Polaris Sportsman 600 2004 Parts List

E 2003 Polaris Sales Inc.

P ARTS MANUAL PN 9918731 and MICROFICHE PN 9918732 9/03

SPORTSMAN 600

Model #A04CH59AK

Model #A04CH59AL

Model #A04CH59AN

Model #A04CH59AW

Rev. 01

This page left blank intentionally.

T ABLE OF CONTENTS

SPORTSMAN 600A04CH59AK andSPORTSMAN 600A04CH59AL andSPORTSMAN 600A04CH59AN andSPORTS-

MAN 600 A04CH59AW

Parts Manual

A

A--ARM/STRUT MOUNTING B12.............

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

B

BRAKE LINE B10........................

BRAKE, FRONT B8.....................

BUMPER MOUNTING A7-8.................

C

CAB, 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.....................

G

GEARCASE (Cases and Snorkel) D1-2..........

GEARCASE (INTERNAL COMPONENTS) C13-14...

H

HANDLEBAR B13-14........................

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

I

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

M

MAGNETO D13..........................

MASTER CYLINDER B10..................

MASTER CYLINDER, REAR C8............

O

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

P

PISTON D4............................

PROP SHAFT, FRONT B4.................

PROP SHAFT, REAR B5.................

D

DECALS A9...........................

DRIVE CLUTCH C1......................

DRIVE SHAFT, FRONT B2.................

DRIVE SHAFT, REAR B3.................

DRIVEN CLUTCH C2.....................

E

ELECTRICAL C7........................

ENGINE MOUNTING A13-14..................

EXHAUST D9..........................

EXHAUST SYSTEM A11...................

F

FRAME A3-4............................

FRONT HOUSING C11....................

FUEL TANK A12.........................

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

RACK MOUNTING, REAR A6..............

REAR WHEEL DRIVE C4..................

S

SEAT A3-4..............................

STARTING MOTOR D14...................

STEERING POST B11.....................

STRUT, FRONT B6......................

SUSPENSION, REAR C5-6.................

T

T AILLIGHT C7..........................

THROTTLE ASM. B9.....................

TOOL KIT E1...........................

TRANSMISSION MOUNTING C 12............

W

R

G

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

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

WATER PUMP D11.......................

WHEEL, FRONT B7.....................

WINCH ASM. E2........................

REAR CAB, SEAT and MAIN FRAME

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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A3

REAR CAB, SEAT and MAIN FRAME

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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
2 7555792 4 Washer
3 581 1107 1 Foil, Rear Cab, Rear
4 54321 17-400

5432117-053
5432117-341

5432117-288
5 751 1930 2 Bolt
6 5246076 1 Retainer, Seat Latch
7 7079902 1 Decal, 4 Stroke, Carb/Filter Information
8 581 1308 1 Foil, Tape, Rear Cab
9 7512242 4 Screw

10 7555859 4 Washer, Flat
11 7556034 4 Washer
12 7512085 2 Screw
13 5431786 1 Box, Tool
14 7517375 2 Screw
15 7621403 2 Rivet
16 5211033 2 Bracket, Lever Retainer
17 1040387 1 Latch, Seat
18 7041370 1 Spring, Latch
19 2683197-070

2682958-070

1

Cab, Rear (AK)

1

Cab, Rear (AL)

1

Cab, Rear (AN)

1

Cab, Rear (AW)

11Asm.,Seat,Black

Covering, Seat, Black

20 5431787 1 Cover, Tool Box
21 7517377 4 Screw
22 5432280 2 Spacer (LH Only)
23 7542122 8 Nut, Nylok
24 7542153 6 Nut, Nylok, Flanged
25 7512283 6 Screw
26 5244751-067 1 Brace, Frame
27 1014461-067 1 Frame, Main
28 7170509 1 Decal, Hit ch
29 7512232 22 Screw
30 58 11111 1 Foil, Rear Fender
31 5811087 1 Foil
32 5811106 2 Foil, Rear Cab, Front
33 5434704-070

5434705-070
34 7670057 22 Nut, U-Type Speed
35 7555832 2 Washer
36 7517312 2 Screw
37 7517264

7517376
38 5432221-070

5433929-070

11Guard, Mud, Rear, LH

Guard, Mud, Rear, RH

44Screw (LH Side)

Screw (RH Side)

11Footwell, Black, LH

Footwell, Black, RH

9/03

A4

FRONT CAB

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

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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 5811491 1 Foil, Side Panel, Gen. IV, RH
2 5433853-177

2632471-177
5435322-070
2632471-070

2632471-382
3 5812326 1 Foil, Side Panel, RH
4 7512232 10 Screw
5 2632748-400

2632748-053

2632748-341

2632748-288
6 7670057 10 Nut, U-Type Speed
7 5432088-400

5432088-053

5432088-341

5435110-288
8 7517861 2 Screw

1

Panel, Side, LH (AK)

1

Panel/Foil, RH (AK)

1

Panel, Side, LH (AL)(AN)(AW)

1

Panel/Foil, RH (AL)(AW)

1

Panel/Foil, RH (AN)

1

Cab, Front (AK)

1

Cab, Front (AL)

1

Cab, Front (AN)

1

Cab, Front (AW)

1

Cover, Front (AK)

1

Cover, Front (AL)

1

Cover, Front (AN)

1

Cover, Front (AW)

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16

15

14

14

10

9 5246872 1 Guard, Splash, LH/Pump Mount

10 7517386 3 Screw

11 7670135 2 Nut, Push-on
12 7517312 2 Screw
13 7670156 2 Clip, Retainer
14 7542122 2 Nut, Nylok
15 7556034 2 Washer
16 7555859 2 Washer, Flat
17 5246021-067 1 Guard, Splash, RH
18 5434702-070

5434703-070
19 7515158 2 Screw
20 7541925 2 Nut, Nylok
21 7555792 2 Washer
22 7512085 2 Screw

9

8

11Guard, Mud, Front, Black, LH

Guard, Mud, Front, Black, RH

9/03

A5

REAR RACK MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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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 1040510-418 1 Extender , Rack, Rear (Incl. 12)(AW)
2 7517983 2 Screw
3 7517685 2 Screw
4 7555916 2 Washer, Nylon
5 2632836-070 1 Asm., Rack, Rear (Incl. Warning Decal)
6 5334092 2 Spacer

7 7512329 4 Bolt
8 5241663 1 Bracket, Silencer, Frame
9 7558402 8 Washer, Flat

10 7542324 4 Nut, Nylok

11 1013724-067 1 Support, Rear Rack

12 7517208 6 Screw (AW)

A6

9/03

FRONT RACK and BUMPER MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

(See Winch Asm. Pg. E2 for Winch Components)

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A7

FRONT RACK and BUMPER MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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 1013972-418 1 Extender, Front Rack (AW)
2 7517685 4 Screw
3 7081085 2 Plug (AW)
4 5434697-070

5435240-070
5 7558402 14 Washer, Flat
6 7517208 4 Screw
7 2431017

4030059
8 7542324 6 Nut, Nylok
9 2632757-070

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

10 7515306 4 Screw
11 5434699-070 1 Panel
12 7512094 2 Screw
13 1014412-067 1 Guard, Brush

11Rack, Front, Black

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

22Headlight

Bulb, Replacement, 27W

11Asm., Bumper, Front, Black

(Incl. Warning Decal)(AK)(AL)(AN)
Bumper, Front (AW)
(See Winch Pg. E2, Ref. 20)

14 5434314

5434315
15 5412504 4 Grommet
16 5435046 1 Cover, Radiator
17 5247507-067 1 Grill, Brush Guard
18 7518046 4 Screw
19 7670094 6 Nut, U-Type
20 7512097 6 Screw
21 7515399 6 Screw
22 5245767-067 1 Bracket, Bumper, Lower
23 7512329 2 Screw
24 7171474

7171475
25 1014020-067 1 Support, Front Rack
26 5810467 1 Plug, Frame
27 1014261-067

1014262-067
28 7512232 6 Screw
29 7555960 2 Washer, Flat

11Shield, Side, Radiator, LH

Shield, Side, Radiator, RH

11Decal, Reflector, Amber, LH

Decal, Reflector, Amber, RH

11Support, Front Rack, LH

Support, Front Rack, RH

9/03

A8

DECALS

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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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 7179927 2 Decal, Reflector, Red
2 7170912 2 Decal, Warning, Front/Rear Rack
3 7171016

7171017
7171008
7171009
7171012
7171013
7172060

7172061
4 7078253 1 Decal, Age Warning
5 7079780 1 Decal, Warning AWD Switch
6 7078003 1 Decal, Headlight Adjustment
7 7078465 1 Logo, Polaris Star
8 7079773

7079916
9 7171474

7171475

10 7079672 1 Decal, Foot Brake
11 7079604 1 Decal, Override Switch, AWD

1

Decal, “4X4”, Side Panel, LH (AK)

1

Decal, “4X4”, Side Panel, RH (AK)

1

Decal, “4X4”, Side Panel, LH (AL)

1

Decal, “4X4”, Side Panel, RH (AL)

1

Decal, “4X4”, Side Panel, LH (AN)

1

Decal, “4X4”, Side Panel, RH (AN)

1

Decal, “4X4”, Side Panel, LH (AW)

1

Decal, “4X4”, Side Panel, RH (AW)

11Decal, “POLARIS”, Frt Cover (AK)(AN)(AW)

Decal, “POLARIS”, Front Cover (AL)

11Decal, Reflector, Amber, LH

Decal, Reflector, Amber, RH

12 7171004

7171005
7171315
7171316
7172056
7172057

13 7171014

7171015
7171006
7171007
7171797
7171798
7172058

7172059
14 7077920 1 Decal, Passenger Warning
15 7079959

7079960
16 7079084 1 Decal, Tire Pressure/Load
17 7171383 1 Decal, Discretionary Warning
18 7079083 1 Decal, Warning, General, CPSC

1

Decal, Tank Side, LH (AK)(AL)

1

Decal, Tank Side, RH (AK)(AL)

1

Decal, “600”, T ank Side, LH (AN)

1

Decal, “600”, T ank Side, RH (AN)

1

Decal, Tank Side, LH (AW)

1

Decal, Tank Side, RH (AW)

1

Decal, Side Panel, Top, LH (AK)

1

Decal, Side Panel, Top, RH (AK)

1

Decal, Side Panel, Top, LH (AL)

1

Decal, Side Panel, Top, RH (AL)

1

Decal, Side Panel, Top, LH (AN)

1

Decal, Side Panel, Top, RH (AN)

1

Decal, Side Panel, Top, LH (AW)

1

Decal, Side Panel, Top, RH (AW)

11Decal, “POLARIS”, Rear (AK)(AN)(AW)

Decal, “POLARIS”, Rear (AL)

9/03

A9

COOLING SYSTEM

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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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
2 5434325

5435196
3 5521644 1 Guard, Hose
4 7042089 1 Retainer, Hose
5 7512084 5 Screw
6 5412311 1 Hose, Filler Neck
7 7080827 1 Clamp, 1 Inch
8 7080003 2 Clamp, Hose
9 8450040-150 AR Line, Fuel

10 5430743 1 Cap, Overflow, Drilled
11 5810279 1 Gasket, Overflow Cap
12 5433774 1 Plug, Cap
13 5431673 1 Tank, Surge
14 7052065 1 Fitting, Barbed, 90 Degree
15 8450003-1525 1 Line, Fuel
16 7080307 1 Clamp, Hose
17 7080826 3 Clamp
18 5412030 1 Hose, Engine, Upper
19 7081174 2 Clamp, Hose
20 5521597 2 Hose, Guard

11Filler, Coolant (If built before 10/02/03)

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

21 5246656 1 Bracket, Radiator Mount, Upper
22 7518014 2 Screw
23 7556196 2 Washer
24 7547197 6 U-Clip
25 4010161 1 Sensor, Thermal
26 1240103 1 Radiator
27 5411975 2 Grommet
28 7515179 2 Screw
29 7052296 1 Valve, Drain
30 5410584 2 Bushing, Mount
31 5245773-067 1 Bracket, Radiator, Lower
32 7517386 2 Screw
33 5434171 1 Shroud, Fan
34 4010631 1 Clip, Wiring
35 2410288 1 Asm., Fan
36 7517975 4 Screw
37 5412312 1 Hose, Radiator, Lower
38 7052282 1 Connector, Tee
39 7081047 2 Clamp
40 5412313 1 Hose, Engine, Lower

8/03

A10

EXHAUST SYSTEM

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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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
2 7555716 2 Washer, Flat
3 5010192 2 Bushing
4 5410436 2 Washer, Rubber
5 7555863 2 Washer
6 5241663 1 Bracket, Silencer, Frame
7 7555935 8 Washer
8 7517615 4 Screw
9 5410241 2 Dampener, Vibration

10 7515316 2 Bolt, Carriage
11 7558402 4 Washer, Flat
12 7512329 4 Bolt
13 1261223-029 1 Silencer, Exhaust
14 7556230 1 Washer

18

20

15 7512666 1 Bolt
16 3610047 2 Seal, Exhaust
17 7041804 2 Spring, Exhaust
18 1261242-029 1 Pipe, Exhaust
19 5244014 1 Shield, Heat
20 7515197 5 Screw
21 7555935 5 Washer
22 7041789 3 Spring, Exhaust
23 7542301 1 Nut
24 3110064 1 Mount, Torque Stop
25 7547101 1 Nutsert
26 1261077-029 1 Manifold
27 5245502 1 Shield, Heat, Exhaust

6/03

A11

FUEL T ANK

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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18

E 2003 Polaris Sales Inc.

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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

5435324
2 5812123 1 Gasket, Fuel Cap
3 5812265 1 Seal, Foam
4 8360009-600 AR Line, Fuel
5 7517685 2 Screw
6 5247184

5247185
7 5431053 1 Vent, Tank
8 5812004 1 Foil, Tank
9 8450103 AR Hose, Fuel

10 7080003 4 Clamp, Hose, Red
11 7052346 1 Fitting, Fuel Outlet, Reserve

11Cap, Gas Tank (If built before 7/01/03)

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

11Bracket, Mounting, Rear, LH

Bracket, Mounting, Rear, RH

12 7052028 1 Grommet
13 7517505 1 Screw
14 5432559 1 Knob, Fuel Valve
15 5432733 1 Nut, Fuel Valve
16 5247585 1 Bracket, Fuel Valve
17 7661637 2 Rivet
18 7052159 1 Valve, On/Off
19 2520339 1 Asm., Fuel Tank w/Sender

(Incl. 7,8,11,12,20-23)
20 5812005 1 Foil, Tank
21 5810858 1 Gasket
22 2410289 1 Sender, Fuel
23 7512056 5 Screw

6/03

A12

ENGINE MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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A13

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ENGINE MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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 2520227 1 Pump, Fuel
2 7517867 2 Screw
3 7558301 2 Washer, Flat
4 7546601 2 Nut, Nylok
5 7541923 2 Nut, Well
6 5243829 1 Strap, Fuel Pump Mounting
7 7512329 4 Bolt
8 7080003 8 Clamp, Hose

9 8450103--600 AR Line, Fuel
10 2530009 1 Filter
11 8450080-50 1 Sheath, Foil
12 2202361

2202697

13 7555770 2 Washer (If built before 10/02/03)
14 4010132 1 Cable, Ground, Engine
15 7517386 1 Screw
16 8360009--600 AR Line, Fuel
17 5412287 1 Hose, Formed
18 5247141 1 Bracket, Carburetor Mount
19 7542105 2 Nut

11Kit, Short Block, ATV 680

(If built before 10/02/03)
Kit, Short Block, ATV 600
(If built after 10/02/03) NOTE: The
Short Block assembly contains a
crankcase assembly, cylinder & cylin­der head assembly and a piston &
crankshaft assembly. Prior authoriza­tion is required for warranty consider­ation.

20 7558301 2 Washer, Flat
21 7558203 2 Washer
22 3110050 2 Mount, Carb
23 7051011 1 Valve, Check
24 7516714 2 Screw
25 7552901 2 Washer, Spring Lock
26 7547108 6 Nut, Flange Lock
27 5244622--067

5247368

28 7555815 3 Washer
29 7517868 1 Screw
30 4010470 1 Cable, Black
31 5411944 1 Boot, Intake
32 7080451 1 Clamp, Hose
33 3021119 2 Mount, Rubber
34 7518197 1 Bolt
35 7575202 1 Washer, Interlock
36 5210748 1 Washer, Flat
37 5430261 1 Bushing
38 7552603 2 Washer, Spring Lock
39 7512492 2 Screw
40 3110044 2 Mount, Rubber, Top
41 5244771--067 1 Mount, Lower, Front
42 7555823 AR Washer, Flat
43 5245043--067 1 Bracket, Torque Stop

11Bracket, Mount, Top

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

9/03

A14

AIR BOX

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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1

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30

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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 5811633 1 Filter, Precleaner Sleeve

2 7080595 1 Filter, Air Intake

3 7080413 1 Clamp, Narrow Band

4 5433847 1 Sleeve

5 5432868 1 Cover, Air Box

6 7527317 4 Screw

7 5434013 1 Duct, Air Inlet

8 5411422 1 Gasket, Intake

9 5811482 1 Seal, Air Box Cover
10 5433678 1 Box, Air
11 5434044 1 Duct, Clutch Air Inlet
12 7670102 1 Clip
13 5812316 1 Seal, Foam
14 7080451 2 Clamp, Hose
15 5411944 1 Boot
16 7080511 1 Clamp, Narrow Band

27

26

25

24

23

17 7080699 3 Clamp, Hose
18 8450073-600 AR Line, Breather
19 7080694 1 Clamp
20 5411966 1 Hose, Breather, Formed
21 2530029 1 Filter, Breather
22 7080534 1 Clamp, Hose
23 5433396 1 Cap, End
24 5242044 6 Clip, Air Box
25 5432377 1 Plug, Trap
26 8450059-150 AR Line, Fuel
27 7080650 1 Clamp, Hose
28 5811650 1 Foil, Air Box
29 7558301 2 Washer, Flat
30 7515179 2 Screw
31 5412066 1 Boot, Carb

18

22

16

17

17

19

21

20

6/03

B1

FRONT DRIVE SHAFT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

1

5

4

3

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

1380218 2 Asm., Drive Shaft
1 7670092 2 Circlip
2 1590358 2 Joint, CV

3 2201015 2 Kit, Boot (Incl. Clamps and Grease)
4 1380186 2 Shaft(Incl.5)
5 2202015 2 Kit, Cross and Bearing

B2

12/02

REAR DRIVE SHAFT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

1

2

3

10

4

5

4

9

6

2

7

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

1380197 2 Asm., Drive Shaft, Rear (Incl. 1-8)
1 1590362 1 CV Joint
2 1350044 2 Clamp, Large
3 1350046 1 Grease, 30g
4 1350045 2 Boot
5 1350043 2 Clamp, Small

6 1350047 1 Grease, 50g
7 1590281 1 Joint, Plunging
8 1350042 1 Ring, Spring
9 2201374 1 Kit, Boot, Gear Side

10 2201373 1 Kit, Boot, Wheel Side

B3

5/03

FRONT PROP SHAFT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

E 2003 Polaris Sales Inc.

4

3

5

7

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

1380221 1 Asm., Front Prop Shaft
1 7661913 1 Pin, Spring
2 3260133 1 Yoke, Gear Case, Front
3 2202015 2 Kit, Cross and Bearing

4 1350089 1 Shaft, Bar
5 3260131 1 Yoke, Prop Shaft, Transmission
6 7080424 1 Fitting, Lubrication
7 5411092 1 O-Ring

B4

12/02

REAR PROP SHAFT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

E 2003 Polaris Sales Inc.

4

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

1380208 1 Asm, Prop Shaft, Rear
1 7661913 1 Pin, Spring
2 1350039 3 Yoke, Prop Shaft, Rear

2

3

3 2202015 2 Kit, Cross and Bearing
4 1380209 1 Shaft, Prop, Rear

2

12/02

B5

FRONT STRUT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

22

2

3

4

5

6

7

8

10

9

11

E 2003 Polaris Sales Inc.

21

19

20

10

12

18

17

18

15

13

14

16

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 7547104 2 Nut, Nylok
2 7555749 2 Washer
3 5810291 2 Spacer, Rubber
4 5432872 2 Ball, Pivot, Top
5 5132062 2 Spacer
6 5432871 2 Ball, Pivot, Bottom
7 5243364 2 Retainer, Spring
8 7042054-293 2 Spring, Compression
9 7515339 4 Bolt

10 7558402 10 Washer, Flat
11 5132301

5132302

11Hubstrut, LH

Hubstrut, RH

12 3514342 2 Bearing, Hubstrut
13 7710507 2 Ring, Retaining
14 -- -- -- -- -- -- -- 1 Asm., Front Brake Caliper, LH

(See Front Brake Pg. B8 for Details)
15 7080306 2 Fitting, Lubrication
16 7552901 4 Washer, Spring Lock
17 7512365 4 Screw
18 7542324 4 Nut, Nylok
19 7080367 2 Clamp, Cable
20 5 2 1111 5 2 Washer
21 7041761 2 Strut, Front
22 5411608 2 Bumper

B6

6/03

FRONT WHEEL

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

E 2003 Polaris Sales Inc.

4

5

6

7

8

9

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
2 5244314 2 Disc, Brake
3 7515513 8 Stud
4 5133360 2 Hub, Wheel
5 1520563-067

1520563-385

6 5411952 2 Tire, 25x8-12

22Rim, Front, Black (AK)(AW)

Rim, Front, Silver (AL)(AN)

7 7547237 8 Nut, Flange
8 7556004 2 Washer
9 7542810 2 Nut, Slotted

10 5411164 2 Cover, Dust

11 7661401 2 Pin, Cotter

12 1525017 2 Valve, Rim

10

9/03

B7

FRONT BRAKE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

2

12

E 2003 Polaris Sales Inc.

1

3

11

4

6

5

7

8

10

9

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

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

1 1910681

1910682

2 7515489 1 Screw, Socket Set
3 5133407

5133408
1930642

4 5410494 1 Boot, Pin Seal

11Asm., Brake Caliper, LH

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

1

Caliper,Brake,LH

1

Caliper,Brake,RH

1

Kit, Front Brake Boot

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, Long
9 2201398 1 Kit, Front Brake Pad

10 1910411 1 Mount, Caliper

11 5410495 1 Boot, Bushing

12 7080352 1 Screw, Bleeder

B8

12/02

CONTROLS - THROTTLE ASM./CABLE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

4

5

E 2003 Polaris Sales Inc.

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 5410193 1 O-Ring
2 5434113 1 Cover, Throttle Control
3 5411439 1 O-Ring

4 7081025 1 Cable, Throttle
5 2010230 1 Asm., Throttle Control, AWD (Incl. 6)
6 2010191 1 Asm., Throttle Clamp

6/03

B9

CONTROLS - MASTER CYLINDER/BRAKE LINE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

17

20

19

18

2

13

1

4

3

10

11

12

14

4

5

6

9

E 2003 Polaris Sales Inc.

7

8

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
2 5410988 4 Seal
3 4110164 1 Switch
4 7517899 2 Screw
5 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 Cylinder
8 2201833 1 Kit, Master Cylinder Clamp

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

(Incl. Pin, Lever, Clip)

10 1910759 1 Line, Brake, Hand, Rear

11 7621462 1 Rivet
12 7080539 1 Clamp, Nylon
13 8360031-34 1 Conduit
14 1910474 1 Line, Brake, Left Front
15 7080138 4 Cable Tie
16 7512024 2 Screw
17 1910475 1 Line, Brake, Right Front
18 7052292 1 Fitting, Cross
19 1910470 1 Line, Brake, Pod
20 1910499 1 Bolt, Banjo

6/03

B10

STEERING POST

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

E 2003 Polaris Sales Inc.

3

2

4

5

2

5

7

6

12

1

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
2 5433866 2 Bushing, Steering, Upper
3 1013920-067 1 Post, Steering
4 5246732 1 Bracket, Steering Post
5 7512377 2 Bolt, Carriage
6 7517428 2 Bolt, Carriage

7 7556162 2 Bushing
8 5222393 1 Flangette
9 3514352 1 Bearing

10 7547158 1 Nut

11 7661633 1 Pin, Cotter
12 7558402 2 Washer, Flat

8

9

2/03

B11

A-ARM/STRUT MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

4

E 2003 Polaris Sales Inc.

27

1

3

2

5

6

7

8

9

10

11

26

25

25

26

23

22

21

20

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

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

1 7542439 2 Nut, Nylok
2 1820805 2 Asm., Tie Rod
3 7517909 2 Bolt
4 5411291 2 Boot, Seal, Rod End
5 7061034 2 Rod End
6 7542711 2 Nut
7 5020926 2 Tie Rod
8 7547028 2 Nut, LH

9 7061054 2 Rod End, LH
10 5411920 1 Boot, Seal, Rod End
11 7556099 4 Washer, Flat
12 -- -- -- -- -- -- -- 1 Asm., Hubstrut

(See Front Strut Pg. B6 for Details)
13 7547177 2 Nut
14 7661203 4 Pin, Cotter

24

22

15

16

18

14

19

15 7080927 2 Joint, Ball
16 5211121 2 Bracket, Ball Joint
17 7512284 4 Screw
18 5410548 2 Boot, Rubber
19 7542438 2 Nut, Castle
20 7512084 6 Screw
21 5435028-070

5435029-070
22 5434551 4 Bushing, A-Arm, Long
23 5133806 2 Shaft, A-Arm
24 2202274

2202275
25 7571611 4 Washer, Dish Lock
26 7512492 4 Screw
27 7515415 2 Screw

11Shield, CV Front, LH

Shield, CV Front, RH

11Kit, A-Frame, LH (Incl. 14,23,25,26)

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

12

13

14

17

12/02

B12

HANDLEBAR and HEADLIGHT POD

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

1

2

33

3

4

5

34

32

31

29

30

28

27

6

7

13

14

15

9

8

16

17

12

10

11

18

26

25

25

B13

24

23

22

19

20

21

HANDLEBAR and HEADLIGHT POD

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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
2 3280431 1 Cluster
3 5412138 1 Mount, Rubber
4 7511881 3 Screw
5 5434706-400

5434706-053
5434706-341

5434706-288
6 7517238 4 Screw
7 5433903 1 Spacer, Switch, LH
8 4010592 1 Switch, Handlebar
9 5433834-070 2 Grip, Handlebar

10 2461213 1 Harness, Wire, Pod
11 5432952 1 Plug
12 7517625 1 Screw, Set
13 -- -- -- -- -- -- -- 1 Asm., Master Cylinder

14 5244969-067 1 Bracket, Pod Mounting
15 7517317 2 Screw
16 4032079 1 Knob, Adjusting
17 4032078 1 Rod, Adjusting
18 2410268

4010253

19 7081008 1 Cable, Choke
20 4010638 1 Receptacle, Pod Mount, 12V
21 2461045 1 Harness, Light, Pod/Accy.

1

Pod, Headlight, Upper (AK)

1

Pod, Headlight, Upper (AL)

1

Pod, Headlight, Upper (AN)

1

Pod, Headlight, Upper (AW)

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

11Asm., Headlamp

Bulb, Headlight

22 7542122 4 Nut, Nylok
23 5433762-070

5433762-177

5433762-382
24 7080631 1 Clip, Cable Retaining
25 4011002

4010278

4010321

26 5433534 1 Cover, Key
27 5132382 1 Cap
28 4010298 1 Sensor
29 7517658 1 Screw
30 7080922 1 Nut, Choke
31 7670127 1 Clip, Screw
32 5242987-067 1 Tube, Handlebar
33 -- -- -- -- -- -- -- 1 Asm., Throttle Control (See Controls -

34 5631146

5631147

5631516

5631517

1

Pod, Headlight, Lower (AL)(AW)

1

Pod, Headlight, Lower (AK)

1

Pod, Headlight, Lower (AN)

1

Switch, Key, 3 Position (Incl. Key)

1

Blank, Key, Series 2000, 6700, 6800

1

Blank, Key, Series 2200, 2300, 2700,
2800 NOTE: Your key can be dupli­cated only by obtaining a key blank
from Polaris and having it cut by mat­ing it with your existing key.

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

1

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

1

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

1

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

1

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

9/03

B14

DRIVE CLUTCH

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

5

E 2003 Polaris Sales Inc.

4

6

16

12

7

5

9

8

11

10

1

2

3

13

14

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

1321971 1 Asm., Drive Clut ch, EBS, Wide

(Incl. All Less 11,15)
1 1520231 1 Clutch, One Way Drive
2 7556202 1 Washer, Brass
3 5631119 1 Spacer
4 7541906 3 Nut, FLEXLOC
5 5431936 6 Button, Clutch, Stemless
6 5020422 3 Pin, Roller
7 3585712 1 Bearing

8 7547130 1 Nut, Jam
9 3576510 1 Cover, Bearing

10 7518062 6 Screw

11 7041157 1 Spring, Clutch
12 1321622 3 Roller and Bushing
13 5430945 6 Washer, Multilube
14 7512266 3 Bolt, Shoulder
15 5630513 3 Weight, Shift, 10-MH
16 7556204 1 Washer, Thrust

C1

12/02

DRIVEN CLUTCH

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

18

17

16

15

18

13

17

14

16

15

1322407

12

14

13

9

10

1321973

10

1

12

1

9

11

2

5

7

2

3

4

5

6

8

7

6

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 7556120 AR Bushing
2 1321973

1322407

3 7556203 1 Washer
4 7710461 1 Ring, Retaining (1321973)
5 7552901 1 Washer, Spring Lock
6 7515382 1 Bolt
7 5220646 1 Washer, Domed
8 7556010 1 Bushing (1321973)
9 3211069 1 Belt, Drive

11Asm., Driven Clutch

(Incl. 4-8,12-18)(If built before 7/01/03)
Asm., Driven Clutch, EBS
(Incl. 5-7,12-18)(If built after 7/01/03)

14

3

19

18

10 7517323 3 Screw

11 1321977 3 Roller, Taper
12 3585710 1 Bearing
13 5 2 1111 5 1 Washer
14 3576511 1 Bearing, Moveable (Qty. 3 in 1322407)
15 7041635 1 Spring, Driven
16 5132751 1 Ramp, Stationary
17 5210753 1 Spacer
18 7710448 1 Ring, Retaining (Qty. 2 in 1322407)
19 5133655 1 Plate

9/03

C2

CLUTCH COVER

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

3

E 2003 Polaris Sales Inc.

15

1

2

14

13

12

11

6

4

5

6

7

8

9

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 5434235 1 Cover, Clutch, Inner
2 7517599 5 Asm., Bolt/Washer
3 5434012 1 Duct, Clutch Outlet
4 7080707 2 Clamp, Narrow Band
5 5411489 1 Boot, Duct
6 7512094 9 Screw
7 5434255-070 1 Cover, Clutch, Outer
8 5410542 1 O-Ring

9 5434264 1 Plug

10 7077666 1 Decal, “Automatic/EBS”, Clutch

11 7078689 1 Decal, Warning, Clutch Cover
12 5521578 1 Seal, Cover, Clutch, Outer
13 7517867 3 Screw
14 5244527-067 1 Bracket, Retainer, Seal
15 5411918 1 Seal, Cover, Inner

C3

4/02

REAR WHEEL DRIVE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

9

8

E 2003 Polaris Sales Inc.

6

5

4

7

10

11

2

3

1

15

14

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

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

1 5411164

5412489
2 7661404 2 Pin, Cotter
3 7555796 4 Washer, Cone
4 1520564-385

1520564-067
5 5133361

5134311
6 5244635 2 Disc, Brake, Rear
7 7710440 2 Ring, Retaining

22Cover, Dust, Hub (If built before 7/21/03)

Cover, Dust, Hub (If built after 7/21/03)

22Rim, Rear, Silver (AL)(AN)

Rim, Rear, Black (AK)(AW)

22Hub, Rear Wheel (If built before 9/29/03)

Hub, Rear Wheel (If built after 9/29/03)

12

13

8 3585502 2 Bearing
9 -- -- -- -- -- -- -- 2 Carrier, Bearing, Wheel

(See Rear Suspension Pg. C6, Ref. 39)

10 7512325 8 Screw

11 5411949 2 Tire, 25x11-12
12 7515513 8 Stud
13 1525017 2 Valve, Rim
14 7547237 8 Nut, Flange
15 7543005 2 Nut, Castle

9/03

C4

REAR SUSPENSION

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

4

14

16

30

18

11

19

16

15

22

21

18

23

24

25

9

10

12

1

2

3

4

5

6

3

2

7

17

11

6

14

10

9

8

14

2

3

13

18

4

38

14

37

17

13

14

15

17

3

20

2

21

32

31

33

39

36

E 2003 Polaris Sales Inc.

36

35

C5

34

18

26

27

28

29

REAR SUSPENSION

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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
2 7555761 8 Washer, Flat
3 5432598 8 Bushing, Stabilizer
4 7512329 6 Bolt
5 1580107-067 2 Arm, Stabilizer Bar
6 7542324 6 Nut, Nylok
7 5020827 2 Rod, Linkage, Stabilizer
8 5334114-067 1 Bar, Stabilizer Tube

9 5434549 2 Bushing, Stabilizer Tube
10 7555939 2 Washer
11 7558402 8 Washer, Flat
12 1541801-067 1 Support, Stabilizer
13 7515472 6 Screw
14 5434548 12 Bushing, A-Arm, Short
15 7512492 4 Screw
16 7552603 4 Washer, Spring Lock
17 5020826 6 Shaft, A-Arm, Short
18 7542439 10 Nut, Nylok
19 5245140-067 1 Strap, Rear Skid Plate
20 1014320-293

1014321-293
21 5434551 4 Bushing, A-Arm, Long
22 7555806 2 Washer, Flat

11Arm, Control, Upper, LH

Arm, Control, Upper, RH

23 7515433 2 Screw
24 5630885 2 Retainer, Spring
25 7041453-293

7042311-293

26 5433551 2 Sleeve, Shock Protector
27 5631014 2 Cam, Adjusting, Spring
28 7041959 2 Shock, Rear
29 7515415 2 Screw
30 5133806 2 Shaft, A-Arm
31 1014174-293

1014175-293
32 5631142 4 Bushing, Bearing Carrier
33 7552614 4 Washer, Lock
34 7517873 4 Screw
35 7555740 4 Washer, Flat
36 5434550 8 Bushing, Control, Lower
37 5434890-1038

5434891-1038
38 7512084 4 Screw
39 5133663

5133664

22Spring, Compression

(If built before 6/16/03)
Spring, Compression
(If built after 6/16/03)

11Control, Lower, LH

Control, Lower, RH

11Shield, LH

Shield, RH

11Carrier, Wheel Bearing, LH

Carrier, Wheel Bearing, RH

6/03

C6

ELECTRICAL/TAILLIGHT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

3

1

23

2

2

24

18

E 2003 Polaris Sales Inc.

25

5

12

4

7

6

11

13

8

14

15

9

10

22

21

18

19

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 2461208 1 Harness, Main
2 2200593 2 Kit, Circuit Breaker, 20 AMP
3 4010924 1 Module, Resistor
4 2410320 1 Asm., T aillig h t, 12V (Incl. 7-12)
5 4032045 1 Gasket, Taillight
6 4030043 1 Bulb, Taillight
7 4032046 1 Lens, Taillight
8 4032029 2 Screw, Taillight

9 5247376 1 Strap, Battery Holddown
10 4010630 1 Battery, 30 AMP
11 4032064 1 Backing, Taillight/Brake Light
12 7670054 2 Nut, Speed
13 4010470 1 Cable
14 2202099 1 Kit, Battery Bolt

15 4010471 1 Cable, Battery/Solenoid (AF)(AH)(AJ)
16 5434037 1 Box, Battery
17 5432077 AR Tube, Battery Vent
18 7512024 6 Screw
19 3087196

4010930
20 4010376 1 Cable, Solenoid/Starter
21 4010796

4010929

22 5133182 1 Sink, Heat
23 4020139 3 Clip, Rosebud (Small)
24 7080138 7 Cable Tie
25 7512027 2 Screw

11Switch, Magnetic (If built before 6/26/03)

Switch, Magnetic (If built after 6/26/03)

11Rectifier, Regulator

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

17

16

6/03

C7

REAR MASTER CYLINDER/FOOT PEDAL

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

17

18

16

15

2

1

14

3

4

5

6

4

7

13

12

9

10

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 7512240 1 Screw
2 1930854 1 Reservoir, Brake, Rear
3 7542153 1 Nut
4 7080003 2 Clamp, Hose
5 1910438 1 Hose, Reservoir
6 1013414-067 1 Mount, Brake
7 7517386 3 Screw
8 7661401 1 Pin, Cotter
9 7555919 2 Washer

7

7

E 2003 Polaris Sales Inc.

10 5433189 2 Bushing, Pivot, Pedal

11 1013415-067 1 Rod, Brake
12 7041750 1 Spring
13 1910301 1 Master Cylinder, Brake, Rear
14 7515158 2 Screw
15 7042075 1 Spring, Gear Selector Lockout
16 5410988 2 Seal
17 1910499 2 Bolt, Banjo
18 1910766 1 Line, Rear Brake, Foot

6/03

C8

REAR CALIPER

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

12

13

12

14

15,

E 2003 Polaris Sales Inc.

16

14

16

4

1

2

3

9

10

11

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

8

7

6

5

16

15,

17

12,

12

12,

14

16

14

14,

17

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

1910690 1 Asm., Caliper
1 7512365 2 Screw
2 7552901 2 Washer, Spring Lock
3 7558402 2 Washer, Flat
4 -- -- -- -- -- -- -- 2 Carrier , Bearing
5 1910529 1 Bracket, Caliper
6 7080960 1 Clamp, Nylon
7 7621462 1 Rivet
8 1910759 1 Line, Brake, Rear, Hand

9 1910429 1 Line, Brake, Rear, Foot

10 7517756 1 Screw

11 7670126 1 Clip, Retaining, Dual
12 2201873 1 Kit, Anvil Body
13 1910538 2 Fitting,Bleed, Compact
14 2201870 1 Kit, Slide Bolt
15 2201872 1 Kit, Seal
16 2201869 1 Kit, Piston and Seal
17 2202414 1 Kit, Brake Pad

C9

6/03

GEAR SELECTOR

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

E 2003 Polaris Sales Inc.

11

9

4

5

6

6

7

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 5412003 1 Cover
2 7512024 1 Screw
3 5411007 1 Knob, Gear Selector
4 5435042 2 Mount, Gear Selector
5 7515175 2 Screw
6 7542122 2 Nut, Nylok

7 1821055 1 Asm., Linkage
8 7542324 2 Nut, Nylok
9 7558402 2 Washer, Flat

10 1013315-067 1 Selector, Gear

11 7515306 2 Screw

9

8

10

12/02

C10

FRONT HOUSING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

34

5

6

15

14

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

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

1341344

1341497

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

3234159

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

3234161
6 3233926 2 Bearing, Roller Ball
7 3233953 1 Asm., Race/Output Hub (Incl. 23)
8 3233928 1 Pin, Dowel
9 3233932 1 Bearing, Roller Ball (1341344)

10 3233933

3234166

11 3234167

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

2

26

25

11Asm., Front Gearcase

(If built before 7/14/03)
Asm., Front Gearcase
(If built after 7/14/03)

11Asm., Cover Plate (Incl. Output Cover,

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

11Kit, Shim Set (Incl. Shims)(1341344)

Shim, Armature Plate (1341497)

11Clutch Housing/Ring Gear (1341344)

Clutch Housing/Ring Gear (1341497)

11Asm., Roll Cage

(Incl. Spring and Roll Cage)
Spring

7

9

8

10

11

24

E 2003 Polaris Sales Inc.

14

12

7

13

17

18

23

6

12 3233957 14 Kit, Roll
13 -- -- -- -- -- -- --

3234169

14 3233956 1 Kit, Minor Repair

15 3233918 11 Bolt
16 3233947 1 Cover, Input
17 3234112 1 Bearing, Roller Ball
18 3233944 1 Shaft, Pinion, 11T
19 -- -- -- -- -- -- -- 1 Bushing
20 -- -- -- -- -- -- -- 1 Gearcase, LH
21 3233942 1 Plug, Oil Fill
22 3233951 1 Asm., Drain Plug

23 3233929 1 Bearing, Needle, Roller Thrust
24 3233954

3234168
25 3234162 1 Ring, Retaining, Internal
26 3233924

3234160

11Bushing (1341344)

Bushing (1341497)

(Incl. O-Rings and Seals)

(Incl. Plug and Washer)

11Asm., Clutch (Incl. 9-12)(1341344)

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

11Plate, Armature (1341344)

Plate, Armature (1341497)

19

20

14

2122

16

15

6/03

C11

TRANSMISSION MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

13

12

10

3

1

2

1

1

3

11

6

4

5

E 2003 Polaris Sales Inc.

1

9

6

3

7

8

10

11

6

15

14

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

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

1 8450003-1525 AR Line, Fuel
2 7052075 1 T-Fitting
3 7080307 3 Clamp, Hose
4 7080756 2 Clip
5 7670102 1 Clip
6 7547108 4 Nut, Flange, Lock
7 7512377 2 Bolt, Carriage
8 5247348 1 Bracket, Mount, Rear Transmission
9 7542321 2 Nut, Flange

10 7555976 3 Washer, Flat

11 7515417 2 Screw
12 7552603 2 Washer, Spring Lock
13 7515522 2 Bolt
14 7517289 2 Screw
15 1013134-067

5247348

11Mount, Rear Engine

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

6/03

C12

GEARCASE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

19

18

17

E 2003 Polaris Sales Inc.

16

15

20

21

14

13

22

26

25

12

11

10

8

6

4

5

3

1

2

68

71

69

70

9

7

67

66

642317

65

63

62

61

60

24

2

17

59

16

27

58

47

13

48

57

29

28

31

30

24

34

33

32

49

50

56

35

46

34

45

51

25

36

32

52

43
44

53

31

30

42

54

29

41

37

30

40

55

13

39

38

34

13

8

C13

16

GEARCASE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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

1341473 1 Asm., Main Gearcase
1 3233961 1 Nut
2 3233826 8 Screw
3 3234124 1 Cover
4 3234123 1 Gasket
5 3233829 1 Pawl, Detent
6 3233869 1 O-Ring
7 3233831 1 Shaft, Shift
8 3233788 2 Seal
9 3233832 1 Gear, 31T

10 3234128 1 Gearcase, Main
11 3233524 1 Tube, Vent
12 3234143 1 Label, Oil Fill/Level Check
13 3233018 4 Bearing
14 3233036 1 Chain, Silent
15 3234012 1 Shaft, Input
16 3233019 4 Bearing
17 3233794 2 Plug
18 3234127 1 Cover, LH
19 3233874 1 Seal
20 3234042 2 Screw
21 3234142 1 Bracket, Mount
22 3233910 1 Drum, Shift
23 3233548 1 O-Ring
24 3233858 2 Fork, Shift
25 3233859 2 Pin, Dowel
26 3233860 1 Rail, Shift Shaft
27 3233915 1 Plate, Park
28 3234040 1 Engagement Dog
29 3234144 2 Spring, Wave
30 3233875 3 Engagement Dog
31 3233850 2 Ring, Retaining
32 3233851 2 Washer
33 3233852 1 Gear, 33T
34 3233718 3 Bearing, Needle
35 3233853 1 Shaft, Reverse

36 3233854 1 Sprocket, 24T
37 3233855 1 Washer
38 3234011 1 Gear, 29T
39 3234136 1 Gear, 51T
40 3234137 1 Gear, 56T
41 3234086 4 Screw
42 3234122 1 Cover, Bearing
43 3233106 1 Ring
44 3233357 1 Spacer
45 3233607 1 Bearing, Ball
46 3234140 1 Shaft, Pinion, 10T
47 3233619 1 Washer, Thrust
48 3233873 1 Sprocket, 22T/18T
49 3233621 1 Gear, 31T
50 3233911 1 Shaft, Output, Main, Rear
51 3233582 1 Button, Thrust
52 3233583 1 Shim
53 3233611 1 Shim
54 3234130 1 Cover, Output, Front
55 3233846 15 Screw
56 3233625 1 Shaft, Output, Front
57 3233784 1 Chain, Silent
58 3233844 1 Sprocket, 22T
59 3233552 1 Bushing
60 3234013 1 Clamp, Tie
61 3233917 1 Lockout, Park
62 3233247 4 Pin, Dowel
63 3234043 2 Nut
64 3233839 1 Gear, 16T
65 3233838 1 Disc, Lockout
66 3234082 1 Star, Detent
67 3233076 1 O-Ring
68 3233830 1 Spring, Compression
69 3233835 1 Switch
70 3233834 1 Ring, Retaining
71 3233906 1 Bellcrank

6/03

C14

REAR GEARCASE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

5

4

2

1

19

3

6

17

18

17

16

10

6

42

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

E 2003 Polaris Sales Inc.

11 12

7

8

9

13

14

15

1341352 1 Asm., Gearcase, Rear
1 3233876 1 Cover, Output, LH
2 3233846 8 Screw
3 3233524 1 Tube, Vent
4 3233254 2 Washer
5 3233777 2 Plug
6 3233878 2 Seal
7 3233583 AR Shim
8 3233582 1 Button, Thrust
9 3233529 2 Pipe, Knock

10 3233577 1 Bushing

11 3233881 1 Shaft, Pinion, 10T
12 3233714 1 Bearing, Ball
13 3233588 1 O-Ring
14 3233882 1 Cover, Input
15 3233785 1 Seal
16 3233880 1 Gearcase, Housing, Rear
17 3233268 2 Bearing, Ball
18 3233879 1 Gear, 31T
19 3233581 AR Shim

6/03

D1

REAR GEARCASE MOUNTING

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

1

2

4

5

1

2

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
2 7555806 12 Washer, Flat
3 7547008 5 Nut, FLEXLOC

2

5

4

2

3

5

4

4 7512492 6 Screw
5 7552603 6 Washer, Spring Lock

4/01

D2

CRANKCASE

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

5

1

2

3

4

21

22

23

18

6

7

8

13

12

9

10

11

11

20

15

14

6

18

19

16

E 2003 Polaris Sales Inc.

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
2 3514361 1 Bearing, Ball
3 7556194 1 Bushing
4 3514318 1 Bearing, Ball
5 7518007 1 Plug
6 1202658 1 Asm., Crankcase (Incl. 14-23)
7 5132753 2 Bearing
8 5812364

5812511

9 5411184

5412455
10 1202384 1 Cover, Magneto
11 7517950 4 Screw

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

Gasket (If built after 10/02/03)

11Seal, Oil (If built before 10/02/03)

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

12 5412048 1 Seal
13 3585704 2 Bearing, Main Journal
14 7052306 1 Plug, Magnetic
15 5812232 1 Washer, Copper
16 7517793 9 Screw
17 7517792 6 Screw
18 7663001 2 Pin, Dowel
19 5211785 1 Baffle
20 7518045 5 Screw
21 7516603 1 Screw
22 1201970

1202663

23 5812016 2 O-Ring

11Pickup, Oil (If built before 10/02/03)

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

11

6/03

D3

CRANKSHAFT and PISTON

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

4

3

2

E 2003 Polaris Sales Inc.

5

6

7

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

5 2202362

2202701

and Chrome Rings)

11Kit, Crankshaft 600 ATV, ’03

(Incl. 7, from Crankcase Pg. D3, Ref.
2,3,4,13)
Kit, Crankshaft 600 ATV
(Incl. 7, from Crankcase Pg. D3, Ref.
2,3,4,13)

10

9

8

6 7721117 1 Key, Woodruff
7 2202145 1 Gear, Set
8 7517865 1 Screw
9 7555982 1 Washer

10 7721131 1 Key, Woodruff

11 5132485 1 Shaft, Balance

6/03

D4

CYLINDER and CYLINDER HEAD

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

4

3

1

E 2003 Polaris Sales Inc.

2

5

6

19

18

17

20

22

21

23

24

15

25

26

7

10

9

8

27

11

12

16

13

D5

14

CYLINDER and CYLINDER HEAD

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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
2 5432533 1 Cover, Breather
3 3021413 1 Valve, Breather
4 7516822 7 Screw
5 1201973 1 Cover, Rocker
6 5411862 1 Seal
7 7517883

7518274

8 5811511 1 Gasket, Exhaust
9 1261077--029 1 Manifold, Exhaust

10 7516730

7518234
11 1202171

3021483

5131429
12 5812212

5247358

13 2202368

2202695

66Screw (If built before 10/02/03)

Bolt (If built after 10/02/03)

44Screw (If built before 10/02/03)

Screw (If built after 10/02/03)

1

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

1

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

4

Guide, Valve

11Gasket, Cylinder Head

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

11Kit, Cylinder

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

14 5811455

5247360
15 7051534 1 Plug
16 7661175 2 Dowel (If built after 10/02/03)
17 -- -- -- -- -- -- -- 1 Asm., Carburetor

18 7080681 1 Clamp, Hose
19 7516734 2 Screw

20

1253415 1 Adapter, Carburetor
21 3070195 2 Spark Plug, RC7YC
22 7516822 2 Screw
23 5631196

5631390

24 7052308

7052352
25 5411521 1 O-Ring
26 4010356 1 Switch, Temperature
27 7052135

7052145

11Gasket, Base (If built before 10/02/03)

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

(See Carburetor Pg. D8, Ref. 48)

11Cover, Thermostat

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

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

Thermostat (If built after 10/02/03)

22Fitting (If built before 10/02/03)

Fitting (If built after 10/02/03)

6/03

D6

CARBURETOR

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

3

4

5

6

9

10

11

16

15

12

14

17

2

51

50

E 2003 Polaris Sales Inc.

49

7
8

13

26

25

47

46

48

27

28

29

30

31

43

45

34

33

32

35

44

13

42

36

41

37

40

39

38

18

19

20

D7

24

23

22

21

CARBURETOR

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

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
2 3130508 1 E-Ring
3 3131449

3130963
4 3130752 1 Ring
5 3130732 1 Diaphragm
6 3131450

3131363

7 3130541 2 Screw
8 3130540 2 Washer, Spring
9 -- -- -- -- -- -- -- 1 Asm., Jet Block

10 3130014 1 Washer
11 3130571

3130572

12 5434505 2 Cap
13 3130515 2 Seal
14 3130517 1 Packing
15 -- -- -- -- -- -- -- 1 E-Ring
16 3130519 1 Cap
17 3130361 1 Pin, Float
18 3130594 1 Plate
19 3130532 1 O-Ring
20 3130520 4 Screw
21 3130590 1 Asm., Float Body
22 3130521 1 Screw
23 3130529 1 Asm., Float
24 3130591 1 Screw
25 3131360 1 Valve, Needle (1.5)

11Needle, Jet (If built before 10/02/03)

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

11Jet, Needle (P-4)

(If built before 10/02/03)
Jet, Needle, P-6
(If built after 10/02/03)

11Jet, Main, #155 (If built before 10/02/03)

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

26 3130533 1 O-Ring
27 3131397 1 Jet, Pilot, #45
28 3130522 1 O-Ring
29 3130523 1 Washer
30 3130525 1 Spring
31 3130524 1 Adjuster
32 3130546 1 Screw, Adjust
33 3130545 1 Ring
34 3130544 1 Spring
35 -- -- -- -- -- -- -- 1 Valve, Throttle (100)
36 3131398 1 Spring
37 3130514 1 Ring
38 -- -- -- -- -- -- -- 2 Screw
39 -- -- -- -- -- -- -- 1 Asm., Throttle Shaft
40 3130543 1 Guide, Cable
41 3130535 4 Screw
42 3130511 1 Cover
43 3130512 1 O-Ring
44 3131396 1 Holder, Guide
45 3130538 1 Spring
46 3131395 1 Asm., Plunger
47 3130625 1 Jet, Air, #160
48 1253436

1253537

49 3131451 1 Spring, Compression
50 3130503 1 Asm., Cover
51 3130592 4 Screw

11Asm., Carburetor

(Incl. 1-12)(If built before 10/02/03)
Asm., Carburetor, 600
(Incl. 1-12)(If built after 10/02/03)

6/03

D8

INTAKE and EXHAUST

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

E 2003 Polaris Sales Inc.

16

15

2

14

13

3

4

5

6

7

6

8

9

10

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
2 5132402 4 Pushrod
3 2202363

2202693

4 5244286 1 Plate, Thrust
5 7517598 3 Screw
6 2202145 1 Kit, Gear
7 7041999 3 Spring, Compression
8 7556183 1 Washer, Spring

11Kit, Camshaft

(Incl. 7)(If built before 10/02/03)
Kit, Camshaft
(Incl. 7)(If built after 10/02/03)

11

9 7517865 1 Screw

10 5131415

5134152

11 5133141

5133363

12 5131417

5132696
13 5411895 4 Seal, Valve Guide
14 7041565 4 Spring, Valve
15 5131413 4 Retainer, Spring
16 5910042 8 Lock, Valve Stem

44Lifter, Valve (If built before 10/02/03)

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

22V alve, Exhaust (If built before 10/02/03)

V alve, Exhaust (If built after 10/02/03)

22V alve, Intake (If built before 10/02/03)

V alve, Intake (If built after 10/02/03)

6/03

D9

OIL DIPSTICK

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

1

2

3

4

5

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

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

1 1202109 1 Asm., Dipstick
2 1202110

1202629

11Tube, Oil Fill (If built before 10/02/03)

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

3 7517795 2 Screw
4 5245805 1 Clamp
5 5812016 1 O-Ring

6/03

D10

WATER PUMP

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

4

5

E 2003 Polaris Sales Inc.

12

6

7

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 5131419 1 Shaft, Oil/Water Pump
2 3584404 1 Bearing
3 7710531 1 Ring, Retaining (If built after 10/02/03)
4 -- -- -- -- -- -- -- 1 Kit, Gear Set 680/780

(See Intake and Exhaust Pg. D9, Ref. 6)
5 5433684 1 Impeller
6 7555874 1 Washer, Flat
7 7546804 1 Nut, Nylok

8 7516823

7516822

9 7517950 2 Screw

10 1202019

5631389

11 5812048

5812508

12 3610075 1 Seal, Water Pump

55Screw (If built before 10/02/03)

Screw (If built after 10/02/03)

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

Cover (If built after 10/02/03)

11O-Ring (If built before 10/02/03)

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

D11

6/03

OIL PUMP

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

9

8

7

E 2003 Polaris Sales Inc.

10

6

5

4

3

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

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

1 2540006

2540086
2 2540115 1 Nipple, Oil Filter
3 7517807 4 Screw
4 5131426

5133852

5 1202079

1202588
6 7661127 1 Pin, Dowel

11Filter, Oil (If built before 10/02/03)

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

11Housing, Oil Pump

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

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

Gerotor (If built after 10/02/03)

7 7041563

7042203
8 7556005 1 Washer
9 7516824 1 Screw

10 2202159

2202699

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

Spring (If built after 10/02/03)

11Kit, Oil Pump

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

6/03

D12

MAGNETO

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

2

3

4

5

E 2003 Polaris Sales Inc.

15

8

9

10

11

12

13

14

6

7

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 5245364 1 Holddown, Wire
2 4010901

2202603
3 7517847 2 Screw
4 7517714 3 Screw
5 4010899 1 Asm., Flywheel
6 7555907 1 Washer
7 7546909

7547213
8 5812359

5412458

11Asm., Stator

Kit, Ignition (Incl. Jumper)

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

Nut (If built after 10/02/03)

11O-Ring (If built before 10/02/03)

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

9 1201684

1202641

10 5812283 1 Cover, Sound

11 5434310

5435099
12 5411564 1 O-Ring (If built before 10/02/03)
13 7517950 10 Screw
14 5433820 1 Plug (If built before 10/02/03)
15 4010920

4010951
16 4010898 1 Coil, Ignition

11Housing, Stator (If built before 10/02/03)

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

11Cover, Outer (If built before 10/02/03)

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

11Controller, Ignition (If built before 10/02/03)

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

D13

6/03

STARTING MOTOR

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

7

E 2003 Polaris Sales Inc.

2

3

5

6

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 7516823 1 Screw
2 4010417 1 Starter
3 7555908 1 Washer, Thrust
4 4010418 1 Bendix

5 7552616 1 Washer, Lock
6 7546705 1 Nut
7 7517868 1 Bolt

D14

4/02

TOOL KIT

SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW

1

E 2003 Polaris Sales Inc.

2

8

3

4

5

9

6

7

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

2874735 1 Kit , Tool (Incl. 1-7)
1 2870725 1 Gauge, Tire Pressure
2 -- -- -- -- -- -- -- 1 Screwdriver
3 -- -- -- -- -- -- -- 1 Wrench, 8-10 Open
4 -- -- -- -- -- -- -- 1 Wrench, 9/16 x 1 1/2 Open
5 -- -- -- -- -- -- -- 1 Wrench, Plug

6 -- -- -- -- -- -- -- 1 Puller, Spark Plug (Wrench Handle)
7 2682572 1 Pouch, Tool Kit
8 9918724

9919069

9 2873647 1 Wrench, T orx

11Owner’s Manual, ‘04.5 Sportsman

400-700
Supplement, Owner’s Manual, ’04.5
Sportsman 600

6/03

E1

WINCH ASM.

SPORTSMAN 600 A04CH59AW

E 2003 Polaris Sales Inc.

25

26

24

22

23

19

21

1

2

3

4

19

6

6

16

6

19

20

15

6

16

6

19

18

17

5

6

7

8

9

10

11

12

13

14

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

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

1 2410423 1 Asm., Winch Switch
2 7518304 2 Screw
3 5247139 1 Plate, Switch Mount
4 5133010 2 Spacer, Master Cylinder Clamp
5 7512247 2 Bolt
6 7558402 10 Washer, Flat
7 7512329 1 Bolt
8 5247570 1 Bracket, Contractor
9 7542122 2 Nut, Nylok

10 2202253 1 Asm., Hook, Warn Winch
11 2202643 1 Asm., Winch, Warn w/Cable
12 5247568 1 Plate, Fairlead Mount
13 2871462 1 Roller, Fairlead, Warn Winch

14 7515494 2 Screw
15 7542451 2 Nut, Nylok
16 7512392 4 Screw
17 2461220 1 Harness, Front
18 2461218 1 Harness, Main
19 7542324 10 Nut, Nylok
20 5434698-070 1 Bumper, Front
21 2431017 2 Asm., Headlight, Bottom Mount
22 1014020-067 1 Support, Rack, Front
23 5247569 1 Plate Winch Mount
24 7515321 4 Bolt
25 7515317 4 Screw
26 7552901 4 Washer, Spring Lock

E2

6/03

PRINTED IN THE USA PARTS MANUAL PN 9918731 and MICROFICHE PN 9918732 9/03