2004 Polaris RANGER Service Manual

Complete service and repair information for the 2004 Polaris RANGER 2x4, 4x4, and 6x6 models. Covers engine, chassis, and body systems.

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Document Details

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Document Number / Seller:
32044 / Susan Parker
File Size:
20.09 MB
File Type:
PDF
Language:
English
Pages:
424
Printable:
Yes
Category:
UTV
Last updated / verified
Dec 26, 2025

Models Covered & Key Technical Specifications

2004 Polaris RANGER Service Manual PDF Procedure-Library

2004 Polaris RANGER (2x4, 4x4, 6x6) Service Manual PDF | Reference Data.

  • Engine Specifications: 653cc Displacement provides robust power.
  • Transmission Type: Features a Dual Sensing Automatic PVT.
  • Front Suspension: Utilizes MacPherson Strut for smooth handling.
  • Ground Clearance: Offers 5.5 inches for trail capability.
  • Fuel Capacity: Holds 8.5 gallons for extended operation.
  • Coolant Capacity: Supports 2.25 quarts for optimal cooling.

Professional Workshop Service Manual & Technical Specifications

Polaris RANGER TM 2004 Service Manual PDF Procedure-Library

Serial-Range: 2004 // Product-Line: RANGER TM / 2x4 / 4x4 / 6x6 // Repair-Classification: Service Manual.

Repair procedures are structured around the following:

  • Engine Component Specifications: Detailed measurements for cylinder, piston, and crankshaft.
  • Carburetor Operation: Explains the function of the Nikki 27mm and Mikuni BST 34 carburetors.
  • Fuel Tank and Pump: Covers removal, installation, and troubleshooting.
  • Steering and Suspension: Includes exploded views and replacement procedures.
  • Brake System: Details inspection and maintenance for safe operation.

This manual documents torque specifications for critical engine components to ensure proper assembly and reliability.

FAQ

What **calibrated** values are needed for the system architecture? keyboard_arrow_down

For the pilot system, the 0.75 turns out pilot screw setting is specified for initial starting, with adjustments possible for optimal performance.

Assess the **applicable** tool requirements for steering adjustments. keyboard_arrow_down

When adjusting the tie rod ends, a 10 mm wrench and screwdriver are needed for the adjuster lock nut, and a torque wrench is required for final tightening to 12-14 ft. lbs. (16-19 Nm).

What **exact** electrical values are documented for the ignition system? keyboard_arrow_down

The ignition system utilizes a transistor controlled magneto ignition system. The spark plug gap is specified as 0.030" (0.762 mm) for the RANGER TM, and 0.036" (0.914 mm) for the 2x4, 4x4, 6x6 models.

Confirm the **specific** calibration settings for the drive belt. keyboard_arrow_down

The drive belt deflection is specified at 1.125" / 28.57 mm. Proper deflection is crucial for optimal power transmission and belt longevity.

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Reviews (4)

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Rated 4 out of 5 stars
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This service manual is a lifesaver! The detailed instructions and diagrams made maintenance a breeze. Highly recommend it!
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The manual covers everything from engine rebuilds to electrical systems. A must-have for RANGER enthusiasts!
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The download process was quick and seamless. I received the email with the link almost immediately. Great service!