Model Variants:
Ranger 2x4, Ranger 4x4, Ranger 6x6
Model Years Covered:
2004, 2005, 2006, 2007, 2008, 2009
Vehicle Type:
All-Terrain Vehicle (ATV) / Utility Task Vehicle (UTV)
Positioning:
The Polaris Ranger of this era was a workhorse utility vehicle, popular for farm, ranch, and recreational trail use. It competed against other utility ATVs/UTVs from manufacturers like Yamaha, Arctic Cat, and Kawasaki.
Key Competitors:
Yamaha Rhino, Arctic Cat Prowler, Kawasaki Mule
Versatility:
Offered in 2WD, 4WD, and 6WD configurations, providing flexibility for various terrain and load requirements.
Durability:
Designed for demanding work and off-road conditions, with a focus on robust construction.
Primary Coverage:
Complete service, repair, and maintenance for Polaris Ranger 2x4, 4x4, and 6x6 models
Secondary Coverage:
Troubleshooting, diagnostics, wiring diagrams, specifications, and procedures
Estimated Pages:
Extensive (typical service manuals of this era are 300-600+ pages)
Type:
Service Manual / Repair Manual
Powertrain:
Engine, fuel system, ignition system, exhaust system, transmission (CVT), final drive, drivetrain (2WD, 4WD, 6WD engagement)
Chassis:
Frame, suspension (front and rear), steering, wheels, tires
Brakes:
Hydraulic disc brake system (front and rear), parking brake
Electrical:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, ignition switch, electrical components, wiring diagrams
Bodywork:
Body panels, seats, cargo bed, guards, operator controls
Routine Maintenance:
Oil changes, filter replacements, lubrication, spark plug service, air filter cleaning/replacement, coolant checks
Major Repairs:
Engine overhaul, transmission rebuild, carburetor service, brake caliper overhaul, suspension component replacement, starter motor replacement
Diagnostics Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon issues, diagnostic charts
Electrical Diagnostics:
Wiring diagram interpretation, voltage drop testing, continuity checks, component testing
Depth:
Comprehensive, covering everything from basic adjustments to full engine and transmission overhauls
Diagnostic Tools:
Details on using common tools and basic diagnostic techniques
Searchability:
Likely searchable text, enabling quick access to information
Quality:
Original factory quality, typically clear text and well-defined illustrations
Binding:
Not applicable (digital download)
Paper:
Not applicable (digital download)
Engine Type:
Four-stroke, SOHC, V-twin (typically)
Engine Displacement:
Commonly 480cc to 700cc, with variations across models and years (e.g., 4x4 models might feature larger displacement engines).
Bore X Stroke:
Specific to engine variant, but typically around 90mm x 75mm for a 700cc class engine.
Cooling System:
Liquid-cooled
Horsepower:
Typically in the range of 30-40 HP, depending on engine displacement and tuning.
Torque:
Torque figures will vary, optimized for low-end grunt for hauling and towing.
Fuel Delivery:
Carbureted (e.g., Mikuni BSR34/BS38) or Electronic Fuel Injection (EFI) on later or higher-trim models.
Fuel Type:
Unleaded Gasoline
Fuel Capacity:
Typically around 9-10 gallons.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Spark Plug Gap:
Refer to manual, typically 0.024-0.031 inches (0.6-0.8mm).
Exhaust Type:
Single or dual exhaust depending on configuration.
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with Hi/Lo range and Reverse
Optional Transmissions:
None, CVT was standard across the range.
Drive Modes:
On-demand AWD (for 4x4 and 6x6 models), selectable 2WD/4WD/6WD.
Cv Belt Maintenance:
Manual will detail inspection and replacement intervals for the drive belt.
Cv Fluid Type:
Specific Polaris CVT fluid or equivalent (refer to manual for exact specification).
Cv Fluid Capacity:
Typically around 1.5 - 2 quarts for the transmission/differential assembly.
Length:
Varies by model and year, but generally around 110-120 inches (279-305 cm).
Width:
Varies by model, often around 50-60 inches (127-152 cm).
Height:
Varies by model, typically around 70-75 inches (178-190 cm).
Cargo Bed Capacity:
Typically around 400-600 lbs (181-272 kg).
Dry Weight:
Approximately 900-1100 lbs (408-499 kg), depending on 2WD/4WD/6WD configuration.
Towing Capacity:
Often rated at 1500 lbs (680 kg) or more.
Payload Capacity:
Includes rider(s) and cargo, typically around 600-800 lbs (272-363 kg).
Rollover Protection:
Roll cage structure standard for operator safety.
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Four Wheel Drive:
On-demand AWD system provides enhanced traction in slippery conditions.
Seatbelts:
Standard seatbelts (usually 3-point).
Operator Protection:
Full-frame chassis and integrated roll cage.
Infotainment System:
Basic instrumentation cluster: speedometer, odometer, fuel gauge, engine hour meter, indicator lights. No advanced infotainment systems typical of modern vehicles.
Assistance Features:
Limited; primary assistance is through the 4WD/6WD system for traction.
Connectivity Features:
None.
Engine Oil Change:
Typically every 50-100 operating hours or annually, refer to manual for precise intervals based on usage.
Air Filter Service:
Inspect every 25-50 operating hours, clean or replace as needed, especially in dusty conditions.
Cv Belt Inspection:
Inspect annually or at 100 operating hours for wear and tear.
Spark Plug Replacement:
Every 100-200 operating hours or as performance dictates.
Engine Oil Type:
Polaris Synthetic 2W-50 or equivalent API SG, SH, SJ rated oil with JASO MA certification.
Engine Oil Capacity:
Refer to manual, typically around 2-2.5 quarts (2.0-2.4 liters) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Cv Belt Wear:
CVT belts can be prone to wear and breakage if overstressed or not maintained, especially with aggressive riding or heavy loads.
Carburetor Issues:
Carbureted models may require periodic cleaning and adjustment, especially if the vehicle sits for extended periods or uses poor quality fuel.
Charging System Reliability:
Early models sometimes had stator or regulator/rectifier issues, manual will aid in diagnosing these.
Polarisfamily:
Polaris Industries has a long history of manufacturing powersports vehicles, originating from snowmobiles and expanding into ATVs and UTVs.
Ranger Lineage:
The Ranger line, introduced in 1999, quickly became a dominant force in the utility UTV market, known for its ruggedness and utility.
Generational Changes:
The 2004-2009 models represent a significant iteration of the early Ranger platform, evolving in engine size, drivetrain options, and features.
Manufacturing Location:
Primarily manufactured in the USA by Polaris Industries.
