This is the official full factory service repair manual from POLARIS for the RANGER AND RANGER TM, covering production model years 2004 to 2009. With over 400 pages, it provides comprehensive repair and service information for both professional mechanics and DIY enthusiasts. Each manual offers detailed substeps, notes, cautions, and warnings throughout each chapter, along with numbered instructions and bold figure numbers to guide you through every repair procedure. The manual also includes detailed illustrations, drawings, and photos to facilitate easy understanding. It is an invaluable resource for diagnosing and repairing problems with your machine's electrical system, with troubleshooting and electrical service procedures combined with detailed wiring diagrams for ease of use.
The manual comes in .PDF format, which is compatible with all PC-based Windows operating systems and Mac. It can be saved to your hard drive and burned to CD-ROM, making it easily accessible without the need for shipping or waiting for delivery.
FRAME/BODY PANELS/EXHAUST SYSTEM TROUBLESHOOTING
Excessive exhaust noise
Deformed exhaust system
Exhaust gas leaks
Poor performance
Clogged muffler
Broken exhaust system
Exhaust gas leaks
LUBRICATION SYSTEM TROUBLESHOOTING
Oil level too low - high oil consumption
Oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation
Worn cylinder
Worn valve guide or stem seals
Oil pump worn or damaged
Oil contamination
Oil or filter not changed often enough
Worn piston rings or incorrect piston ring installation
Worn valve guide or stem seals
FUEL SYSTEM TROUBLESHOOTING
Engine cranks but won't start
No fuel in tank
No fuel to carburetor
Clogged fuel strainer
Clogged fuel line
Clogged fuel tank breather tube
Misadjusted fuel level
Too much fuel getting to the engine
Clogged air cleaner
Flooded carburetor
Intake air leak
Contaminated/deteriorated fuel
Clogged jets
Clogged starting enrichment valve circuit
Improper starting enrichment valve operation
Improper throttle operation
No spark at plug (faulty ignition system)
Lean mixture
Clogged fuel jets
Faulty float valve
Float level too low
Restricted fuel line
Clogged carburetor air vent tube
Restricted fuel tank breather tube
Intake air leak
Faulty vacuum piston
Faulty throttle valve
Rich mixture
Starting enrichment valve open (ON)
Clogged air jets
Faulty float valve
Float level too high
Dirty air cleaner
Worn jet needle or needle jet
Faulty vacuum piston
Engine stalls, hard to start, rough idling
Restricted fuel line
Fuel mixture too lean/rich
Contaminated/deteriorated fuel
Clogged jets
Intake air leak
Misadjusted idle speed
Misadjusted pilot screw
Misadjusted float level
Restricted fuel tank breather tube
Clogged air cleaner
Clogged slow circuit
Clogged starting enrichment valve circuit
Faulty ignition system
Afterburn when engine braking is used
Lean mixture in slow circuit
Faulty air cut-off valve
Faulty ignition system
Backfiring or misfiring during acceleration
Lean mixture
Faulty ignition system
Poor performance (driveability) and poor fuel economy
Clogged fuel system
Faulty ignition system
CYLINDER HEAD/VALVE TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check for seized piston ring.
Compression too low, hard starting or poor performance at low speed
Valves
Incorrect valve adjustment
Burned or bent valves
Incorrect valve timing
Broken valve spring
Uneven valve seating
Valve stuck open
Cylinder head
Leaking or damaged cylinder head gasket
Warped or cracked cylinder head
Loose spark plug
Compression too high
Excessive carbon build-up on piston head or combustion chamber
Worn or damaged decompressor system
Excessive smoke
Worn valve stem or valve guide
Damaged stem seal
Cylinder/piston problem
Excessive noise
Incorrect valve clearance
Sticking valve or broken valve spring
Excessive worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve stem end
Worn or damaged push rod and/or cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem
Rough idle
Low cylinder compression
For more detailed troubleshooting and repair information, refer to the complete manual.
