Polaris Ranger 2004 Service

Polaris Ranger · 2004 · service manual · 435 pages

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Washer19 N·m19.4 N·mp. 29
Radiator hose clamp4.1 N·m36 in·lbp. 42
Skid Plate19 N·mp. 48
Rocker arm nuts13.7 N·m10.1 ft·lbp. 52
Housing13.7 N·mp. 52
Front Wheel Nuts47.5 N·m47 N·mp. 56
Rear Wheel Nuts47.5 N·m47 N·mp. 56
Front Spindle Nut54.2 N·m55 N·mp. 56
Bolts Evenly18.6 N·m13.7 ft·lbp. 94
Cover Bolts H C41.2 N·m30.4 ft·lbp. 95
F. Spring Retainer4.9 N·mp. 95
J. Head Gasket41.2 N·m30.4 ft·lbp. 95
I. Spring I41.2 N·mp. 95
Intake Manifold18.6 N·m13.7 ft·lbp. 96
H. Ignition Coils18.6 N·mp. 96
Regulator H8.8 N·m6.5 ft·lbp. 96
Coil Bolts8.8 N·mp. 96
Coil Bolts18.6 N·mp. 96
Drive Clutch Bolt 7/1655 N·mp. 104
Ring Profile8.1 N·m8 N·mp. 146
Bolts evenly27.1 N·m27 N·mp. 153
Bolt Front A-Arm Ball Joint33.9 N·m35 N·mp. 184
Washers29.8 N·m22 ft·lbp. 194
Steering post arms40.7 N·m30 ft·lbp. 195
Vehicle Frame Bolt40.7 N·m30 ft·lbp. 196
A--Arm Bushing10.8 N·m8 ft·lbp. 196
Cotter pin holes40.7 N·m41 N·mp. 196
Frame Bushing Screw40.7 N·m30 ft·lbp. 197
Shaft Wheel Bearing33.9 N·m25 ft·lbp. 197
Shaft Wheel Bearing35 N·mp. 197
Washer40.7 N·m30 ft·lbp. 197
Ring Bearing81 N·mp. 198
Bearing203.4 N·m150 ft·lbp. 198
Pivot Bushing203.4 N·m150 ft·lbp. 198
Skid Plate81.3 N·m60 ft·lbp. 198
Rear Axle203.4 N·m150 ft·lbp. 199
Pivot Bolt Bolt Lock203 N·mp. 199
Pivot Bolt Bolt Lock40.7 N·m30 ft·lbp. 199
Spacer Washer Clamp24.4 N·m18 ft·lbp. 200
Spacer Washer Clamp25 N·mp. 200
Pinch bolts20.3 N·m21 N·mp. 201
Strut Rod Nut20.3 N·m21 N·mp. 201
Drive Clutch Retaining54.2 N·m54 N·mp. 209
Driven Clutch23 N·m23 N·mp. 209
Drive Clutch Spider271.2 N·m271 N·mp. 209
Drive Clutch Cover16.3 N·m16 N·mp. 209
Retaining bolt54.2 N·m55 N·mp. 211
Bushing Spring Pin Weight Roller16.3 N·m12 ft·lbp. 213
Dust Cover Bushing16 N·mp. 213
PVT Inner Cover16.3 N·m16 N·mp. 230
PVT Outer Cover5.6 N·m50 in·lbp. 230
Drive Clutch Spider20.3 N·m20.3 N·mp. 230
Drive Clutch Cover10.2 N·m10 N·mp. 230
4x4 Rear Wheel47.5 N·m35 ft·lbp. 254
Rear Hub149.1 N·m110 ft·lbp. 254
RANGER 6x6 Nuts47 N·mp. 254
Mid Hub Re149.1 N·m110 ft·lbp. 254
Taining Nut150 N·mp. 254
Brake Caliper Bolt24.4 N·m24 N·mp. 256
Brake caliper mounting bolts upon assembly47.5 N·m47 N·mp. 256
Rim24.4 N·m24.9 N·mp. 257
Slotted Nut54.2 N·m55 N·mp. 257
Washer54.2 N·m40 ft·lbp. 260
O-ring and bolts19 N·m19 N·mp. 271
Cover Bolts Drain plug Fill plug19 N·m19 N·mp. 273
Rear Wheel Nut47.5 N·m47 N·mp. 279
Flat Washer149.1 N·m110 ft·lbp. 283
Gearcase bolts81.3 N·m81 N·mp. 299
U--bolts nuts54.2 N·m54 N·mp. 300
Gearcase housing54.2 N·m54 N·mp. 300
Rear coil over shock bolts33.9 N·m25 ft·lbp. 300
Rear Coil Over Shock Bolt24.4 N·m24.8 N·mp. 300
Rear Spindle Nut149.1 N·m149 N·mp. 301
Output shaft48 N·mp. 304
Differential cover47.5 N·m35 ft·lbp. 304
Output cover bolts27.1 N·m27 N·mp. 316
Output Cover Bolt27.1 N·m27 N·mp. 316

Spark plugs

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
YB30L—p. 14
BP6ES—p. 39
EH63—p. 69
EH42PLE—p. 104

Service intervals

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Coolant change2 yearsp. 22
Air filter service1 yearsp. 44

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