Polaris RANGER 2004 User manual

Owner's Manual
for Vehicle Maintenance
and Safety
RANGER
2004
Owner's Manual
for Vehicle 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.
RANGER 2x4
RANGER 4x4
RANGER 6x6
RANGER TM
RANGER 2x4
RANGER 4x4
RANGER 6x6
RANGER TM

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

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We’ve created a web site just for YOU!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner

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Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production 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 reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.

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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
SSnowmobiles
SAll-terrain vehicles (ATVs)
SPersonal watercraft
SVictory motorcycles
SRANGER utility vehicles
Polaris Professional Series Workmobilest
SUtility Task Vehiclest(UTVs)
SPersonal Task Vehiclest(PTVs)
SAll-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, 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 instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.

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VEHICLE IDENTIFICATION NUMBERS
The vehicle frame vehicle identification number (VIN)(1), engine serial
number and vehicle model number (2) are important for model
identification when registering your vehicle, when obtaining insurance,
and when ordering replacement parts. In the event your vehicle is
stolen, these numbers 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
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (3) in the
spaces provided.
1
31XX
3
2
Frame VIN (behind left front wheel):
Engine Serial Number (right front side of engine crankcase):
Vehicle Model Number (under hood):
Key Number:

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TABLE OF CONTENTS
WELCOME 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 101.....................
WARRANTY 104..............................
INDEX 114...................................

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SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may
ride as a passenger in this vehicle.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
The RANGER is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning 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 designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris RANGER is not a toy and can be hazardous to operate.
This vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating the vehicle.

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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your RANGER. Your safety is involved when these
words and symbols are used. Become familiar with their meanings
before reading the manual.
The safety alert symbol, on 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 caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
NOTE
A note will alert you to important information or instructions.
A caution indicates a situation that may result in damage to the
vehicle.
CAUTION
WARNING