 Strut, Front22 5411608 2 Bumper

4/01

B7

FRONT WHEELSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

2

4

3

6

12

5

8

9

7

11

10



1 7512325 8 Bolt2 5244314 2 Disc, Brake3 7515513 8 Stud4 5133360 2 Hub, Wheel5 1520563-067

1520563-38522

Rim, Front, Black (AH)Rim, Front, Silver (AJ)(AF)

6 5411952 2 Tire (25x8-12)

7 7547237 8 Nut, Flange8 7556004 2 Washer9 7542810 2 Nut, Slotted10 5411164 2 Cover, Dust11 7661401 2 Pin, Cotter12 1525017 2 Valve, Rim

12/02

B8

FRONT BRAKESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

12

23

9

10

4

11

56

7

8

1



1 1910681

1910682

1

1

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

2 7515489 1 Screw, Socket Set3 5133407

51334081930642

111

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

4 5410494 1 Boot, Pin Seal

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

12/02

B9

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

5

2

4

3

6

1



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

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

2/03

B10

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

16

19

10

13

14

15

1718

3

1112

20

2

1

9

8

6

5

4

4

7



1 5411297 1 Boot, Brake Line, Rubber2 5410988 2 Seal3 4110164 1 Switch4 7517899 2 Screw5 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2010196 1 Asm., Master Cylinder8 2201833 1 Kit, Master Cylinder Clamp

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

(Incl. Pin, Lever, Clip)

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

9/01

B11

STEERING POSTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

31

42

5

9

11

7

10

8

2

5

7

112

6



1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1013920-067 1 Post, Steering4 5246732 1 Bracket, Steering Post5 7512377 2 Bolt, Carriage6 7517428 2 Bolt, Carriage

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

2/03

B12

A-ARM/STRUT MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

14

56

7

89

2

11

13

14

12

15

16

18

17

1920

24

2326

25

22

21

27

3

10

14

25

26

22




1 7542439 2 Nut, Nylok2 1820805 2 Asm., Tie Rod3 7517909 2 Bolt4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061054 2 Rod End, LH10 5411920 1 Boot, Seal, Rod End11 7556099 4 Washer, Flat12 ------ -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B6 for Details)13 7547177 2 Nut14 7661203 4 Pin, Cotter

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

5435029-07011

Shield, CV Front, LHShield, CV Front, RH

22 5434551 4 Bushing, A-Arm, Long23 5133806 2 Shaft, A-Arm24 2202274

220227511

Kit, A-Frame, LH (Incl. 14,23,25,26)Kit, A-Frame, RH (Incl. 14,23,25,26)

25 7571611 4 Washer, Dish Lock26 7512492 4 Screw27 7515415 2 Screw

12/02

B13

HANDLEBAR and HEADLIGHT PODSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

24

47

29

2

1

5

3332

34

6

12

8

9

13

17

22 19

30

25

23

25

15

1826

14

16

1011

27

20

28

3

31

21

B14

HANDLEBAR and HEADLIGHT PODSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ



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

5434706-3825434706-341

111

Pod, Handlebar, Upper (AH)Pod, Handlebar, Upper (AF)Pod, Handlebar, Upper (AJ)

6 7517238 4 Screw7 5433903 1 Spacer, Switch, LH8 4010592 1 Switch, Handlebar9 5433834-070 2 Grip, Handlebar10 5432952 1 Plug11 7517625 1 Screw, Set12 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B10 for details)

13 5244969-067 1 Bracket, Pod Mounting14 7517317 2 Screw15 4032079 1 Knob, Adjusting16 4032078 1 Rod, Adjusting17 2410268

401025311

Asm., HeadlampBulb, Headlight

18 5410163 2 O-Ring19 7081008 1 Cable, Choke20 4010638 1 Receptacle, Pod Mount, 12V21 2461045 1 Harness, Light, Pod/Accy.

22 7542122 4 Nut, Nylok23 5433762-070

5433762-1775433762-382

111

Pod, Headlight, Lower (AJ)Pod, Headlight, Lower (AH)Pod, Headlight, Lower (AF)

24 7080631 1 Clip, Cable Retaining25 4010390

4010278

4010321

11

1

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, Key, Series 2200, 2300, 2700,2800 NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

26 5433534 1 Cover, Key27 5132382 1 Cap28 4010298 1 Sensor29 7517658 1 Screw30 7080922 1 Nut, Choke31 7670127 1 Clip, Screw32 5242987-067 1 Tube, Handlebar33 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B9, Ref. 5)34 5631146

563114711

Block, Handlebar, PeggedBlock, Handlebar

12/02

C1

DRIVE CLUTCHSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

16

10

9

11

5

6

13

12

5

72

4

1514

31

17

8



1 1520231 1 Clutch, One Way Drive2 7556202 1 Washer, Brass3 5631119 1 Spacer4 7541906 3 Nut, FLEXLOC5 5431936 6 Button, Clutch, Stemless6 5020422 3 Pin, Roller7 3585712 1 Bearing8 7547130 1 Nut, Jam9 3576510 1 Cover, Bearing

10 7518062 6 Screw11 7041157 1 Spring, Clutch12 1321622 3 Roller and Bushing13 5430945 6 Washer, Multilube14 7512266 3 Bolt, Shoulder15 5630513 3 Weight, Shift, 10-MH16 1321971 1 Asm., Drive Clutch, EBS, Wide

(Incl. All Less 11,15)17 7556204 1 Washer, Thrust

12/02

C2

DRIVEN CLUTCHSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

9

2

67

8

12

14

15

16

18

2

1

17

13

11

10

543



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

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

10 7517323 3 Screw11 1321977 3 Roller, Taper12 3585710 1 Bearing13 5211115 1 Washer14 3576511 1 Bearing, Moveable, 1 Inch15 7041635 1 Spring16 5132751 1 Ramp, Stationary17 5210753 1 Spacer18 7710448 1 Ring, Retaining

12/02

C3

CLUTCH COVERSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

12

7

6

11

10

1314

15

2

4

3

5

6

89



1 5434235 1 Cover, Clutch, Inner2 7517599 5 Asm., Bolt/Washer3 5434012 1 Duct, Clutch Outlet4 7080707 2 Clamp, Narrow Band5 5411489 1 Boot, Duct6 7512094 9 Screw7 5434255-070 1 Cover, Clutch, Outer8 5410542 1 O-Ring

9 5434264 1 Plug10 7077666 1 Decal, “Automatic/EBS”, Clutch11 7078689 1 Decal, Warning, Clutch Cover12 5521578 1 Seal, Cover, Clutch, Outer13 7517867 3 Screw14 5244527-067 1 Bracket, Retainer, Seal15 5411918 1 Seal, Cover, Inner

4/02

C4

REAR WHEEL DRIVESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

11

13

3

15

2

1

12

4

14

5

7

9

8

6

10



1 5411164 2 Cover, Dust, Hub2 7661404 2 Pin, Cotter3 7555796 4 Washer, Cone4 1520564-385

1520564-06722

Rim, Rear, Silver (AJ)(AF)Rim, Rear, Black (AH)

5 5133361 2 Hub, Rear Wheel6 5244635 2 Disc, Brake, Rear7 7710440 2 Ring, Retaining8 3585502 2 Bearing

9 ------ -- -- -- -- 2 Carrier, Bearing, Wheel(See Rear Suspension Pg. C6, Ref. 39)

10 7512325 8 Screw11 5411949 2 Tire, 25x11-1212 7515513 8 Stud13 1525017 2 Valve, Rim14 7547237 8 Nut, Flange15 7543005 2 Nut, Castle

12/02

C5

REAR SUSPENSIONSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

24

3725

27

20

14

16

3130

21

36

34

3332

39

38

28

29

23

5

12

86

10

11

7

4

9

3

2

1

17

13

36

14

1615

154

1417

14

172

33

2

21

4

3

2611

109

19

35

14

22

13

26

18

1818

18

C6

REAR SUSPENSIONSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ



1 7517231 4 Screw2 7555761 8 Washer, Flat3 5432598 8 Bushing, Stabilizer4 7512329 6 Bolt5 1580107-067 2 Arm, Stabilizer Bar6 7542324 6 Nut, Nylok7 5020827 2 Rod, Linkage, Stabilizer8 5334114-067 1 Bar, Stabilizer Tube9 5434549 2 Bushing, Stabilizer Tube10 7555939 2 Washer11 7558402 8 Washer, Flat12 1541801-067 1 Support, Stabilizer13 7515472 6 Screw14 5434548 12 Bushing, A-Arm, Short15 7512492 4 Screw16 7552603 4 Washer, Spring Lock17 5020826 6 Shaft, A-Arm, Short18 7542439 10 Nut, Nylok19 5245140-067 1 Strap, Rear Skid Plate20 1014320-067

1014321-06711

Arm, Control, Upper, LHArm, Control, Upper, RH

21 5434551 4 Bushing, A-Arm, Long22 7555806 2 Washer, Flat23 7515433 2 Screw24 5630885 2 Retainer, Spring25 7041453-067 2 Spring, Compression26 5433551 2 Sleeve, Shock Protector27 5631014 2 Cam, Adjusting, Spring28 7041959 2 Shock, Rear29 7515415 2 Screw30 5133806 2 Shaft, A-Arm31 1014174-067

1014175-06711

Arm, Control, Lower, LHArm, Control, Lower, RH

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

5434891-103811

Shield, LHShield, RH

38 7512084 4 Screw39 5133663

513366411

Carrier, Wheel Bearing, LHCarrier, Wheel Bearing, RH

2/03

C7

ELECTRICAL/TAILLIGHTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1 2 47 865

1213

21

17

15

14

10

18

11

23

24

1916

26

20

2725

2

9

19

3

22



1 24609762461147

11

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

2 2200593 2 Kit, Circuit Breaker, 20 AMP3 4010924 1 Module, Resistor4 2410320 1 Asm., Taillight, 12V (Incl. 7-13)5 4032045 1 Gasket, Taillight6 4030043 1 Bulb, Taillight7 4032046 1 Lens, Taillight8 4032029 2 Screw, Taillight9 7517386 1 Screw10 5245125-067 1 Strap, Battery Holddown11 4010630 1 Battery, 30 AMP12 4032064 1 Backing, Taillight/Brake Light13 7670054 2 Nut, Speed14 4010470 1 Cable15 2202099 1 Kit, Battery Bolt

16 4010471 1 Cable, Battery/Solenoid17 5434037 1 Box, Battery18 5432077 AR Tube, Battery Vent19 7512024 6 Screw20 3087196 1 Switch, Magnetic21 4010376 1 Cable, Solenoid/Starter22 2410411 1 Jumper, Harness

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

4010929

1

1

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

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

3/03

C8

REAR MASTER CYLINDER/FOOT PEDALSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

5

7

2 3

4

129

1011

8

1314

17

16

18

4

10

6

1

15

7

7

9



1 7512240 1 Screw2 1930854 1 Reservoir, Brake, Rear3 7542153 1 Nut4 7080003 2 Clamp, Hose5 1910438 1 Hose, Reservoir6 1013414-067 1 Mount, Brake7 7517386 3 Screw8 7661401 1 Pin, Cotter9 7555919 2 Washer

10 5433189 2 Bushing, Pivot, Pedal11 1013415-067 1 Rod, Brake12 7041750 1 Spring13 1910301 1 Master Cylinder, Brake, Rear14 7515158 2 Screw15 7042075 1 Spring, Gear Selector Lockout16 5410988 2 Seal17 1910499 1 Bolt, Banjo18 1910429 1 Line, Rear Brake, Foot

12/02

C9

REAR CALIPERSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1 2 3

4

59

8

12

15,

17

16

14

12,

12

12,

12

15,

17

16

16

16

14

14

14

14,

11

710

6

13

18



1 7512365 2 Screw2 7552901 2 Washer, Spring Lock3 7558402 2 Washer, Flat4 ---- -- -- -- -- -- 2 Carrier, Bearing5 1910529 1 Bracket, Caliper6 7080960 1 Clamp, Nylon7 7621462 1 Rivet8 1910430 1 Line, Brake, Rear, Hand9 1910429 1 Line, Brake, Rear, Foot

10 7517756 1 Screw11 7670126 1 Clip, Retaining, Dual12 2201873 1 Kit, Anvil Body13 1910538 2 Fitting,Bleed, Compact14 2201870 1 Kit, Slide Bolt15 2201872 1 Kit, Seal16 2201869 1 Kit, Piston and Seal17 2202414 1 Kit, Brake Pad18 1910690 1 Asm., Caliper

12/02

C10

GEAR SELECTORSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

2

3

8

10

4

6

11

6

7

5

9

9

5



1 5412003 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 5435042 2 Mount, Gear Selector5 7515175 2 Screw6 7542122 2 Nut, Nylok

7 1821055 1 Asm., Linkage8 7542324 2 Nut, Nylok9 7558402 2 Washer, Flat10 1013315-067 1 Selector, Gear11 7515306 2 Screw

12/02

C11

FRONT HOUSINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

2

1

34

56

7 89

10

11

1213

1415

161718

1920

21

23

13

11

4

24

22

1

1

1

5



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

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

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

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

1

1

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

10 3233957 14 Kit, Roll11 3233934 2 Ring, Retaining, Wire Form12 ------ -- -- -- -- 1 Bushing

13 3233955 11 Kit, Bolt14 3233947 1 Cover, Input15 3233945 1 Bearing, Roller Ball16 3233944 1 Shaft, Pinion, 11T17 ------ -- -- -- -- 1 Bushing18 ------ -- -- -- -- 1 Gearcase, LH19 3233942 1 Plug, Oil Fill20 3233951 1 Asm., Drain Plug (Incl. Plug and

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

3233950

1

1

Asm., Front Gearcase(Incl. 2-12,16-19,20-23)Asm., Gearcase (Incl. 12,17,18)

1/03

C12

TRANSMISSION MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

11

6

9

7

1413

15

15

1314

10

6

1110

8

12

16

6

6

2

3

3 4

1

1

1

5

3

1



1 8450003-1525 AR Line, Fuel2 7052075 1 T-Fitting3 7080307 3 Clamp, Hose4 7080756 2 Clip5 7670102 1 Clip6 7547108 6 Nut, Flange, Lock7 7542321 2 Nut, Flange8 5244599-067 1 Mount, Rear Transmission9 7515398 2 Screw

10 7555976 3 Washer, Flat11 7515417 2 Screw12 5245524-067 1 Mount, Transmission13 7552603 4 Washer, Spring Lock14 7515522 4 Bolt15 7517289 4 Screw16 1013134-067

5247348

1

1

Mount, Rear Engine(If built before 2/03/03)Bracket, Mount, Transmission, Rear(If built after 2/03/03)

2/03

C13

GEARCASESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

70

2 34

67

5 68

60

6968

666564

6362

9

61

16

1011

19

7

1543

44

55

45

16

464957

56

54

4748

50 51

53

15

7

52

4241

39 3837

36

12

2425

12

27282930

3132

33 34 35

20

21

22

13

14

17

18

27

25 30

12

16

21

20

12

15

2

2326

59

3028 26

40

58

26

71

C14

GEARCASESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ



1 3233961 1 Nut2 3233826 8 Screw3 3233827 1 Cover4 3233829 1 Pawl, Detent5 3233869 1 O-Ring6 3233831 1 Shaft, Shift7 3233788 2 Seal8 3233832 1 Gear, 31T9 3233711 1 Plug, Oil Fill10 3233524 1 Tube, Vent11 3233578 1 Plug, Cap Vent12 3233018 4 Bearing13 3233036 1 Chain, Silent14 3234012 1 Shaft, Input15 3233019 4 Bearing16 3233529 4 Pipe, Knock17 3233865 1 Cover, LH18 3233874 1 Seal19 3233910 1 Drum, Shift20 3233858 2 Fork, Shift21 3233859 2 Pin, Dowel22 3233860 1 Rail, Shift Shaft23 3233915 1 Plate, Park24 3234040 1 Engagement Dog25 3233849 2 Spring, Wave26 3233875 3 Engagement Dog27 3233850 2 Ring, Retaining28 3233851 2 Washer29 3233852 1 Gear, 33T30 3233718 3 Bearing, Needle31 3233853 1 Shaft, Reverse32 3233854 1 Sprocket, 24T33 3233855 1 Washer34 3234011 1 Gear, 29T35 3233913 1 Gear, 40T36 3234039 1 Gear, 44T

37 3233608 4 Screw38 3233609 1 Cover, Bearing39 3233106 1 Ring40 3233357 1 Spacer41 3233607 1 Bearing, Ball42 3233606 1 Shaft, Pinion, 10T43 3233619 1 Washer, Thrust44 3233873 1 Sprocket, 22T/18T45 3233621 1 Gear, 31T46 3233911 1 Shaft, Output, Main, Rear47 3233582 1 Button, Thrust48 3233583 1 Shim49 3233611 1 Shim50 3233781 1 Cover, Output, Front51 3233846 17 Screw52 3233777 1 Plug53 3233254 1 Washer54 3233625 1 Shaft, Output, Front55 3233784 1 Chain, Silent56 3233844 1 Sprocket, 22T57 3233552 1 Bushing58 3234013 1 Clamp, Tie59 3233917 1 Lockout, Park60 3233867 1 Gearcase, Main61 3233324 1 Washer62 3233548 1 O-Ring63 3233839 1 Gear, 16T64 3233838 1 Disc, Lockout65 3233909 1 Star, Detent66 3233076 1 O-Ring67 3233830 1 Spring, Compression68 3233835 1 Switch69 3233834 1 Ring, Retaining70 3233906 1 Bellcrank71 1341432 1 Asm., Main Gearcase

12/02

D1

REAR GEARCASESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

23 4

5 6

7

10

89

20

1819

17

18

7

65 3

1112 13 14 15

16

1



1 1341352 1 Asm., Gearcase, Rear2 3233876 1 Cover, Output, LH3 3233846 8 Screw4 3233524 1 Tube, Vent5 3233254 2 Washer6 3233777 2 Plug7 3233878 2 Seal8 3233583 AR Shim9 3233582 1 Button, Thrust10 3233529 2 Pipe, Knock

11 3233577 1 Bushing12 3233881 1 Shaft, Pinion, 10T13 3233714 1 Bearing, Ball14 3233588 1 O-Ring15 3233882 1 Cover, Input16 3233785 1 Seal17 3233880 1 Gearcase, Housing, Rear18 3233268 2 Bearing, Ball19 3233879 1 Gear, 31T20 3233581 AR Shim

2/03

D2

REAR GEARCASE MOUNTINGSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

14

3

5

2

1

2

2

2

4

45

5

3

2



1 7517878 5 Screw2 7555806 12 Washer, Flat3 7547008 5 Nut, FLEXLOC

4 7512492 6 Screw5 7552603 6 Washer, Spring Lock

4/01

D3

CRANKCASESPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

4

10

11

2

20

21

1

23

6

16

3

19

17

9

15 14

12

13

22

6

7

11

11

5

18

18

8



1 5412114 1 Seal, Flanged2 3514361 1 Bearing, Ball3 7556194 1 Bushing4 3514318 1 Bearing, Ball5 7518007 1 Plug6 1201655 1 Asm., Crankcase (Incl. 14-23)7 5132753 4 Bearing8 5812364 1 Gasket9 5411184 1 Seal, Oil10 1202384 1 Cover, Magneto11 7517950 4 Screw12 5412048 1 Seal

13 3585704 4 Bearing, Main Journal14 7052306 1 Plug, Magnetic15 5812232 1 Washer, Copper16 7517793 9 Screw17 7517792 6 Screw18 7663001 2 Pin, Dowel19 5211785 1 Baffle20 7518045 5 Screw21 7516603 1 Screw22 1201970 1 Pickup, Oil23 5812016 2 O-Ring

12/02

D4

CRANKSHAFT and PISTONSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

6

10

5

98

3

11

2

1

4

32

7



1 2202365 2 Kit, Piston (Incl. 2,3,4)2 3022996 4 Circlip, Piston3 ------ -- -- -- -- 2 Pin, Piston4 2202366 1 Kit, Piston Ring (Incl. Control, Iron,

and Chrome Rings)5 2202362 1 Kit, Crankshaft 600 ATV, ’03 (Incl. 7,

from Crankcase Pg. D3, Ref.2,3,4,13)

6 7721117 1 Key, Woodruff7 2202145 1 Gear, Set8 7517865 1 Screw9 7555982 1 Washer10 7721131 1 Key, Woodruff11 5132485 1 Shaft, Balance

9/02

D5

CYLINDER and CYLINDER HEADSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

2

20

23

22

25

12

4

107

16

17

3

6

18

1

8

11

14

15

19

5

13

921

2624

D6

CYLINDER and CYLINDER HEADSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ



1 7517277 2 Screw2 5432533 1 Cover, Breather3 3021413 1 Valve, Breather4 7516822 7 Screw5 1201973 1 Cover, Rocker6 5411862 1 Seal7 7517883 6 Screw8 5811511 1 Gasket, Exhaust9 1261077--029 1 Manifold, Exhaust10 7516730 4 Screw11 1202171

513142914

Head, CylinderGuide, Valve

12 5812212 1 Gasket, Cylinder Head13 2202368 1 Kit, Cylinder (Incl. 15)

14 5811455 1 Gasket, Base15 7051534 1 Plug16 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D8, Ref. 48)17 7080681 1 Clamp, Hose18 7516734 2 Screw19 1253415 1 Adapter, Carburetor20 3070195 2 Spark Plug, RC7YC21 7516822 2 Screw22 5631196 1 Cover, Thermostat23 7052308 1 Thermostat24 5411521 1 O-Ring25 4010356 1 Switch, Temperature26 7052135 2 Fitting

4/02

D7

CARBURETORSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

48

38

35

9

50

5

49

12

4

6

4243

39

37

1336

1413

1516

22

20

28

31

30

27

1110

3

23

21

17

25

19

26

41

24

51

4546

87

47

40

3433

32

29

18

44

12

D8

CARBURETORSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ



1 3130507 1 Ring2 3130508 1 E-Ring3 3131449 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131450 1 Needle, Jet (P-4)7 3130541 2 Screw8 3130540 2 Washer, Spring9 ------ -- -- -- -- 1 Asm., Jet Block10 3130014 1 Washer11 3130571 1 Jet, Main (#155)12 5434505 2 Cap13 3130515 2 Seal14 3130517 1 Packing15 ------ -- -- -- -- 1 E-Ring16 3130519 1 Cap17 3130361 1 Pin, Float18 3130594 1 Plate19 3130532 1 O-Ring20 3130520 4 Screw21 3130590 1 Asm., Float Body22 3130521 1 Screw23 3130529 1 Asm., Float24 3130591 1 Screw25 3131360 1 Valve, Needle (1.5)26 3130533 1 O-Ring

27 3131397 1 Jet, Pilot (#45)28 3130522 1 O-Ring29 3130523 1 Washer30 3130525 1 Spring31 3130524 1 Adjuster32 3130546 1 Screw, Adjust33 3130545 1 Ring34 3130544 1 Spring35 ------ -- -- -- -- 1 Valve, Throttle (100)36 3131398 1 Spring37 3130514 1 Ring38 ------ -- -- -- -- 2 Screw39 ------ -- -- -- -- 1 Asm., Throttle Shaft40 3130543 1 Guide, Cable41 3130535 4 Screw42 3130511 1 Cover43 3130512 1 O-Ring44 3131396 1 Holder, Guide45 3130538 1 Spring46 3131395 1 Asm., Plunger47 3130625 1 Jet, Air (#160)48 1253436 1 Asm., Carburetor (Incl. 1-12)49 3131451 1 Spring, Compression50 3130503 1 Asm., Cover51 3130592 4 Screw

9/02

D9

INTAKE and EXHAUSTSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

15

16

1

11

5

9

32

4

10

13

14

11

12

8

76

6



1 1202169 4 Asm., Rocker Arm2 5132402 4 Pushrod3 2202363 1 Kit, Camshaft (Incl. 7)4 5244286 1 Plate, Thrust5 7517598 3 Screw6 2202145 1 Kit, Gear7 7041999 3 Spring, Compression8 7556183 1 Washer, Spring

9 7517865 1 Screw10 5131415 4 Lifter, Valve11 5133141 2 Valve, Exhaust12 5131417 2 Valve, Intake13 5411895 4 Seal, Valve Guide14 7041565 4 Spring, Valve15 5131413 4 Retainer, Spring16 5910042 8 Lock, Valve Stem

4/02

D10

OIL DIPSTICKSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

4

5

3

1

2



1 1202109 1 Asm., Dipstick2 1202110 1 Tube, Oil Fill3 7517795 2 Screw

4 5245805 1 Clamp5 5812016 1 O-Ring

4/01

D11

WATER PUMPSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

11

6

32

1

7

9

10

5

4

8



1 5131419 1 Shaft, Oil/Water Pump2 3584404 1 Bearing3 ------ -- -- -- -- 1 Kit, Gear Set 680/780 (See Intake and

Exhaust Pg. D9, Ref. 6)4 5433684 1 Impeller5 7555874 1 Washer, Flat

6 7546804 1 Nut, Nylok7 7516823 5 Screw8 7517950 2 Screw9 1202019 1 Cover10 5812048 1 O-Ring11 3610075 1 Seal, Water Pump

12/02

D12

OIL PUMPSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

5

2

7

3

6

4

8

9

1

10



1 2540086 1 Filter, Oil2 2540115 1 Nipple, Oil Filter3 7517807 4 Screw4 5131426 1 Housing, Oil Pump5 1202079 1 Gerotor6 7661127 1 Pin, Dowel

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

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

12/02

D13

MAGNETOSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

54

7

89

12

14

17

18

3

6

12

1913

1011

16

15



1 5245364 1 Holddown, Wire2 4010709

40109012202603

111

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

3 7517847 2 Screw4 7517848

751771433

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

5 40601524010899

11

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

6 7555907 1 Washer7 7546909 1 Nut8 5812359 1 O-Ring

9 1201684 1 Housing, Stator10 5812283 1 Cover, Sound11 5434310 1 Cover, Outer12 5411564 1 O-Ring13 7517950 10 Screw14 5433820 1 Plug15 4010920 1 Controller, Ignition (If built after 2/23/03)16 4010898 1 Coil, Ignition (If built after 2/23/03)17 4010785 1 Controller, Ignition (If built before 2/23/03)18 4010124-66 2 Wire, Ignition (If built before 2/23/03)19 4010526 2 Boot (If built before 2/23/03)

2/03

D14

STARTING MOTORSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

4

3

2

567



1 7516823 1 Screw2 4010417 1 Starter3 7555908 1 Washer, Thrust4 4010418 1 Bendix

5 7552616 1 Washer, Lock6 7546705 1 Nut7 7517868 1 Bolt

4/02

E1

TOOL KITSPORTSMAN 600 A04CH59AF and SPORTSMAN 600 A04CH59AH and SPORTSMAN 600 A04CH59AJ

1

3

8

2

94

5

6

7

10

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the PartSmart, which is updated monthly.


1 2873687 1 Kit, Tool (Incl. 2-8)2 2870725 1 Gauge, Tire Pressure3 ------ -- -- -- -- 1 Screwdriver4 ------ -- -- -- -- 1 Wrench, 8-10 Open5 ------ -- -- -- -- 1 Wrench, 9/16 x 1 1/2 Open6 ------ -- -- -- -- 1 Wrench, Plug

7 ------ -- -- -- -- 1 Puller, Spark Plug (Wrench Handle)8 2682572 1 Pouch, Tool Kit9 9918540 1 Owner’s Manual, ‘04 Sportsman

400-70010 2873647 1 Wrench, Torx

12/02

PRINTED IN THE USA PARTS MANUAL PN 9918610 and MICROFICHE PN 9918611 12/02

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sportsman 600 model #a04ch59af model …pi54.com/corp/manuals/parts/9918610.pdf · sportsman 600...

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