PARTS MANUAL PN 9918731 and MICROFICHE PN 9918732 9/03
SPORTSMAN 600
Model #A04CH59AK
Model #A04CH59AL
Model #A04CH59AN
Model #A04CH59AW
Rev. 01
E 2003 Polaris Sales Inc.
This page left blank intentionally.
TABLE OF CONTENTS
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTS-
MAN 600 A04CH59AW
Parts Manual
A |
|
G |
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A--ARM/STRUT MOUNTING . . . . . . . . . . . . . |
B12 |
GEARCASE (Cases and Snorkel) . . . . . . . . . . |
D1-2 |
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . |
B1 |
GEARCASE (INTERNAL COMPONENTS) . . . |
C13-14 |
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
|
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
|
G |
GEAR SELECTOR . . . . . . |
. . . . . . . . . . . . . . C10 |
R
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
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . C7 THROTTLE ASM. . . . . . . . . . . . . . . . . . . . . . B9 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . E1 TRANSMISSION MOUNTING . . . . . . . . . . . . C12
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D11 WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . B7 WINCH ASM. . . . . . . . . . . . . . . . . . . . . . . . . E2
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
REAR CAB, SEAT and MAIN FRAME
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
19
E 2003 Polaris Sales Inc.
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21 |
24 |
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25 |
35 |
36 |
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26 |
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 |
|
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|
|
|
1 |
7541925 |
4 |
Nut, Nylok |
2 |
7555792 |
4 |
Washer |
3 |
5811107 |
1 |
Foil, Rear Cab, Rear |
4 |
5432117-400 |
1 |
Cab, Rear (AK) |
|
5432117-053 |
1 |
Cab, Rear (AL) |
|
5432117-341 |
1 |
Cab, Rear (AN) |
|
5432117-288 |
1 |
Cab, Rear (AW) |
5 |
7511930 |
2 |
Bolt |
6 |
5246076 |
1 |
Retainer, Seat Latch |
7 |
7079902 |
1 |
Decal, 4 Stroke, Carb/Filter Information |
8 |
5811308 |
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 |
1 |
Asm., Seat, Black |
|
2682958-070 |
1 |
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, Hitch |
29 |
7512232 |
22 |
Screw |
30 |
5811111 |
1 |
Foil, Rear Fender |
31 |
5811087 |
1 |
Foil |
32 |
5811106 |
2 |
Foil, Rear Cab, Front |
33 |
5434704-070 |
1 |
Guard, Mud, Rear, LH |
|
5434705-070 |
1 |
Guard, Mud, Rear, RH |
34 |
7670057 |
22 |
Nut, U-Type Speed |
35 |
7555832 |
2 |
Washer |
36 |
7517312 |
2 |
Screw |
37 |
7517264 |
4 |
Screw (LH Side) |
|
7517376 |
4 |
Screw (RH Side) |
38 |
5432221-070 |
1 |
Footwell, Black, LH |
|
5433929-070 |
1 |
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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9 |
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8 |
13 |
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19 12
16 14
10 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 |
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||||
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1 |
5811491 |
1 |
Foil, Side Panel, Gen. IV, RH |
2 |
5433853-177 |
1 |
Panel, Side, LH (AK) |
|
2632471-177 |
1 |
Panel/Foil, RH (AK) |
|
5435322-070 |
1 |
Panel, Side, LH (AL)(AN)(AW) |
|
2632471-070 |
1 |
Panel/Foil, RH (AL)(AW) |
|
2632471-382 |
1 |
Panel/Foil, RH (AN) |
3 |
5812326 |
1 |
Foil, Side Panel, RH |
4 |
7512232 |
10 |
Screw |
5 |
2632748-400 |
1 |
Cab, Front (AK) |
|
2632748-053 |
1 |
Cab, Front (AL) |
|
2632748-341 |
1 |
Cab, Front (AN) |
|
2632748-288 |
1 |
Cab, Front (AW) |
6 |
7670057 |
10 |
Nut, U-Type Speed |
7 |
5432088-400 |
1 |
Cover, Front (AK) |
|
5432088-053 |
1 |
Cover, Front (AL) |
|
5432088-341 |
1 |
Cover, Front (AN) |
|
5435110-288 |
1 |
Cover, Front (AW) |
8 |
7517861 |
2 |
Screw |
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 |
1 |
Guard, Mud, Front, Black, LH |
|
5434703-070 |
1 |
Guard, Mud, Front, Black, RH |
19 |
7515158 |
2 |
Screw |
20 |
7541925 |
2 |
Nut, Nylok |
21 |
7555792 |
2 |
Washer |
22 |
7512085 |
2 |
Screw |
9/03
A5
REAR RACK MOUNTING
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
E 2003 Polaris Sales Inc.
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 |
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||||
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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) |
9/03
A6
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)
1
3
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29 |
7 |
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5 |
9
11
12
8
21
20 |
19 |
18 |
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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 |
1 |
Rack, Front, Black |
|
|
|
(If built before 2/03/03) |
|
5435240-070 |
1 |
Rack, Front, Black (If built after 2/03/03) |
5 |
7558402 |
14 |
Washer, Flat |
6 |
7517208 |
4 |
Screw |
7 |
2431017 |
2 |
Headlight |
|
4030059 |
2 |
Bulb, Replacement, 27W |
8 |
7542324 |
6 |
Nut, Nylok |
9 |
2632757-070 |
1 |
Asm., Bumper, Front, Black |
|
|
|
(Incl. Warning Decal)(AK)(AL)(AN) |
|
-------------- |
1 |
Bumper, Front (AW) |
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|
(See Winch Pg. E2, Ref. 20) |
10 |
7515306 |
4 |
Screw |
11 |
5434699-070 |
1 |
Panel |
12 |
7512094 |
2 |
Screw |
13 |
1014412-067 |
1 |
Guard, Brush |
14 |
5434314 |
1 |
Shield, Side, Radiator, LH |
|
5434315 |
1 |
Shield, Side, Radiator, RH |
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 |
1 |
Decal, Reflector, Amber, LH |
|
7171475 |
1 |
Decal, Reflector, Amber, RH |
25 |
1014020-067 |
1 |
Support, Front Rack |
26 |
5810467 |
1 |
Plug, Frame |
27 |
1014261-067 |
1 |
Support, Front Rack, LH |
|
1014262-067 |
1 |
Support, Front Rack, RH |
28 |
7512232 |
6 |
Screw |
29 |
7555960 |
2 |
Washer, Flat |
9/03
A8
DECALS
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
2 |
3 |
4 |
5 |
6 |
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E 2003 Polaris Sales Inc.
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11 12 |
13
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. |
Qty. Description |
|
Ref. Part No. |
Qty. Description |
|
||||
|
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1 |
7179927 |
2 |
Decal, Reflector, Red |
2 |
7170912 |
2 |
Decal, Warning, Front/Rear Rack |
3 |
7171016 |
1 |
Decal, “4X4”, Side Panel, LH (AK) |
|
7171017 |
1 |
Decal, “4X4”, Side Panel, RH (AK) |
|
7171008 |
1 |
Decal, “4X4”, Side Panel, LH (AL) |
|
7171009 |
1 |
Decal, “4X4”, Side Panel, RH (AL) |
|
7171012 |
1 |
Decal, “4X4”, Side Panel, LH (AN) |
|
7171013 |
1 |
Decal, “4X4”, Side Panel, RH (AN) |
|
7172060 |
1 |
Decal, “4X4”, Side Panel, LH (AW) |
|
7172061 |
1 |
Decal, “4X4”, Side Panel, RH (AW) |
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 |
1 |
Decal, “POLARIS”, Frt Cover (AK)(AN)(AW) |
|
7079916 |
1 |
Decal, “POLARIS”, Front Cover (AL) |
9 |
7171474 |
1 |
Decal, Reflector, Amber, LH |
|
7171475 |
1 |
Decal, Reflector, Amber, RH |
10 |
7079672 |
1 |
Decal, Foot Brake |
11 |
7079604 |
1 |
Decal, Override Switch, AWD |
12 |
7171004 |
1 |
Decal, Tank Side, LH (AK)(AL) |
|
7171005 |
1 |
Decal, Tank Side, RH (AK)(AL) |
|
7171315 |
1 |
Decal, “600”, Tank Side, LH (AN) |
|
7171316 |
1 |
Decal, “600”, Tank Side, RH (AN) |
|
7172056 |
1 |
Decal, Tank Side, LH (AW) |
|
7172057 |
1 |
Decal, Tank Side, RH (AW) |
13 |
7171014 |
1 |
Decal, Side Panel, Top, LH (AK) |
|
7171015 |
1 |
Decal, Side Panel, Top, RH (AK) |
|
7171006 |
1 |
Decal, Side Panel, Top, LH (AL) |
|
7171007 |
1 |
Decal, Side Panel, Top, RH (AL) |
|
7171797 |
1 |
Decal, Side Panel, Top, LH (AN) |
|
7171798 |
1 |
Decal, Side Panel, Top, RH (AN) |
|
7172058 |
1 |
Decal, Side Panel, Top, LH (AW) |
|
7172059 |
1 |
Decal, Side Panel, Top, RH (AW) |
14 |
7077920 |
1 |
Decal, Passenger Warning |
15 |
7079959 |
1 |
Decal, “POLARIS”, Rear (AK)(AN)(AW) |
|
7079960 |
1 |
Decal, “POLARIS”, Rear (AL) |
16 |
7079084 |
1 |
Decal, Tire Pressure/Load |
17 |
7171383 |
1 |
Decal, Discretionary Warning |
18 |
7079083 |
1 |
Decal, Warning, General, CPSC |
9/03
A9
COOLING SYSTEM
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
8
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3 |
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16 |
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5 |
20 |
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40 |
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39 |
38 |
17 |
22 |
23 |
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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 |
|
||||
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1 |
1240044 |
1 |
Cap, Pressure |
2 |
5434325 |
1 |
Filler, Coolant (If built before 10/02/03) |
|
5435196 |
1 |
Filler, Coolant, (If built after 10/02/03) |
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 |
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
|
|
1 |
1 |
|
2 |
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2 |
|
|
3 |
|
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4 |
|
3 |
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||
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4 |
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5 |
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|
E 2003 Polaris Sales Inc. |
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6 |
|
|
7
8
12 11
26
22
16
22 |
25 |
|
|
23 |
24 |
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. |
Qty. |
Description |
|
||
|
|
|
|
|
|
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 |
|
Ref. Part No. |
Qty. |
Description |
||
|
|
|
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15 |
7512666 |
1 |
Bolt |
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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 TANK
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
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1 |
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E 2003 |
2 |
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3 |
4 |
5 |
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23
22
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6 |
|
21 |
7 |
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17 |
|
8 |
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|
|
16 |
|
12
11
10
9
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. |
Qty. Description |
|
Ref. Part No. |
Qty. Description |
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1 |
5433687 |
1 |
Cap, Gas Tank (If built before 7/01/03) |
|
5435324 |
1 |
Cap, Gas Tank (If built after 7/01/03) |
2 |
5812123 |
1 |
Gasket, Fuel Cap |
3 |
5812265 |
1 |
Seal, Foam |
4 |
8360009-600 |
AR |
Line, Fuel |
5 |
7517685 |
2 |
Screw |
6 |
5247184 |
1 |
Bracket, Mounting, Rear, LH |
|
5247185 |
1 |
Bracket, Mounting, Rear, RH |
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 |
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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5 |
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|
17 |
18 |
19 |
|
3 |
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2 |
7 |
6 |
10 |
|
20 |
|
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21
22
11
8
8
12
E 2003 Polaris Sales Inc.
13
42
A13
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 |
1 |
Kit, Short Block, ATV 680 |
|
|
|
(If built before 10/02/03) |
|
2202697 |
1 |
Kit, Short Block, ATV 600 |
|
|
|
(If built after 10/02/03) NOTE: The |
|
|
|
Short Block assembly contains a |
|
|
|
crankcase assembly, cylinder & cylin- |
|
|
|
der head assembly and a piston & |
|
|
|
crankshaft assembly. Prior authoriza- |
|
|
|
tion is required for warranty consider- |
|
|
|
ation. |
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 |
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 |
1 |
Bracket, Mount, Top |
|
|
|
(If built before 10/02/03) |
|
5247368 |
1 |
Bracket, Mount, Top |
|
|
|
(If built after 10/02/03) |
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 |
9/03
A14
AIR BOX
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
13
12
31
14
15
14
16
18
17
E 2003 Polaris Sales Inc. |
17 |
19
23 22
Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.
Ref. Part No. |
Qty. |
Description |
|
|
|
|
|
1 |
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 |
Ref. Part No. |
Qty. |
Description |
|
|
|
||||
|
|
|
|
|
|
|
|
Clamp, Hose |
|
17 |
7080699 |
3 |
|
|
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 |
|
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
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 |
|
|
|
|
|
|
|
|
1380218 |
2 |
Asm., Drive Shaft |
|
1 |
7670092 |
2 |
Circlip |
|
2 |
1590358 |
2 |
Joint, CV |
|
Ref. Part No. Qty. Description
3 |
2201015 |
2 |
Kit, Boot (Incl. Clamps and Grease) |
4 |
1380186 |
2 |
Shaft (Incl. 5) |
5 |
2202015 |
2 |
Kit, Cross and Bearing |
12/02
B2
REAR DRIVE SHAFT
SPORTSMAN 600 A04CH59AK and SPORTSMAN 600 A04CH59AL and SPORTSMAN 600 A04CH59AN and SPORTSMAN 600 A04CH59AW
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 |
|
|
|
|
|
|
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 |
Ref. Part No. |
Qty. |
Description |
|
|
|
||||
|
|
|
|
|
|
|
|
Grease, 50g |
|
6 |
1350047 |
1 |
|
|
7 |
1590281 |
1 |
Joint, Plunging |
|
8 |
1350042 |
1 |
Ring, Spring |
|
9 |
2201374 |
1 |
Kit, Boot, Gear Side |
|
10 |
2201373 |
1 |
Kit, Boot, Wheel Side |
|
5/03
B3
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