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General
Information/Foreword
This Service Manual contains service, maintenance, and
troubleshooting information for the 2024 600 ATV mod-
els. The complete manual is designed to aid service per-
sonnel in service-oriented applications.
This manual is divided into sections. Each section covers
a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling,
inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as
to how much disassembly is needed to correct any given
condition.
This service manual is designed primarily for use by a
basic level technician. The procedures found in this man-
ual are of varying difficulty, and certain service proce-
dures in this manual require one or more special tools to
be completed. The technician should use sound judgment
when determining which procedures can be completed
based on skill level and access to appropriate special
tools.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
When replacement of parts is necessary, use only genuine
parts. They are precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated Parts Man-
ual for the correct part number, quantity, and description.
All publications and decals display the words Warning,
Caution, Note, and At This Point to emphasize important
information. The symbol ! WARNING identifies
personal safety-related information. Be sure to follow the
directive because it deals with the possibility of severe
personal injury or even death. A CAUTION identifies
unsafe practices which may result in ATV-related dam-
age. Follow the directive because it deals with the possi-
bility of damaging part or parts of the ATV. The symbol
NOTE: identifies supplementary information worthy
of particular attention. The symbol
AT THIS
POINT directs the technician to certain and specific
procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only and are not designed to depict actual conditions.
Because products are constantly refined and improved,
no retroactive obligation is incurred.
All materials and specifications are subject to change
without notice.
Specifications
NOTE: Specifications subject to change without notice.
* Level with bottom of plug hole threads.
MISCELLANEOUS
Tire Size (Front) 25 x 8 – 12
26 x 9 – 14NHS
27 x 9 – 14
28 x 10 – 14
Tire Size (Rear) 25 x 10 – 12
26 x 11 – 14NHS
27 x 11 – 14
28 x 10 – 14
Tire Inflation Pressure (no load) 48.3 kPa (7.0 psi)
Tire Inflation Pressure (load ≥143 kg
[315 lbs] to max. 233 kg [515 lbs])
68.9 kPa (10.0 psi)
Spark Plug Type NGK LKR7E
Spark Plug Gap 0.7-0.8 mm (0.027-0.031 in)
Gas Tank Capacity 20.06 L (5.3 U.S. gal)
Coolant Capacity 2 L (2.1 U.S. qt)
Rear Drive Capacity 1200 mL (40.5 fl oz)*
Front Differential Capacity 270 mL (9.1 fl oz)*
Engine Oil Capacity (Approx.) 2.35 L (2.5 U.S. qt) — Overhaul
2.35 L (2.5 U.S. qt) — Change
Gasoline (Recommended) 87 Octane Regular Unleaded
Engine Oil (Recommended) 0W-40 ACX All Weather
(Synthetic)
Front Differential Lubricant (actuator
on gas cap side)
SAE-Approved 80W-90 Hypoid
Rear Transaxle Lubricant/Front
Differential Lubricant (actuator on foot
brake side)
Synthetic Extreme Pressure
Transaxle Fluid
Drive Belt Width 30.8 mm (1.22 in)
Brake Fluid DOT 4
Taillight/Brake Light LED
Headlight 12 V — 60 W/55 W Halogen
12 V — 60 W/55 W Halogen
with LED accent
ELECTRICAL SYSTEM
Spark Plug Cap Resistance 4250-5750 ohms
Ignition Coil Resistance (Primary)
Ignition Coil Resistance (Secondary)
Less than 5.0 ohms
N.A.
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance (CKP sensor)
Stator Coil Resistance (AC generator)
200 ohms
Less than 1 ohm
Crankshaft Position Sensor 2.0 AC volts or more
AC Generator Output (no load) 75 AC volts @ 5000 RPM
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