1
PN 9919069 Rev 01 4/03
E 2003 Polaris Sales Inc.
Printed in U.S.A.
2004 SPORTSMAN 600
OWNER’S MANUAL SUPPLEMENT
Engine #EH059OLE023 Model #: A04CH59AK
A04CH59AL
A04CH59AN
IMPORTANT: Your 2004 Sportsman 600 was manufac-
tured with one of two possible engines. If the engine in
your ATV matches the engine number listed above, disre-
gard the specification information in your owner’s manual
and refer to this supplement instead. This supplement to
your owner’s manual should remain with your owner’s
manual at all times.
Capacities
Gross Vehicle Weight 1240 lbs./563 kg
Fuel Capacity 4.25 gal./16 l
Towing Capacity 1500 lbs./681 kg
Hitch Tongue Capacity 150 lbs./68.1 kg (Rear rack capacity
and tongue weight not to exceed 200
lbs./90.7 kg)
Front Rack Capacity 100 lbs./45.4 kg
Rear Rack Capacity 200 lbs./90.8 kg
Overall Length 81 in./205.7 cm
Overall Width 46 in./116.8 cm
Overall Height 47 in./119.4 cm
Wheelbase 50.75 in./128.9 cm
Ground Clearance 11.25 in./28.6 cm
Dry Weight 740 lbs./336 kg
Minimum Turning Radius 71.5 in./181.6 cm unloaded
Engine Oil Capacity 2qts./1.9l
Coolant Capacity 3.2qts./3l
Drive System
Driving System Type 4 Wheel Independent Shaft
Shift Type Side Lever (H/L/N/R/P)
Gear Reduction - Low 7.5/1
Gear Reduction - Reverse 5.11/1
Gear Reduction - High 3.09/1
Drive Ratio - Front 3.82/1
Drive Ratio - Final 3.10/1
Tire Size - Front 25x8-12(5psi)
Tire Size - Rear 25x11-12(5psi)
Features
Headlight (watts) 1 Single Beam on Handlebar (50 w)
2 Single Beam on Grill (27 w)
Taillights 8.26 w
Brake Light 26.9 w
Instrument Cluster LCD
Engine and Cooling
Engine EH059OLE023
Displacement 597
Bore x Stroke 76.5 x 65
Pilot Jet 45
Main Jet 155
Needle Jet P-4
Jet Needle J8-4FA01-3
Pilot Screw 1.5
Alternator Output 300 Watts @ 3000 rpm
Compression Ratio 10.3:1
Starting System Electric
Carburetor BST 34mm Mikuni
Ignition System CDI
Ignition Timing 25° BTDC @ 2750 +/-- 250 RPM
SparkPlug/Gap RC7YC / .035 in. (0.9 mm)
Lubrication System Pressurized Wet Sump
Suspension and Brakes
Front Brake Hydraulic Disc
Rear Brake Hydraulic
Parking Brake Hydraulic lock, all wheel
Front Suspension MacPherson Strut with 6.7” (17 cm)
of travel
Rear Suspension Progressive Rate with 9.5” (24.1 cm)
of travel
Shock Adjustment Rear Spring Preload Adjust
Jetting Chart
AMBIENT TEMPERATURE
ALTITUDE
Meters (Feet)
Below 40° F
Below 5° C
+40° F and above
+5° C and above
0-1800 (0-6000) 162.5 155
1800-3700 (6000-12000) 150 145
Clutching Chart
ALTITUDE
Meters (Feet)
Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
0-1800
(0-6000)
10 MH
PN 5630513
Blu/Grn
PN 7041157
Wht/Yllw
PN 7041635
EBS
PN 5132751
1800-3700
(6000-12000)
10 WH
PN 5630710
Blu/Grn
PN 7041157
Wht/Yllw
PN 7041635
EBS
PN 5132751
*EBS models require no helix / spring adjustment
(141 pages)
(114 pages)
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