Polaris SPORTSMAN 600

Questions and Answers:

J
John AndersenAug 18, 2025
What to do if my Polaris SPORTSMAN 600 engine turns over but fails to start?
- M
  Michael ChapmanAug 18, 2025
  If your Polaris Motorcycle engine turns over but doesn't start, it could be due to several reasons. Check for: * No fuel. * Dirt in the fuel line or filter. * A fuel valve that isn't allowing fuel to pass. * A fuel pump that is inoperative or restricted. * A plugged or pinched tank vent. * A plugged carburetor starter circuit. * A flooded engine. * Low compression due to high cylinder leakage. * No spark, possibly due to a fouled spark plug or ignition component failure.
G
Gavin JacksonAug 23, 2025
What causes low compression in a Polaris Motorcycle engine?
- P
  Patricia HessAug 23, 2025
  Low compression in your Polaris Motorcycle engine can stem from several issues. Inspect the following: * Check for a cylinder head gasket leak. * Verify valve clearance and check for cam wear. * Inspect the cylinder and piston for wear. * Examine the piston rings for wear, leakage, breakage, or sticking. * Look for bent or stuck valves. * Check for broken or weak valve springs. * Ensure the valve is seating properly, checking for bending or carbon accumulation. * Inspect for a sticking rocker arm.
R
rodriguezdarrellAug 26, 2025
What to do if my Polaris Motorcycle engine runs but will not idle?
- D
  danielsjasmineAug 26, 2025
  If your Polaris Motorcycle engine runs but won't idle, consider these potential issues: * A restricted carburetor pilot system. * A misadjusted carburetor. * A choke that is not adjusted properly. * Low compression. * A restricted crankcase breather.
T
Thomas FuentesAug 28, 2025
Why won't my Polaris Motorcycle engine rev up?
- S
  scottschneiderAug 28, 2025
  If your Polaris Motorcycle engine idles but won't rev up, consider the following: * A fouled spark plug or weak spark. * A broken throttle cable. * An obstruction in the air intake. * The air box being removed (reinstall all intake components). * Incorrect or restricted carburetor jetting. * The ETC switch limiting speed. * The reverse speed limiter limiting speed. * A carburetor vacuum slide sticking or a damaged diaphragm. * Incorrect ignition timing. * A restricted exhaust system. * A cam worn excessively.
C
Catherine McleanAug 30, 2025
What causes a Polaris Motorcycle to have low power?
- K
  Kenneth MullinsAug 30, 2025
  If your Polaris Motorcycle engine has low power, check these potential causes: * A fouled spark plug. * Cylinder, piston, ring, or valve wear or damage (check compression). * PVT not operating properly. * A restricted exhaust muffler. * A carburetor vacuum slide sticking or a damaged diaphragm. * A dirty carburetor. * A cam worn excessively.
J
Jerry ChavezSep 2, 2025
Why is my Polaris Motorcycle backfiring?
- Q
  qpriceSep 2, 2025
  Backfiring in your Polaris Motorcycle can occur due to: * ETC or speed limiter system malfunction. * Fouled spark plug or incorrect plug or plug gap. * Carburetion faulty - lean condition. * Exhaust system air leaks. * Ignition system faulty: Spark plug cap cracked/broken. * Ignition coil faulty. * Ignition or kill switch circuit faulty. * Ignition timing incorrect. * Sheared flywheel key. * Poor connections in ignition system. * Valve sticking. * Air leaks in intake. * Lean condition.
S
Sandra MatthewsSep 5, 2025
What causes excessive smoke and carbon buildup in a Polaris SPORTSMAN 600 Motorcycle?
- T
  Todd BrownSep 5, 2025
  Excessive smoke and carbon buildup in your Polaris Motorcycle can be attributed to: * Excessive piston-to-cylinder clearance. * Wet sumping. * Worn rings, piston, or cylinder. * Worn valve guides or seals. * Restricted breather. * Air filter dirty or contaminated.
N
Nicholas RaySep 7, 2025
What to do if the engine on my Polaris Motorcycle does not turn over?
- N
  Natasha ConnerSep 7, 2025
  If your Polaris Motorcycle engine does not turn over, it could be due to: * A dead battery. * A starter motor that does not turn. * An engine that is seized, rusted, or has suffered a mechanical failure.
J
Jacob SharpSep 9, 2025
What causes piston failure and scoring in a Polaris SPORTSMAN 600?
- D
  Dana BurnsSep 10, 2025
  Piston scoring in your Polaris Motorcycle can result from: * Lack of lubrication. * Dirt entering the engine through cracks in the air filter or ducts. * Engine oil that is dirty or contaminated.
F
Felicia OwensSep 12, 2025
What does a leak at the water pump weep hole mean on my Polaris Motorcycle?
- G
  gregory71Sep 12, 2025
  A leak at the water pump weep hole on your Polaris Motorcycle could indicate: * A faulty water pump mechanical seal (coolant leak). * A faulty pump shaft oil seal (oil leak).

Polaris SPORTSMAN 600 Specifications

General

Brand	Polaris
Model	SPORTSMAN 600
Category	Motorcycle
Language	English

Summary

SERVICE MANUAL

Foreword

Introduction to the manual, outlining its purpose and intended audience.

Safety Information

Explains safety symbols like DANGER, WARNING, CAUTION, and NOTE used in the manual.

Trademarks

Lists trademarks acknowledged by Polaris for products mentioned in the manual.

GENERAL INFORMATION

Model Identification and Specifications

Identifies models, dimensions, and detailed specifications for early/late 600/700 Sportsman.

Publication and Service Data

Lists publication numbers, paint codes, torque specs, conversion tables, and glossary of terms.

Early;Late Model Identification

Explains how to differentiate between early and late 2004 Sportsman models based on visual cues.

MAINTENANCE

Periodic Maintenance Chart

Outlines recommended inspection, adjustment, and lubrication intervals for components based on hours and calendar time.

Pre-Ride; Daily Inspection

Lists essential daily inspection items, including tires, fluids, brakes, throttle, lights, and engine coolant.

Lubrication and Fluid Services

Details lubrication for engine oil, transmission, gearcases, and brake fluid, including types, methods, and frequencies.

Special Tools and Troubleshooting

Lists special tools for maintenance and provides troubleshooting guidance for common issues.

ENGINE

Engine Exploded Views and Specifications

Provides exploded views and key service data for engine components, including torque specifications.

Engine Removal, Installation, and Break-In

Covers engine removal, installation procedures, and essential break-in period recommendations.

Internal Engine Component Service

Details procedures for cylinder honing, valve service, piston/ring inspection, and crankshaft/camshaft service.

Engine Troubleshooting

Provides guidance for diagnosing and resolving common engine problems, including spark, idle, power, and cooling issues.

FUEL SYSTEM;CARBURETION

Carburetor Service Procedures

Covers carburetor exploded views, disassembly, cleaning, inspection, assembly, and float adjustment.

Fuel System Components and Testing

Explains fuel tank assembly, fuel flow, fuel filter maintenance, and fuel pump testing.

Jetting Guidelines and Carburetor Operation

Provides guidelines for carburetor jetting based on conditions and explains the operation of Mikuni CV carbs.

Troubleshooting Fuel System Issues

Lists symptoms and causes for fuel starvation, rich mixture, poor idle, and erratic idle, offering troubleshooting steps.

BODY; STEERING; SUSPENSION

Body Panel and Rack Removal

Details procedures for removing body panels, racks, bumpers, and grills.

Steering and Suspension Service

Covers steering post assembly, A-arm replacement, and suspension component inspection and adjustment.

Wheel and Hub Service

Provides torque specifications and procedures for wheel and hub removal, installation, and inspection.

CLUTCH

PVT System Operation and Maintenance

Covers PVT system overview, maintenance, inspection, drying, overheating diagnosis, and troubleshooting.

Drive Clutch Service Procedures

Details drive clutch disassembly, inspection, reassembly, and related component service.

Driven Clutch Service Procedures

Outlines disassembly, inspection, and assembly procedures for EBS driven clutches, including bushing service.

Drive Belt Inspection and Installation

Details inspection of the drive belt for wear, and procedures for its removal and installation.

FINAL DRIVE

Front Axle and Gearcase Service

Covers front axle removal/installation, CV joint boot replacement, hub service, and gearcase operation/disassembly.

Rear Hub and Drive Shaft Service

Details procedures for rear hub removal/installation, drive shaft removal/service, and handling tips.

Rear Gearcase Service

Outlines rear gearcase removal, installation, disassembly, and reassembly procedures, including exploded views.

TRANSMISSION

Transmission Exploded Views and Specifications

Provides exploded views and torque specifications for early and late 2004 transmissions.

Transmission Removal and Installation

Details the procedures for removing and installing the transmission, including disconnecting related components and supports.

Transmission Disassembly and Reassembly

Covers the complete process of disassembling and reassembling the transmission, including gear and shaft procedures.

BRAKES

Brake System Overview and Service Notes

Explains the hydraulic brake system overview, service notes, and troubleshooting for brake noise.

Front Brake Caliper Service

Details front brake pad removal/installation, disc inspection/replacement, and caliper removal/disassembly/inspection.

Rear Brake Caliper Service

Covers rear brake pad removal/installation and rear caliper removal/inspection/assembly.

Master Cylinder and Auxiliary Brake Service

Explains hydraulic caliper bleeding, fluid change, master cylinder removal/installation, and auxiliary brake adjustment.

ELECTRICAL

Ignition System Testing and Troubleshooting

Covers flywheel identification, ignition system operation, testing flow charts, and troubleshooting CDI and ignition components.

Instrument Cluster and Speedometer Service

Explains instrument cluster overview, gear position switch test, and speedometer troubleshooting.

Charging System and Battery Maintenance

Details charging system testing, battery identification, maintenance, testing, and charging procedures for both battery types.

Wiring Diagrams and Component Identification

Provides wiring diagrams for various systems and identifies components, including hand warmers, winch, and ignition systems.

Related product manuals

Polaris Slingshot SL 2015

136 pages

Polaris Slingshot SL 2020

173 pages

Polaris 2003 SPORTSMAN 600

22 pages

Polaris SPORTSMAN 600 2003

262 pages

Polaris Victory Cross Roads

130 pages

Polaris Ranger 4x4 700 EFI

131 pages

Polaris Sportsman 6x6

131 pages

Sportsman 800 EFI Big Boss 6x6 2013

485 pages

Sportsman 800 EFI Big Boss 6x6 2012

485 pages

Sportsman 800 EFI Big Boss 6x6 2014

485 pages

Polaris SPORTSMAN 600 - User Manual

Table of Contents

Questions and Answers:

Polaris SPORTSMAN 600 Specifications

Summary

SERVICE MANUAL

Foreword

Safety Information

Trademarks

GENERAL INFORMATION

Model Identification and Specifications

Publication and Service Data

Early;Late Model Identification

MAINTENANCE

Periodic Maintenance Chart

Pre-Ride; Daily Inspection

Lubrication and Fluid Services

Special Tools and Troubleshooting

ENGINE

Engine Exploded Views and Specifications

Engine Removal, Installation, and Break-In

Internal Engine Component Service

Engine Troubleshooting

FUEL SYSTEM;CARBURETION

Carburetor Service Procedures

Fuel System Components and Testing

Jetting Guidelines and Carburetor Operation

Troubleshooting Fuel System Issues

BODY; STEERING; SUSPENSION

Body Panel and Rack Removal

Steering and Suspension Service

Wheel and Hub Service

CLUTCH

PVT System Operation and Maintenance

Drive Clutch Service Procedures

Driven Clutch Service Procedures

Drive Belt Inspection and Installation

FINAL DRIVE

Front Axle and Gearcase Service

Rear Hub and Drive Shaft Service

Rear Gearcase Service

TRANSMISSION

Transmission Exploded Views and Specifications

Transmission Removal and Installation

Transmission Disassembly and Reassembly

BRAKES

Brake System Overview and Service Notes

Front Brake Caliper Service

Rear Brake Caliper Service

Master Cylinder and Auxiliary Brake Service

ELECTRICAL

Ignition System Testing and Troubleshooting

Instrument Cluster and Speedometer Service

Charging System and Battery Maintenance

Wiring Diagrams and Component Identification

Related product manuals