2004 Polaris Ranger 425, 500, TM 2x4, 4x4, 6x6 Service Manual
Official Maintenance & Repair Manual for Polaris Ranger 425, 500, TM 2x4, 4x4, 6x6 UTVs. Covers all models, systems, and procedures. Part Number P-067.
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Models Covered & Key Technical Specifications
2004 Polaris Ranger 425, 500, TM 2x4, 4x4, 6x6 Service Manual
Official Maintenance & Repair Manual for Polaris Ranger 425, 500, TM 2x4, 4x4, 6x6 UTVs. Covers all models, systems, and procedures. Part Number P-067.
- System Specifications: Engine oil capacity of 1.64 qts. signifies the required fluid volume for optimal operation.
- Maximum Storage Capacity: Cargo box capacity reaches 850 lbs. to accommodate substantial hauling needs.
- Measured Dimensions: Ground clearance is 7.2 in. establishing a stable operational height Framework.
- Published Weights: Dry weight is 1105 lbs. representing the base operational mass.
- Authorized Capacities: Hitch towing capacity is 1400 lbs. defining the maximum safe towing limit Parameters.
- Technical Specifications: Fuel capacity is 8.5 gal. confirming the adequate operational range.
Professional Workshop Service Manual & Technical Specifications
Essential Engineering Technical Manual: UTV Polaris Ranger 425, Ranger 500, Ranger TM 2x4, 4x4, 6x6 - Official Maintenance & Repair Manual (2004) Transmission-Guide
Year-Coverage: 2004 // Technical-Scope: Engine, Drivetrain, Fuel System, Body, Steering // Year-Coverage: Complete Vehicle Logic.
| Specification | System-Path | Calibration-Spec |
|---|---|---|
| Engine | EH63 Twin-Cylinder | 653cc Displacement |
| Drivetrain | Dual Sensing Automatic PVT | 3.70:1 Final Drive Ratio |
| Carburetion | Nikki 27mm Down Draft | 132 Main Jet |
| Electrical | Alternator Max Output | 360 watts |
| Fuel System | 87 Octane Minimum | 8.5 gal. Capacity |
| Chassis | Wheels | 25x10-12 Front, 25x11-12 Rear |
Engineering chapters address:
General Information (Chapter 1)
Maintenance (Chapter 2)
Engine (Chapter 3)
Fuel System/Carburetion (Chapter 4)
Body/Steering/Suspension (Chapter 5)
Transmission (Chapter 6)
Detailed maintenance procedures are provided for all critical systems, including engine lubrication and cooling, fuel delivery, and drivetrain maintenance. The manual documents torque specifications for key components to ensure proper assembly and prevent rotational loosening. Specifications cover a wide range of parameters, from engine bore to tire pressure, ensuring a comprehensive reference for all mechanical aspects of the UTV.
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