2004 Polaris Ranger 500 4x4 Service Repair Manual

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

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

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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)