Polaris 2004 RANGER 2x4 Owner'S Manual Download

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103

TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel

Kinked or plugged fuel vent line

Inspect and replace

Water present in fuel

Replace with new fuel

Overuse of choke

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

Check all connections and tighten

Low battery voltage

Recharge battery to 12.5 VDC

Incorrect fuel

Replace with recommended fuel

Clogged air filter

Inspect and clean or replace

Other mechanical failure

See your Polaris dealer

Overheated engine

Clean radiator screen and core if equipped

Clean engine exterior

See your Polaris dealer

Summary of Contents for 2004 RANGER 2x4

Page 1: ...ehicle Maintenance and Safety RANGER 2004 Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age RANG...

Page 2: ...The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm WARNING...

Page 3: ...ted a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustrie...

Page 4: ...uction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for ref...

Page 5: ...le making it the finest vehicle we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains...

Page 6: ...are essential to the recovery and identification of your vehicle 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 existi...

Page 7: ...ME 3 VEHICLE IDENTIFICATION NUMBERS 4 SAFETY 7 FEATURES AND CONTROLS 25 OPERATION 34 EMISSION CONTROL SYSTEMS 53 MAINTENANCE AND LUBRICATION 54 SPECIFICATIONS 96 POLARIS PRODUCTS 100 TROUBLESHOOTING 1...

Page 8: ...6...

Page 9: ...ng the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is desig...

Page 10: ...n your RANGER or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert cautio...

Page 11: ...driving this vehicle in an aggressive manner Eye protection is recommended at all times S Never consume alcohol or drugs before or while operating this ve hicle S Never operate at excessive speeds Alw...

Page 12: ...l downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where pos sible S Always check for obstacles before op...

Page 13: ...case of a sudden stop or collision S Always keep arms and legs inside the cab frame while the vehicle is in motion S Always apply the parking brake before getting out of the vehicle See page 33 S Alw...

Page 14: ...accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yours...

Page 15: ...ll If you lose all forward speed Apply the brakes Lock the parking brake after when fully stopped If you begin rolling backwards Never apply engine power Apply the brake gradually When fully stopped l...

Page 16: ...he vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HA...

Page 17: ...ARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and...

Page 18: ...RNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition...

Page 19: ...he inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN L...

Page 20: ...s described on the decal and in the Owner s Manual See page 97 WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the c...

Page 21: ...ed to brakes throttle and steering systems CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire WARNING Leaving the keys in the...

Page 22: ...an cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT ___ REAR ___ MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS _______ LBS Reduce...

Page 23: ...gers in cargo box Maximum 2x4 TM Box Load 750 lbs 340 kg Maximum 2x4 Box Load 850 lbs 386 kg Maximum 4x4 Box Load 1000 lbs 454 kg Maximum 6x6 Box Load 1000 lbs 454 kg 1 2 3 4 Remove flammable containe...

Page 24: ...on 5 under hood 5 6 ATTENTION S Operation of this vehicle without the filter element will severely damage the engine S Clean air filter often more frequent cleaning required in dusty conditions S Oper...

Page 25: ...ALWAYS S Avoid paved surfaces which may adversely affect handling and control S Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns S Wear eye protection RE...

Page 26: ...Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing i...

Page 27: ...ot 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 Console 4 Steering Wheel 5...

Page 28: ...26 FEATURES AND CONTROLS Component Locations 10 Headlights 11 Radiator if equipped 12 Front Bumper Brush Guard 13 Hood Hold Down Strap 12 11 10 13...

Page 29: ...ons 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 R...

Page 30: ...d with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlin...

Page 31: ...ross your lap as low on your hips as possible taking care that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center b...

Page 32: ...lder 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 Shift Lever 13 Differential Lo...

Page 33: ...with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Always place the transmission in gear with the park...

Page 34: ...ip the AWD switch up to engage the AWD Flip the switch down to return to 2WD Under some conditions it s possible for the AWD to remain engaged See page 51 for manual disengagement instructions OFF ON...

Page 35: ...rom rolling while parked To apply the parking brake push down on the pedal with your foot To release pull the release handle 4 which is located on the lower console Spring pressure helps return the le...

Page 36: ...normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustai...

Page 37: ...ne ignition switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element check for dirt clean or repl...

Page 38: ...6 If the engine slows or stops push the choke knob in half way 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Then push the choke completely in Engi...

Page 39: ...art intermittent use of the choke knob pulled half way out may be necessary 6 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 7 Release the th...

Page 40: ...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 WARNING Failure to allow for increased braki...

Page 41: ...ng brake 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 Variabl...

Page 42: ...he steering wheel in the direction of the skid 4 Drive with AWD engaged to assist in controlling the vehicle Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinn...

Page 43: ...e climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climb...

Page 44: ...hen possible When unavoidable exercise extreme caution Avoid operating on steep hills 15_ maximum WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the...

Page 45: ...ervices outlined in the Periodic Maintenance Schedule beginning on page 54 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings WARNING The large tire...

Page 46: ...rrain you re traveling on Watch for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obsta...

Page 47: ...backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing WARNING Failure to use caution when operating in reverse can result i...

Page 48: ...NING A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hi...

Page 49: ...0 lbs 340 kg 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 hau...

Page 50: ...own securely to latch 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 ti...

Page 51: ...e when hauling or towing heavy cargo 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 t...

Page 52: ...A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine WARNING Gasoline is extremely flammable and can be explosive under certain condi...

Page 53: ...hey will not release until the rear wheels regain traction Disengaging AWD Under certain conditions it may be possible for one or both hubs to remain engaged unnecessarily This condition causes increa...

Page 54: ...52 NOTES...

Page 55: ...the intake system The system does not allow the blow by gases to enter the atmosphere Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design inc...

Page 56: ...re based on 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first Inspect clean lubricate adjust or...

Page 57: ...ration daily apply Po laris dielectric grease to connector when replaced Tail lamp Daily Check daily apply Polaris dielec tric grease to socket when re placed L Air Filter Main Ele ment Weekly Inspect...

Page 58: ...Filter 100 hrs Replace with oil change L Engine breather hose 100 hrs Inspect Carburetor Float Bowl 50 hrs Drain bowl periodically and prior to storage J Throttle Cable 50 hrs Inspect adjust lubricat...

Page 59: ...pump and carburetor Re place lines every two years Fuel Filter 100 hrs Replace annually Cooling System hoses 100 hrs Inspect Front Gearcase Oil 100 hrs Check monthly change annually J Clutches drive a...

Page 60: ...es See page 84 As required change every 200 hours Main Gearcase Oil Transmission Premium Synthetic Gearcase Lube Maintain at the bottom of the fill plug threads See page 66 Check monthly Change annual...

Page 61: ...59 MAINTENANCE AND LUBRICATION Lubrication Recommendations 1 2...

Page 62: ...more power output and lower fuel consumption 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 Oil may n...

Page 63: ...f most trips are slow speed and less than five miles Always change the oil filter when changing oil Oil Check RANGER 2x4 4x4 6x6 The oil tank is located under the seat 1 Position the vehicle on a leve...

Page 64: ...screen fitting C on the bottom of the oil tank 7 Remove the screen fitting and clean the screen thoroughly 8 Apply Loctitet 565 Thread Sealant to the clean and oil free threads of the fitting NOTE Se...

Page 65: ...4 Synthetic Oil 18 Place the gear selector in neutral and set the parking brake 19 Prime the oil pump using the procedure below Then stop the engine and inspect for leaks 20 Re check the oil level on...

Page 66: ...il filler hole 5 as needed Do not overfill NOTE A rising oil level between checks in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is over the full mark c...

Page 67: ...Check to make sure the o ring 3 is in good condition Lubricate the o ring on the new filter with a film of engine oil 10 Install the new filter and turn by hand until the filter gasket contacts the s...

Page 68: ...ube if necessary See page 100 for the part numbers of Polaris products 4 Reinstall the fill plug and torque to specification Oil Change The drain plug 2 is located on the bottom of the transmission Ac...

Page 69: ...b 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 Oil Check 1 With the RANGER on a level surface remove th...

Page 70: ...the gearcase Oil Check 1 With the RANGER on a level surface remove the middle gearcase fill plug and check the lubricant level Lubricant should be even with the bottom thread of the fill plug hole 2...

Page 71: ...he fill plug and torque to specification Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from the bottom of the gearcase and drain the oil into a drain pan Discard used oil properly 3 Clea...

Page 72: ...back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maint...

Page 73: ...f 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 1 Lift the...

Page 74: ...radiator air flow can lead to overheating and consequent engine damage Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level becomes low the e...

Page 75: ...used by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the...

Page 76: ...in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been...

Page 77: ...times with electric start Inspect the drained fuel for water or sediment 6 Dry the spark plug and reinstall or install a new plug 7 Tighten the carburetor drain screw 8 Reconnect the fuel pump wires...

Page 78: ...ket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 1 4 Do not attempt to clean the main element Install a new air filter NOTE Apply a small amount of general...

Page 79: ...ck for clogging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine and secure the clamps Fuel...

Page 80: ...emove the air cleaner cover 3 4 Remove the primary filter 4 and the secondary filter 5 NOTE Do not attempt to clean the primary filter Install new 5 Wash the secondary foam filter with hot soapy water...

Page 81: ...rn the steering wheel left and right 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 syste...

Page 82: ...ot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection Do not stand behind or in fro...

Page 83: ...particles are still suspected to be in the muffler back the vehicle onto an incline so the rear of the vehicle is one foot higher than the front Set the parking brake and block the wheels Make sure th...

Page 84: ...gine begins to pick up speed Freeplay should be 1 16 to 1 8 inches Throttle Freeplay Adjustment 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adju...

Page 85: ...2x4 4x4 and 6x6 is 1200 200 Recommended engine idle RPM for the RANGER TM is 1000 100 If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted...

Page 86: ...the reservoir are unknown Inspection Procedure 1 Position the vehicle on level ground 2 Inspect the brake fluid by looking at the reservoir 1 under the hood The level should be between the upper MAX a...

Page 87: ...h your foot 2 After 8 to 12 clicks of lever travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjustment is necessary Parking Brake Adjustment 1 Place...

Page 88: ...at belt is adjustable and should be adjusted for both the operator and passenger before driving Although having the belt at 30 is typical for many people it will not accommodate all body sizes and sha...

Page 89: ...Center and Rear Hub Retaining Nuts 110 ft lbs 150 Nm WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in ser...

Page 90: ...arking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the whe...

Page 91: ...orming this step 5 Adjust beam to desired position by turning adjustment screws 1 in headlight cover as follows Turn the right screw clockwise to adjust to the left Turn the left screw clockwise to ad...

Page 92: ...5 Grip the light with a needle nose plier and remove the light from the assembly 6 Install the new light and use a small flat head screwdriver to seat it into place 1 4 turn clockwise 7 Snap the assem...

Page 93: ...ttings immediately after washing Also run the vehicle to evaporate any water that may have entered the engine or exhaust system Storage If your vehicle is to be placed in extended or off season storag...

Page 94: ...Make sure the spark plug is tight 3 Fill the fuel tank with fuel 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...

Page 95: ...or tap water into the battery Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Dr...

Page 96: ...battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle being careful not to tip it sideways and spill any e...

Page 97: ...tighten the red positive cable 4 Second connect and tighten the black negative cable 5 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to...

Page 98: ...183 mm Dry Weight 1050 lbs 476 kg 1105 lbs 501 kg Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Min Turning Radius 132 in 335 3 cm 132 in 335 3 cm En...

Page 99: ...1 3 70 1 Tire Size Front 25 x 10 12 25 x 10 12 Tire Size Rear 25 x 11 12 25 x 11 12 Tire Pressure Front 10 psi 10 psi Tire Pressure Rear 10 psi 10 psi Brakes Front Rear Foot Activated 4 wheel hydraul...

Page 100: ...g 4x4 1205 lbs 547 kg NBU 1410 lbs 640 kg Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm 58 x 48 x 10 in 147 x 122 x 25 4 cm Min Turning Radius 132 in 335 3 cm 186 in 472 4 cm Engine Oil Ca...

Page 101: ...0 1 Tire Size Front 25 x 10 12 4x4 25 x 8 12 NBU 25 x 10 12 Tire Size Rear 25 x 11 12 25 x 11 12 Tire Pressure Front 10 psi 10 psi Tire Pressure Rear 10 psi 10 psi Brakes Front Rear Foot Activated 4 w...

Page 102: ...Drive Fluid 2 5 gal 2870465 Oil Pump for Gearcase Oil 2871654 Premium Drive Hub Fluid 8 oz 2872277 Premium Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz...

Page 103: ...resent in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect pl...

Page 104: ...plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery t...

Page 105: ...e 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 Check all connections and t...

Page 106: ...at 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 t...

Page 107: ...of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use...

Page 108: ...ized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer wi...

Page 109: ...s 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 y...

Page 110: ...rranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty s...

Page 111: ...cified in the 2004 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine own...

Page 112: ...r leaks at tank cap lines fuel filter pump and carburetor Replace lines every two years A Valve clearance 100 hrs 12 mos Inspect adjust Idle speed As Required 100 hrs Adjust Repair and Replacement of...

Page 113: ...with applicable U S EPA regulations Emissions Component Defect Warranty Period The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of two...

Page 114: ...of use of the engine or equipment etc S Diagnosis and inspection charges that do not result in warranty eligible service being performed S Any non authorized replacement part or malfunction of author...

Page 115: ...WEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DEALER AUTHORIZED BY POLARIS THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AU THORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF T...

Page 116: ...Driving Procedures 39 Driving Safely 39 50 Driving Through Water 43 Driving Uphill 41 Dumping the Cargo Box 48 E EMISSION CONTROL SYSTEMS 53 Engine Idle RPM Adjustment 83 Engine Oil 60 65 Equipment Mo...

Page 117: ...Spark Arrestor 53 80 81 Spark Plugs 73 SPECIFICATIONS 96 99 Starting a Cold Engine 36 Starting a Warm Engine 37 Steering Wheel Inspection 79 S Stopping the Engine 37 Storage 91 Switches 32 T TABLE OF...

Page 118: ...ottle and brakes gradually NEVER ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in t...

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Polaris 2004 RANGER 2x4, Owner'S Manual

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