2004 Polaris Ranger 500 4x4 Service & Repair Manual

GENERAL MAINTENANCE ENGINE CARBURETION CLUTCHING FINAL DRIVE BODY AND STEERING TRANSMISSION BRAKES ELECTRICAL

GENERAL INFORMATION 1.1 Model Identification 1.2 ....................... Serial Number Location 1.2 ................... Models Numbers / Replacement Key 1.3 ....... Machine Dimensions 1.4-1.6 ..................... Specifications - RANGER TM 1.7, 1.9 .............. Specifications - RANGER 2X4 1.7, 1.10 ............. Specifications - RANGER 4X4 1.8, 1.11 ............. Specifications - RANGER 6X6 1.8, 1.12 ............. Publication Numbers 1.13 ..................... Paint Codes 1.13 ............................. Starting the RANGER 1.13 ..................... Standard Torque Specifications 1.14 ............ Decimal Equivalent Chart 1.15 ................. Tap Drill Charts 1.15 .......................... Glossary of Terms 1.16 ........................ Specs

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification ModelYear Designation Basic Chassis Designation Engine Designation A 04 RB 63 AA Emissions & Model Option Engine Designation Number EH63PFE010 Twin, Air--cooled, OHV 4 Stroke, Electric Start ..... 42 EH42PLE06 Single, L/C, SOHC 4 Stroke, Electric Start 50 EH50PLE16 Single, L/C, SOHC 4 Stroke, Electric Start VIN Identification 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4XARF 50A*4P000000 Vehicle Description Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCA TION Whenevercorrespondingaboutanengine,besuretorefertotheenginemodelnumberandserialnumber. This information can be found on the sticker applied to the flywheel housing on the right side of engine (A). TRANSMISSION I.D. NUMBER LOCA TION A RANGER TM RANGER 2x,4x,6x A The transmission I.D. number is located on the right side of machine.

GENERAL INFORMATION 1.3 MACHINE MODEL NUMBER AND SERIAL NUMBER LOCA TION Themachinemodelnumberandserialnumberare 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. 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. Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 B 31XX Key Series Number A

GENERAL INFORMATION 1.4 MACHINE DIMENSIONS RANGER TM 113 in 287 cm 73 in 185 cm 7.2 in 18.3 cm 60 in 152.40 cm 76 in 193 cm 58 in 147.3 cm 42 in 106.7 cm 13 in 33 cm Front V iew Rear V iew Side V iew

GENERAL INFORMATION 1.5 MACHINE DIMENSIONS RANGER 2X,4X,6X 58 in 147 cm 75 in 190.50 cm 13 in 23 cm (Front of Box) 7.2 in 18 cm

GENERAL INFORMATION 1.6 MACHINE DIMENSIONS RANGER 2X,4X,6X 120 in 305 cm 90 in 229 cm 48 in 152 cm 113 in 76 in 193 cm 42 in 107 cm 33 cm 27 in 69 cm

RANGER 2x4 RANGER TM GENERAL INFORMATION 1.7 MODEL: 2004 RANGER TM .......... 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 1050 lbs./476 kg Gross Vehicle Weight 2400 Lbs. / 1089 kg Cargo Box Capacity 750 lbs./340 kg Vehicle Payload 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 ex- ceed 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 2500 Lbs. / 1135 kg Cargo Box Capacity 850 lbs./385 kg Vehicle Payload 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 ex- ceed 250 lbs/113 kg)

RANGER 4x4 RANGER 6x6 GENERAL INFORMATION 1.8 MODEL: 2004 RANGER 4X4 .......... MODEL NUMBER: A04RB63AA . ENGINE MODEL: EH65DA70 .. 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 1185 lbs./537 kg Gross Vehicle Weight 2700 Lbs. / 1226 kg Cargo Box Capacity 1000 lbs./454 kg Vehicle Payload 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 ex- ceed 250 lbs/113 kg) MODEL: 2004 RANGER 6X6 .......... MODEL NUMBER: A04RF50AA . ENGINE MODEL: EH50PLE164 .. Category Dimension / Capacity Length 120 in./305 cm Width 60 in./152.4 cm Height 51 in./130 cm Wheel Base 90 in./229 cm Ground Clearance 7.2 in./18.25 cm Dry Weight 1410 lbs./526 kg Gross Vehicle Weight 2900 Lbs. / 1315 kg Cargo Box Capacity 1000 lbs./454 kg Vehicle Payload 1500 lbs./681 kg (Includes one driver, 2 passengers) TowingCapacity 1500 lbs./681 kg Hitch Tongue Capacity 150 lbs./68.1 kg (Rear box capacity and tongue weight not to ex- ceed 250 lbs/113 kg)

GENERAL INFORMATION 1.9 MODEL: RANGER TM .......... MODEL NUMBER: A04RB63AA . ENGINE MODEL: EH63PFE010 .. Engine 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 Pressurized Wet Sump Oil Requirements 0W--40 Oil Capacity 1.64 qts. / 1.55L Exhaust System 2 to 1 canister style Carburetion Carburetor model 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 Gravity Fuel Pump Fuel Requirement 87 Octane (minimum) Fuel Capacity 8.5 gal. / 37.9 L Electrical Alternator Max Output 360 watts @ 3600 RPM Lights : Main Headlights Dual Beam 35 watts / 35 watts Tail 5 watts Brake 5 watts Indicator Panel Lights 1 watt (ea.) Ignition System Electric Start Max RPM 3600 Ignition Timing 26.5°± 2° BTDC @ 3600 RPM Ignition Coil Clearance 0.3 -- 0.5 mm Spark plug / Gap NGK BPR5ES/ .035 in./ 0.9 mm Battery / Model / Amp Hr Maintenance--Free 30 Amp/12Volt Circuit Breakers Harness 20 amp Starting Electric -- Standard Instrument Panel Type Indicator Lights/Hour Meter Drivetrain Transmission Type Dual Sensing Automatic PVT Gear Ratio : 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 4.6in./12cm Rear Suspension Swing Arm w/ Dual Shocks Rear Travel 4.25 in. / 11 cm Ground Clearance 5.5in./14cm Shock Preload Adjustment Front / Rear Cam Adjustment 2--2” TwinTubes Turning Radius 132 in. / 335.3 cm Toe Out 1/8--1/4 in. / 3--6.35 mm Wheels / Brakes WheelSize -- Front 25x10--12 WheelSize -- Rear 25x11--12 Recommended Air Pressure F/R 6--10psiFront 6--10psiRear Brake -- Front Dual Hydraulic Disc Brake -- Rear Dual Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT3orDOT4 JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1500 (0--5000) above 1500 (above 5000) Below 40°F Below 5°C +40°F to +80°F +5°C to +28°C 132 (3088426) 124 (3088823) CLUTCH CHART 132 (3088426) 124 (3088823) 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. All Applications Shift Weight 208 grams Drive Spring Black/Grn (3234176) (3234184) Driven Spring Pur/Yel (3234186)