GENERAL
MAINTENANCE
ENGINE
CARBURETION
BODY AND STEERING
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
GENERAL INFORMATION
Specs
Model Identification . . . . . . . . . . . . . . . . . . . . . . . Serial Number Location . . . . . . . . . . . . . . . . . . . Models Numbers / Replacement Key . . . . . . . Machine Dimensions . . . . . . . . . . . . . . . . . . . . . Specifications - RANGER TM . . . . . . . . . . . . . . Specifications - RANGER 2X4 . . . . . . . . . . . . . Specifications - RANGER 4X4 . . . . . . . . . . . . . Specifications - RANGER 6X6 . . . . . . . . . . . . . Publication Numbers . . . . . . . . . . . . . . . . . . . . . Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the RANGER . . . . . . . . . . . . . . . . . . . . . Standard Torque Specifications . . . . . . . . . . . . Decimal Equivalent Chart . . . . . . . . . . . . . . . . . Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . .
1.2 1.2 1.3 1.4-1.6 1.7, 1.9 1.7, 1.10 1.8, 1.11 1.8, 1.12 1.13 1.13 1.13 1.14 1.15 1.15 1.16
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification
A 04 RB 63 AA
Model Year Designation
Emissions & Model Option
Basic Chassis Designation
Engine Designation
Engine Designation Number
EH63PFE010 . . . . . Twin, Air--cooled, OHV 4 Stroke, Electric Start EH42PLE06 Single, L/C, SOHC 4 Stroke, Electric Start EH50PLE16 Single, L/C, SOHC 4 Stroke, Electric Start
42 50
VIN Identification World Mfg. ID
1 4
2 X
3 A
Vehicle Description
4 R
5 F
6 5
7 0
8 A
Vehicle Identifier
9 10 11 12 * 4 P 0
Model Emissions Year Engine Plant No. Check Digit Powertrain
Body Style
13 14 15 16 17 0 0 0 0 0 * This could be either a number or a letter
Individual Serial No.
ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the flywheel housing on the right side of engine (A). RANGER TM A
TRANSMISSION I.D. NUMBER LOCATION The transmission I.D. number is located on the right side of machine. RANGER 2x,4x,6x
1.2
A
GENERAL INFORMATION
MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower frame rail close to the front drive wheel. The model and serial number (B) are also located on a sticker on the hood liner.
B
A
REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.
31XX Key Series Number
Series #
Part Number
20
4010278
21
4010278
22
4010321
23
4010321
27
4010321
28
4010321
31
4110141
32
4110148
67
4010278
68
4010278
1.3
GENERAL INFORMATION
MACHINE DIMENSIONS RANGER TM
Rear View 42 in 106.7 cm
Front View
13 in 33 cm
73 in 185 cm
60 in 152.40 cm Side View
113 in 287 cm 58 in 147.3 cm
7.2 in 18.3 cm 76 in 193 cm
1.4
GENERAL INFORMATION
MACHINE DIMENSIONS RANGER 2X,4X,6X
75 in 190.50 cm
(Front of Box)
13 in 23 cm
7.2 in 18 cm
58 in 147 cm
1.5
GENERAL INFORMATION
MACHINE DIMENSIONS RANGER 2X,4X,6X 120 in 305 cm
48 in 152 cm
27 in 69 cm 90 in 229 cm 113 in 33 cm
42 in 107 cm
1.6
76 in 193 cm
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GENERAL INFORMATION MODEL: . . . . . . . . . . 2004 RANGER MODEL NUMBER: . A04RB63AA ENGINE MODEL: . . EH65DA70 Category
Dimension / Capacity
Length
113 in./287 cm
Width
60 in./152.4 cm
Height
73 in./185 cm
Wheel Base
76 in./193 cm
Turning Radius
76 in./193 cm
Ground Clearance
7.2 in./183 cm
Dry Weight Gross Vehicle Weight Cargo Box Capacity Vehicle Payload
TM
RANGER TM
1050 lbs./476 kg 2400 Lbs. / 1089 kg 750 lbs./340 kg 1250 lbs./567.5 kg (Includes one driver, 2 passengers)
Hitch Towing Capacity
1000 lbs./454 kg
Hitch Tongue Capacity
100 lbs./45.4 kg (Rear box capacity and tongue weight not to exceed 250 lbs/113 kg)
MODEL: . . . . . . . . . . 2004 RANGER 2x4 MODEL NUMBER: . A04RB42AA ENGINE MODEL: . . EH42PLE083 Category
Dimension / Capacity
Length
113 in./287 cm
Width
60 in./152.4 cm
Height
75 in./190.50 cm
Wheel Base
76 in./193 cm
Ground Clearance
7.2 in./18.25 cm
Dry Weight
1105 lbs./412 kg
Gross Vehicle Weight Cargo Box Capacity Vehicle Payload
RANGER 2x4
2500 Lbs. / 1135 kg 850 lbs./385 kg 1500 lbs./681 kg (Includes one driver, 2 passengers)
Hitch Towing Capacity
1400 lbs./523 kg
Hitch Tongue Capacity
150 lbs./68.1 kg (Rear box capacity and tongue weight not to exceed 250 lbs/113 kg)
1.7
GENERAL INFORMATION MODEL: . . . . . . . . . . 2004 RANGER MODEL NUMBER: . A04RB63AA ENGINE MODEL: . . EH65DA70 Category Length
Dimension / Capacity 60 in./152.4 cm
Height
75 in./190.50 cm 76 in./193 cm
Ground Clearance
7.2 in./18.25 cm
Dry Weight
1185 lbs./537 kg
Gross Vehicle Weight Cargo Box Capacity Vehicle Payload
2700 Lbs. / 1226 kg 1000 lbs./454 kg 1500 lbs./681 kg (Includes one driver, 2 passengers)
Hitch Towing Capacity
1500 lbs./681 kg
Hitch Tongue Capacity
150 lbs./68.1 kg (Rear box capacity and tongue weight not to exceed 250 lbs/113 kg)
MODEL: . . . . . . . . . . 2004 RANGER MODEL NUMBER: . A04RF50AA ENGINE MODEL: . . EH50PLE164 Category
120 in./305 cm
Width
60 in./152.4 cm
Height
51 in./130 cm
Wheel Base
90 in./229 cm
Dry Weight Gross Vehicle Weight Cargo Box Capacity
6X6
Dimension / Capacity
Length
Ground Clearance
7.2 in./18.25 cm 1410 lbs./526 kg 2900 Lbs. / 1315 kg 1000 lbs./454 kg
Vehicle Payload
1500 lbs./681 kg (Includes one driver, 2 passengers)
Towing Capacity
1500 lbs./681 kg
Hitch Tongue Capacity
1.8
RANGER 4x4
113 in./287 cm
Width Wheel Base
4X4
150 lbs./68.1 kg (Rear box capacity and tongue weight not to exceed 250 lbs/113 kg)
RANGER 6x6
GENERAL INFORMATION MODEL: . . . . . . . . . . RANGER TM MODEL NUMBER: . A04RB63AA ENGINE MODEL: . . EH63PFE010 Engine
Drivetrain
Platform
Robin V--Twin, OHV 4 stroke
Engine Model Number
EH63PFE010
Engine Displacement
653cc
Number of Cylinders
2
Bore & Stroke (mm)
80 x 65 mm
Compression Ratio
8.3:1
Engine Idle Speed
1000 ± 100 RPM
Valve Clearance Int./Exh.
0.1 ± 0.015 mm
Thermostat Opening Temperature
N/A
Oil Pressure Warning
Dash Light
Lubrication Oil Requirements Oil Capacity Exhaust System
Pressurized Wet Sump 0W--40 1.64 qts. / 1.55L 2 to 1 canister style
27 mm Nikki Down Draft Type (I.D.--610027--861)
Main Jet
132
Pilot (Slow) Jet
60
Jet Needle
N/A
Needle Jet
N/A
Air Screw
0.75 Turns Out (Initial starting point, settings may vary)
Fuel Delivery Fuel Requirement Fuel Capacity
Gravity Fuel Pump 87 Octane (minimum) 8.5 gal. / 37.9 L
Lights :
Main Headlights
360 watts @ 3600 RPM Dual Beam 35 watts / 35 watts
Tail
5 watts
Brake
5 watts
Indicator Panel Lights Ignition System Max RPM Ignition Timing Ignition Coil Clearance Spark plug / Gap Battery / Model / Amp Hr Circuit Breakers Starting Instrument Panel Type
High Rev.
4.71:1 6.84:1
Final Drive Ratio
3.70:1
Shift Type
In Line EZ Shift Hi/Low/Reverse
Trans. Oil Requirements
Polaris Gear Drive Fluid
Belt
3211093
Drive Belt Deflection
1.125″ / 28.57 mm
Center Distance
14.5” / 368 mm
Clutch Offset
0.5” / 12.7 mm
Springs and Clutches
See Chart on Previous Page
Steering / Suspension Front Suspension
MacPherson Strut
Front Travel
4.6 in. / 12 cm Swing Arm w/ Dual Shocks
Rear Travel
4.25 in. / 11 cm
Ground Clearance
5.5 in. / 14 cm
Shock Preload Adjustment Front / Rear
Cam Adjustment 2--2” Twin Tubes
Turning Radius
132 in. / 335.3 cm
Toe Out
1/8--1/4 in. / 3--6.35 mm
Wheels / Brakes Wheel Size -- Front
25x10--12
Wheel Size -- Rear
25x11--12
Recommended Air Pressure F/R
6--10 psi Front 6--10 psi Rear
Brake -- Front
Electrical Alternator Max Output
Gear Ratio :
Dual Sensing Automatic PVT
Rear Suspension
Carburetion Carburetor model
Transmission Type
Dual Hydraulic Disc
Brake -- Rear
Dual Hydraulic Disc
Parking Brake
Foot Actuated (Mechanical)
Brake Fluid
DOT 3 or DOT 4
JETTING CHART AMBIENT TEMPERATURE
1 watt (ea.) Electric Start 3600 26.5° ± 2° BTDC @ 3600 RPM 0.3 -- 0.5 mm NGK BPR5ES/ .035 in./ 0.9 mm Maintenance--Free 30 Amp/12Volt Harness 20 amp Electric -- Standard Indicator Lights/Hour Meter
Altitude Meters (Feet)
Below 40°F Below 5°C 0--1500 (0--5000)
+40°F to +80°F +5°C to +28°C
132 (3088426)
above 1500 (above 5000)
124 (3088823)
132 (3088426) 124 (3088823)
CLUTCH CHART All Applications
Shift Weight
Drive Spring
208 grams (3234176)
Black/Grn (3234184)
Driven Spring Pur/Yel (3234186)
NOTE: The RANGER TM contains a different style clutch than the other RANGER models. The clutches use the same springs and weights for high elevation.
1.9
GENERAL INFORMATION MODEL: . . . . . . . . . . RANGER 2X4 MODEL NUMBER: . A04RB42AA ENGINE MODEL: . . EH42PLE083 Engine
Drivetrain
Platform
Fuji 4 stroke, Single Cylinder
Engine Model Number
EH42PLE083
Engine Displacement
425cc
Number of Cylinders
1
Bore & Stroke (mm)
87.9 x 70 mm
Compression Ratio
9.2:1
Compression Pressure Engine Idle Speed Valve Clearance Int./Exh. Engine Hot Light Lubrication Oil Requirements Oil Capacity
70-- 90 psi 1200 ± 200 RPM 0.006mm (.006 in.) Dash Light Pressurized Dry Sump 0W--40 2 qts. / 2.1 L
Coolant Capacity
2.25 qts. / 2.4 L
Exhaust System
2 to 1 canister style
Carburetion Carburetor model
Transmission Type Gear Ratio :
Dual Sensing Automatic PVT High Low Rev.
3.81:1 8.66:1 5.91:1
Final Drive Ratio
3.70:1
Shift Type
In Line EZ Shift Hi/Low/Reverse
Trans. Oil Requirements
Polaris AGL Gearcase Lube
Belt
3211094
Drive Belt Deflection
1.125″ / 28.57 mm
Center Distance
10” / 254.5 mm
Clutch Offset
0.5” / 12.7 mm
Springs and Weights
See Below
Steering / Suspension Front Suspension
MacPherson Strut
Front Travel
6.7 in. / 170 mm
Rear Suspension Mikuni BST 34 CV
Swing Arm w/ Dual Shocks
Rear Travel
6.25 in. / 158.75 mm
Main Jet
135
Ground Clearance
Pilot Jet
42.5
Shock Preload Adjustment Front / Rear
Jet Needle
4LC38--3
Needle Jet
P--6 (829)
Pilot Screw
2.25 Turns Out (Initial starting point, settings may vary)
Pilot Air Jet
160
Wheel Size -- Front
Float Height
13 ± 1 mm (0.51 ± 0.40“)
Wheel Size -- Rear
Fuel Delivery
Electric Fuel Pump
Fuel Capacity / Requirement
8.5 gal. (32.2 L) 87 Octane (minimum)
Turning Radius
7.2 in. / 180 mm Cam Adjustment 2--2” Twin Tubes 132 in. / 335.3 cm
Toe Out
1/8--1/4 in. / 3--6.35 mm
Wheels / Brakes 25x10--12 25x11--12
Recommended Air Pressure F/R
8--12 psi Front 8--12 psi Rear
Brake -- Front
Dual Hydraulic Disc
Electrical
Brake -- Rear
Dual Hydraulic Disc
Alternator Max Output
Parking Brake
Foot Actuated (Mechanical)
Lights :
Main Headlights
5 watts
Brake
5 watts
CDI Marking Ignition System RPM Limit Ignition Timing Spark plug / Gap Battery / Model / Amp Hr Circuit Breakers Instrument Panel Type
1.10
Dual Beam 35 watts / 35 watts
Tail Indicator Panel Lights
DC Outlet
250 watts @ 5000 RPM
1 watt (ea.) CU2570 Electric Start (Kokusan)
Brake Fluid
JETTING CHART AMBIENT TEMPERATURE Altitude Meters (Feet)
6600 RPM 30° ± 2° BTDC @ 5000 RPM NGK BKR5E/ .036 in./ 0.9 mm
Altitude
Harness 20 amp
Meters (Feet)
Standard
Below 40°F Below 5°C 0--1500 (0--5000)
140 (3130527)
above 1500 (above 5000)
132.5 (3130562)
+40°F to +80°F +5°C to +28°C 135 (3130563) 127.5 (3130560)
CLUTCH CHART
Yuasa YB30L--B/ 30 AmpHr./12Volt
Indicator Lights/Hour Meter
DOT 3 or DOT 4
Shift Weight 0--1500 (0--5000) 1500--3700 (5000--12000)
10 BH (5630711)
Drive Spring
Second Spring
Blu/Grn
Black
(7041157)
(7041782)
10 RH
Blu/Grn
Black
(5630709)
(7041157)
(7041782)
Driven Helix 41--37
(5132344)
41--37
(5132344)
GENERAL INFORMATION MODEL: . . . . . . . . . . RANGER 4X4 MODEL NUMBER: . A04RD50AA ENGINE MODEL: . . EH50PLE164 Engine
Drivetrain
Platform
Fuji 4 stroke, Single Cylinder
Engine Model Number
EH50PLE164
Engine Displacement
499cc
Transmission Type Gear Ratio :
Number of Cylinders
1
Bore & Stroke (mm)
92 x 75 mm
Final Drive Ratio
Compression Ratio
10.2:1
Front Drive Ratio
Compression Pressure Engine Idle Speed Valve Clearance Int./Exh. Engine Hot Light Lubrication Oil Requirements Oil Capacity
70-- 90 psi 1200 ± 200 RPM 0.006 mm (.006 in.) Dash Light Pressurized Dry Sump 0W--40 2 qts. / 2.1 L
Coolant Capacity
2.25 qts. / 2.4 L
Exhaust System
2 to 1 canister style
Carburetion Carburetor model
Dual Sensing Automatic PVT High Low Rev.
3.83:1 8.71:1 5.94:1 3.70:1 3.83:1
Shift Type
In Line EZ Shift Hi/Low/Reverse
Trans. Oil Requirements
Polaris AGL Gearcase Lube
Belt
3211094
Drive Belt Deflection
1.125″ / 28.57 mm
Center Distance
10” / 254.5 mm
Clutch Offset
0.5” / 12.7 mm
Springs and Weights
See Below
Steering / Suspension Front Suspension
MacPherson Strut
Front Travel Mikuni BST 34 CV
6.7 in. / 170 mm
Rear Suspension
Swing Arm w/ Dual Shocks
Main Jet
135
Rear Travel
6.25 in. / 158.75 mm
Pilot Jet
42.5
Ground Clearance
7.2 in. / 180 mm
Shock Preload Adjustment Front / Rear
Cam Adjustment 2--2” Twin Tubes
Turning Radius
132 in. / 335 cm
Jet Needle
4MB32--3
Needle Jet
P--8M (829)
Pilot Screw
2.5 Turns Out (Initial starting point, settings may vary)
Pilot Air Jet
160
Float Height
13 ± 1 mm (0.51 ± 0.40“)
Wheel Size -- Front
25x10--12
Fuel Delivery
Electric Fuel Pump
Wheel Size -- Rear
25x11--12
Fuel Capacity / Requirement
8.5 gal. (32.2 L) 87 Octane (minimum)
Toe Out
1/8--1/4 in. / 3--6.35 mm
Wheels / Brakes
Recommended Air Pressure F/R
8--12 psi Front 8--12 psi Rear
Electrical
Brake -- Front
Dual Hydraulic Disc
Alternator Max Output
250 watts @ 5000 RPM
Brake -- Rear
Dual Hydraulic Disc
Dual Beam 35 watts / 35 watts
Parking Brake
Foot Actuated (Mechanical)
Lights :
Main Headlights Tail Brake
Indicator Panel Lights CDI Marking RPM Limit
5 watts 5 watts CU2570 6600 RPM Electric Start (Kokusan)
Ignition Timing
30° ± 2° BTDC @ 5000 RPM
Battery / Model / Amp Hr Circuit Breakers Instrument Panel Type DC Outlet
NGK BKR5E/ .036 in./ 0.9 mm Yuasa YB30L--B 30 AmpHr./12Volt Harness 20 amp Indicator Lights/Hour Meter Standard
DOT 3 or DOT 4
AMBIENT TEMPERATURE
1 watt (ea.)
Ignition System Spark plug / Gap
Brake Fluid
JETTING CHART Altitude Meters (Feet)
Below 40°F Below 5°C 0--1500 (0--5000)
140 (3130527)
above 1500 (above 5000)
132.5 (3130562)
+40°F to +80°F +5°C to +28°C 135 (3130563) 127.5 (3130560)
CLUTCH CHART Shift Weight
Altitude
Meters (Feet)
0--1500 (0--5000) 1500--3700 (5000--12000)
Drive Spring
Second Spring
10 MH
Blu/Grn
(5630513)
Black
(7041157)
(7041782)
10 WH
Blu/Grn
Black
(5630710)
(7041157)
(7041782)
Driven Helix 40
(5131446)
40 (5131446)
1.11
GENERAL INFORMATION MODEL: . . . . . . . . . . RANGER 6X6 MODEL NUMBER: . A04RF50AA ENGINE MODEL: . . EH50PLE164 Engine
Drivetrain
Platform
Fuji 4 stroke, Single Cylinder
Engine Model Number
EH50PLE164
Engine Displacement
499cc
Transmission Type Gear Ratio :
Dual Sensing Automatic PVT High Low Rev.
3.83:1 8.71:1 5.94:1
Number of Cylinders
1
Bore & Stroke (mm)
92 x 75 mm
Final Drive Ratio
3.70:1
Compression Ratio
10.2:1
Front Drive Ratio
3.83:1
Mid Drive Ratio
3.70:1
Compression Pressure Engine Idle Speed Valve Clearance Int./Exh. Engine Hot Light Lubrication Oil Requirements Oil Capacity
70-- 90 psi 1200 ± 200 RPM 0.006 mm (.006 in.) Dash Light Pressurized Dry Sump 0W--40 2 qts. / 2.1 L
Coolant Capacity
2.25 qts. / 2.4 L
Exhaust System
2 to 1 canister style
Carburetion Carburetor model
Shift Type
In Line EZ Shift Hi/Low/Reverse
Trans. Oil Requirements Belt
3211094
Drive Belt Deflection
10” / 254.5 mm
Clutch Offset
0.5” / 12.7 mm
Springs and Weights
Front Suspension Mikuni BST 34 CV 142.5 42.5
Rear Travel
6.25 in. / 158.75 mm 7.2 in. / 180 mm
Shock Preload Adjustment Front / Rear
Cam Adjustment 2--2” Twin Tubes
Turning Radius
132 in. / 335 cm
4MB32--3
Needle Jet
P--8M (829)
Pilot Screw
2.5 Turns Out (Initial starting point, settings may vary)
Pilot Air Jet
160
Float Height
13 ± 1 mm (0.51 ± 0.40“)
Fuel Delivery
Electric Fuel Pump
Wheel Size -- Front
8.5 gal. (32.2 L) 87 Octane (minimum)
Wheel Size -- Rear
Main Headlights Tail Brake
Indicator Panel Lights CDI Marking RPM Limit
DC Outlet
1.12
25x10--12 25x11--12
Recommended Air Pressure F/R
8--12 psi Front 8--12 psi Rear
Dual Beam 35 watts / 35 watts
Brake -- Rear
Dual Hydraulic Disc
5 watts
Parking Brake
Foot Actuated (Mechanical)
5 watts
Brake Fluid
1 watt (ea.) 6600 RPM
NGK BKR5E/ .036 in./ 0.9 mm Yuasa YB30L--B 30 AmpHr./12Volt Harness 20 amp Indicator Lights/Hour Meter Standard
DOT 3 or DOT 4
JETTING CHART
CU2570
30° ± 2° BTDC @ 5000 RPM
Instrument Panel Type
Wheels / Brakes
Dual Hydraulic Disc
Ignition Timing
Circuit Breakers
1/8--1/4 in. / 3--6.35 mm
Brake -- Front
Electric Start (Kokusan)
Battery / Model / Amp Hr
Toe Out
250 watts @ 5000 RPM
Ignition System Spark plug / Gap
6.7 in. / 170 mm Swing Arm w/ Dual Shocks
Ground Clearance
Jet Needle
Electrical
MacPherson Strut
Front Travel
Pilot Jet
Lights :
See Below
Steering / Suspension
Main Jet
Alternator Max Output
1.125″ / 28.57 mm
Center Distance
Rear Suspension
Fuel Capacity / Requirement
Polaris AGL Gearcase Lube
Altitude Meters (Feet)
0--1500 (0--5000)
140 (3130527)
above 1500 (above 5000)
132.5 (3130562)
CLUTCH CHART Altitude
Meters (Feet)
AMBIENT TEMPERATURE Below 40°F Below 5°C
0--1500 (0--5000) 1500--3700 (5000--12000)
Shift Weight G
(5630514)
F (5630515)
Drive Spring
+40°F to +80°F +5°C to +28°C 135 (3130563) 127.5 (3130560) Second Spring
Blu/Grn
Silver
(7041157)
(7041499)
Blu/Grn
Silver
(7041157)
(7041499)
Driven Helix 41--37
(5132344)
41--37
(5132344)