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Polaris RANGER 2004 Owner's Manual

Vehicle maintenance and safety
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2004
2004
RANGER
RANGER
Owner's Manual
Owner's Manual
for Vehicle Maintenance
for Vehicle Maintenance
and Safety
and Safety
Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
This is an adult vehicle only.
RANGER 2x4
RANGER 2x4
RANGER 4x4
RANGER 4x4
RANGER 6x6
RANGER 6x6
RANGER TM
RANGER TM

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Summary of Contents for Polaris RANGER 2004

  • Page 1 2004 2004 RANGER RANGER Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety RANGER 2x4 RANGER 2x4 RANGER 4x4 RANGER 4x4 RANGER 6x6 RANGER 6x6 RANGER TM RANGER TM Read this manual carefully. It contains important safety information. This is an adult vehicle only.
  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 3 We’ve created a web site just for YOU! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 4 Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest vehicle we’ve ever produced.

  • Page 6: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.

  • Page 7: Table Of Contents

    ......POLARIS PRODUCTS .....

  • Page 9: Safety

    Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 10: Operator Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your RANGER or in this manual, alerts you to the potential for personal injury.
  • Page 11 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully. Follow the operating pro- cedures described.
  • Page 12 Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. S Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. S Never operate this vehicle on hills too steep for the vehicle or for your abilities.
  • Page 13 Gasoline is extremely flammable. See page 24 for refueling instruc- tions. S Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.

  • Page 14: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Lock the parking brake after when fully stopped.
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.
  • Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting jumps and other stunts...
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it’s in safe operating condition.
  • Page 20 WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver’s license should operate a Polaris RANGER. Even though a child may be within the age group for which some...
  • Page 21 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

  • Page 22: Safety Decals And Locations

    RANGER, always read and follow the instructions of the decals on the RANGER. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
  • Page 23 SAFETY Safety Decals and Locations WARNING WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. WARNING Maximum Box Load is ___ lbs. Remove flammable containers from box before refueling. Location 4 (inside front of box) Fuel / Passenger Warning Decal Text Remove flammable containers from box before refueling.
  • Page 24 SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS...
  • Page 25 READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS...

  • Page 26: Fuel Safety

    SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.

  • Page 27: Features And Controls

    FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 96. Component Locations 1. Cab Frame (if equipped) 2. Cab Frame Hand Hold (if equipped) 3.

  • Page 28: Component Locations

    FEATURES AND CONTROLS Component Locations 10. Headlights 11. Radiator (if equipped) 12. Front Bumper/Brush Guard 13. Hood Hold Down Strap...
  • Page 29 FEATURES AND CONTROLS Component Locations 14. Oil Tank (if equipped) 15. Battery (under driver’s seat) 16. Tail Lights 17. Tail Gate 18. Tailgate Latch Release 19. Air Box (under cargo box) 20. Muffler (Spark Arrester) 21. Rear Caliper 22. Trailer Hitch Receiver...

  • Page 30: Indicator Lights

    FEATURES AND CONTROLS Auxiliary Outlet The 12-volt receptacle (1) has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood. Indicator Lights The indicator lights on the console display: 1.
  • Page 31 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
  • Page 32 FEATURES AND CONTROLS Console 1. Storage Box 2. Cup Holder 3. Indicator Lights 4. Light Switch 5. AWD Switch (if equipped) 6. Hour Meter 7. Glove Box with Lid 8. 12V Accessory Plug 9. Storage Tray 10. Choke Knob 11. Ignition Switch 12.

  • Page 33: Gear Selector

    FEATURES AND CONTROLS Gear Selector The transmission gear selector (1) is located on the console to the right of the steering wheel. The RANGER 2x4, 4x4 and 6x6 have four shift positions (2): H: High Gear L: Low Gear N: Neutral R: Reverse The RANGER TM has three shift positions (3): H: High Gear...

  • Page 34: Ignition Switch

    FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Engine off. All electrical circuits are off except Acc. 12V. Electrical circuits are on. Electrical equipment can be used. START Electric starter is engaged by holding ignition switch key in this position.

  • Page 35: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal The brake pedal (1) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle. Throttle Pedal The throttle pedal (2) is the right pedal on the floor board. Push the pedal down to increase engine speed.

  • Page 36: Operation

    1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 24. 2. Check the oil level on the dipstick. See page 61. Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal (safe) operating range.
  • Page 37 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Inspect your vehicle before each operation to ensure it’s in proper working order.

  • Page 38: Starting The Engine

    OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage.

  • Page 39: Stopping The Engine

    OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface.
  • Page 40 OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you’re familiar with the controls. NOTE: When the throttle pedal is released completely and the engine speed drops near an idle, the vehicle has no engine braking.

  • Page 41: Driving Safely

    5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission (PVT) shifting is automatic. 6. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

  • Page 42: Driving On Slippery Surfaces

    OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these conditions, follow these precautions: 1. Slow down when entering slippery areas. 2.

  • Page 43: Driving Uphill

    OPERATION Driving Safely Driving Uphill 15_ Maximum Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15_ maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause loss of control or vehicle overturn.

  • Page 44: Driving Downhill

    OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15_ maximum). Driving Downhill Whenever descending a hill, follow these precautions: 1.

  • Page 45: Driving Through Water

    Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards (1). Follow these procedures when operating through water: 1.

  • Page 46: Driving Over Obstacles

    OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle.

  • Page 47: Driving In Reverse

    OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6.

  • Page 48: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury.

  • Page 49: Hauling Cargo

    OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Always load the cargo box with the load as far forward as possible. Always operate the vehicle with extreme care when hauling or towing loads.

  • Page 50: Dumping The Cargo Box

    OPERATION Hauling Cargo Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions.

  • Page 51: Towing Loads

    OPERATION Hauling Cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.

  • Page 52: Parking The Ranger

    OPERATION Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3.

  • Page 53: All Wheel Drive (Awd)

    All Wheel Drive (AWD) Your Polaris RANGER (4x4 and 6x6) is equipped with an exclusive Polaris All Wheel Drive (AWD) system that can be activated by a switch on the console. When the switch is off, the RANGER is in two-wheel drive at all times.
  • Page 54 -NOTES-...

  • Page 55: Emission Control Systems

    Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 56: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust or replace parts as necessary. When inspection reveals the need for replacement parts, always use genuine Polaris parts available from your Polaris dealer. Maintenance Chart Key Perform these operations more often under severe use, such as in "...

  • Page 57: Periodic Maintenance Schedule

    MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Frequency Remarks Brake System Pre-operation...
  • Page 58 Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Frequency Remarks J Brake pad wear 25 hrs...
  • Page 59 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Frequency Remarks Coolant strength/ 100 hrs Inspect strength seasonally; pressure test system pressure test system annually (if equipped) Engine Mounts 100 hrs Inspect Valve Clearance 100 hrs Inspect; adjust L Spark Plug 100 hrs Inspect;...

  • Page 60: Lubrication Recommendations

    More often under severe use, such as wet or dusty conditions " Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging.
  • Page 61 MAINTENANCE AND LUBRICATION Lubrication Recommendations...

  • Page 62: Engine Oil

    Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40.
  • Page 63 MAINTENANCE AND LUBRICATION Engine Oil Maintain the engine oil at the proper level to ensure a properly functioning engine, and change the oil and oil filter every 100 hours or every six months, whichever comes first. Dirt and metal particles collect in the oil, and oil loses its lubricative quality if used too long.
  • Page 64 8. Apply Loctitet 565 Thread Sealant to the clean and oil-free threads of the fitting. NOTE: See page 100 for the part numbers of Polaris products. 9. Reinstall the screen fitting and tighten to 14 ft. lbs. (19 Nm). 10. Reinstall the oil hose on the fitting and reinstall the clamp.
  • Page 65 16. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm). 17. Remove the dipstick and fill the tank with two quarts (1.9 l) of Polaris Premium 4 Synthetic Oil. 18. Place the gear selector in neutral and set the parking brake.
  • Page 66 MAINTENANCE AND LUBRICATION Engine Oil Oil Check (RANGER TM) 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat as described on page 29. Remove the screws securing the service panel and remove the panel (1).
  • Page 67 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (RANGER TM) 5. Replace the sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 6.

  • Page 68: Oil Change

    Torque to specification. 5. Add Polaris Premium Synthetic Gearcase Lube until the oil level is even with the bottom thread of the fill plug hole. Do not overfill. 6. Reinstall the fill plug and torque to specification.

  • Page 69: Oil Check

    NOTE: Refer to the Gearcase Specifications Chart on page 69. Always use Polaris Premium Drive Hub Fluid. See page 100 for the part numbers of Polaris products. The front gearcase fill plug (1) is located on the right side of the front gearcase.
  • Page 70 NOTE: Refer to the Gearcase Specifications Chart on page 69. Always use Polaris Angle Drive Fluid. See page 100 for the part numbers of Polaris products. The middle gearcase fill plug (1) is located on the driver’s side of the gearcase.

  • Page 71: Gearcases (Oil Check/Specifications)

    Oil should be changed annually. NOTE: Refer to the Gearcase Specifications Chart on page 69. Always use Polaris Angle Drive Fluid. See page 100 for the part numbers of Polaris products. The rear gearcase fill plug (1) is on the driver’s side of the rear gearcase.

  • Page 72: Adding Or Changing Coolant

    50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 100 for the part numbers of Polaris products. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations...

  • Page 73: Coolant Level Inspection

    Reinstall the cap. NOTE: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your Polaris dealer. Radiator Coolant Level WARNING Escaping steam can cause severe burns.

  • Page 74: Radiator And Cooling Fan

    MAINTENANCE AND LUBRICATION Cooling System (RANGER 2x4, 4x4, 6x6) Radiator and Cooling Fan Check and clean the screen and radiator fins for obstructions caused by insects or mud. Refer to the Periodic Maintenance Schedule beginning on page 54. CAUTION Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator’s effectiveness.

  • Page 75: Spark Plugs

    MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 96. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER 9-11 ft.
  • Page 76 Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This PVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the PVT housing is securely in place during operation.

  • Page 77: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your RANGER to a dealer before starting it, follow the steps outlined below.

  • Page 78: Air Filter Service

    MAINTENANCE AND LUBRICATION Filter Systems (RANGER 2x4, 4x4, 6x6) Air Filter Service We recommended that the air filter be replaced annually. When operating in extremely dusty conditions, it should be replaced more often. 1. Lift the cargo box to access the airbox.

  • Page 79: Fuel Filter

    Always reinstall the breather filter after removing it for service. Fuel Filter Your Polaris RANGER is equipped with an in-line fuel filter that should be replaced by your dealer after every 100 hours of operation. Do not attempt to clean the fuel filter.

  • Page 80: Air Filter

    8. Reassemble all components. Fuel Filter Your Polaris RANGER TM is equipped with an in-line fuel filter that should be replaced by your dealer after every 100 hours of operation. Do not attempt to clean the fuel filter.

  • Page 81: Steering Wheel Inspection

    3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play. 4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized Polaris dealer. Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam (1) either clockwise or counterclockwise to increase or decrease spring tension.

  • Page 82: Spark Arrestor

    MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.
  • Page 83 MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs (1) located on the bottom of the muffler. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

  • Page 84: Throttle System

    MAINTENANCE AND LUBRICATION Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.

  • Page 85: Throttle Cable/Carburetor/Engine Idle Rpm Adjustment

    MAINTENANCE AND LUBRICATION Throttle Cable Adjustment (RANGER TM) If the proper freeplay cannot be obtained with the throttle block adjuster, adjust the cable at the carburetor using the following procedure. 1. Remove the seat and loosen the clamp screw (1) and the throttle cable adjustment screw (2).

  • Page 86: Brake Inspection

    MAINTENANCE AND LUBRICATION Brakes Brake Inspection The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 33. Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation.

  • Page 87: Brakes Inspection/Adjustment

    MAINTENANCE AND LUBRICATION Brakes Brake Inspection 5. Check the brake system for fluid leaks. 6. Check the brake pedal for excessive travel or a spongy feel. 7. Check the friction pads for wear, damage and looseness. 8. Inspect the brake disc spline and pad wear surface for excessive wear.

  • Page 88: Seat Belts

    3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The RANGER seat belt is adjustable and should be adjusted for both the operator and passenger before driving.

  • Page 89: Tire Tread Depth

    MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.
  • Page 90 MAINTENANCE AND LUBRICATION Tires WARNING Operating your RANGER with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death. Make sure the wheels are installed properly. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake.

  • Page 91: Headlight Beam Adjustment

    MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 92: Indicator Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the console panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the console panel.

  • Page 93: Cleaning Your Ranger

    Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your Polaris dealer for free replacement. If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels.
  • Page 94 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 35. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5. Lubricate as outlined in the Periodic Maintenance Schedule. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.
  • Page 95 MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

  • Page 96: Battery Removal

    MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1). To refill use only distilled water. Tap water contains minerals that are harmful to a battery.

  • Page 97: Battery Installation

    MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.

  • Page 98: Specifications

    SPECIFICATIONS See your Polaris dealer for jetting and clutching specifications. RANGER TM RANGER 2x4 Gross Vehicle Weight 2400 lbs. (1089 kg) 2500 lbs. (1135 kg) Fuel Capacity 8.5 gal. (32.2 l) 8.5 gal. (32.2 l) Towing Capacity 1000 lbs. (454 kg) 1400 lbs.
  • Page 99 SPECIFICATIONS RANGER TM RANGER 2x4 Lubrication System Full Pressure Dry Sump Engine Oil 0W/40 0W/40 Driving System Type Shift Type Single Lever (console) Single Lever (console) Gear Reduction - Low 8.6:1 Gear Reduction - Reverse 6.84:1 5.9:1 Gear Reduction - High 4.4:1 4.6:1 Drive Ratio - Front:...
  • Page 100 SPECIFICATIONS See your Polaris dealer for jetting and clutching specifications. RANGER 4x4 RANGER 6x6 Gross Vehicle Weight 2700 lbs. (1226 kg) 2900 lbs. (1317 kg) Fuel Capacity 8.5 gal. (32.2 l) 8.5 gal. (32.2 l) Towing Capacity 1500 lbs. (681 kg) 1500 lbs.
  • Page 101 SPECIFICATIONS RANGER 4x4 RANGER 6x6 Lubrication System Dry Sump Dry Sump Engine Oil 0W/40 0W/40 Driving System Type Shift Type Single Lever (console) Single Lever (console) Gear Reduction - Low 8.6:1 8.6:1 Gear Reduction - Reverse 5.9:1 5.9:1 Gear Reduction - High 4.6:1 4.6:1 Drive Ratio - Front:...

  • Page 102: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2871567 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (16 gal.)

  • Page 103: Troubleshooting

    TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections...
  • Page 104 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer...
  • Page 105 Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...

  • Page 106: Warranty

    WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma- terial or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that...
  • Page 107 HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 108 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...

  • Page 109: Limited Warranty

    Manufacturer’s Warranty Coverage: The 2004 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner’s Warranty Responsibilities: S As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Own-...
  • Page 110 During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission-related part.

  • Page 111: Maintenance Schedule

    When the LSI engine is being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
  • Page 112 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed.
  • Page 113 Federal Emissions Component Defect Warranty Emissions Component Defect Warranty Coverage This emission warranty is applicable in all States, except the State of California. Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) war- rant(s) to the initial retail purchaser and each subsequent owner, that this non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial...
  • Page 114 As the engine owner, you should, however, be aware that POLARIS may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 115 CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM. If other than the parts authorized by POLARIS are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by POLARIS in their performance and durability.

  • Page 116: Index

    INDEX Adding or Changing Coolant ..FEATURES AND CONTROLS ..25-33 Age Restrictions ..... Filter Systems .
  • Page 117 ....Parking the RANGER ....POLARIS PRODUCTS ... . . TABLE OF CONTENTS .
  • Page 118 FOLLOW ALL INSTRUCTIONS AND WARNINGS. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No.

This manual is also suitable for:

2004 ranger 2x42004 ranger 4x42004 ranger 6x62004 ranger tm

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