Polaris MS4000 Manuals

Manuals and User Guides for Polaris MS4000. We have 1 Polaris MS4000 manual available for free PDF download: Service And Owner's Manual

Polaris MS4000 Service And Owner's Manual

Polaris MS4000 Service And Owner's Manual (687 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 48.79 MB

Table of Contents

English

116
- Installation Instructions
  49
- Limited Warranty
  54
- Before You Start
  61
- Rear Panel
  62
- Care and Maintenance
  65
- Tools Required
  68
- Ordering Replacement Parts
  111
- Table of Contents
  116
- General Description
  117
- Specifications
  118
- Safety Message to Installers
  119
- Installation
  120
- Safety Message to Operators
  124
- Operation
  125
- Service
  127
- Priority Sound Elimination
  128
  - Parts List
    141
  - Safety Guidelines
    143
- General Safety Precautions
  157
- Winch Basics
  159
- How the Winch Works
  160
- Stretching Wire Rope
  161
- Before You Pull
  162
- Pulling
  163
- Rigging Techniques
  165
- Maintenance
  165
- The Final Analysis
  165
Français

166
- Mesures Générales de Sécurité
  167
- Comment Fonctionne Le Treuil
  170
- Étirement Initial du Cable
  171
- Avant de Treuiller
  172
- Treuillage
  173
- En Dernière Analyse
  175
  - Safety First
    186
- Maintenance
  175
- Techniques de Câblage
  175
- Vehicle Identification Numbers
  195
- Safety
  196
- Equipment Modifications
  204
- Features and Controls
  213
  - Diagnostic Mode
    219
  - Mode Button
    225
- Gear Selector
  226
- Ignition Switch
  229
- Operation
  231
  - Starting the Engine
    233
  - Stopping the Engine
    234
- Driving on Slippery Surfaces
  236
- Driving Uphill
  237
- Driving Downhill
  238
- Driving through Water
  239
- Driving over Obstacles
  240
- Driving in Reverse
  241
- Dumping the Cargo Box
  245
- Emission Control Systems
  250
- Maintenance
  253
  - Air Filter
    276
- Filter Systems
  276
  - Brake Inspection
    281
- Headlight Lamp Replacement
  286
- Headlight Beam Adjustment
  287
- Specifications
  301
- Polaris Products
  305
- Troubleshooting
  306
- Warranty
  310
  - Maintenance Schedule
    317
- Maintenance Log
  319
- Index
  321
- Engine Designation Number
  332
- Engine Serial Number Location
  332
- General Information
  332
- Model Identification
  332
- Model Information
  332
- Vin Identification
  332
- Transmission I.D. Number Location
  333
- Vehicle Identification Number (Vin) Location
  333
- Ranger 4X4 Crew / 6X6 (Height and Width)
  334
- Vehicle Dimensions
  334
- Ranger 4X4 Crew (Length and Wheel Base)
  335
- Ranger 6X6 (Length and Wheel Base)
  335
- General Specifications
  336
- Paint Codes
  340
- Publication Numbers
  340
- Replacement Keys
  340
- Special Tools
  340
- Vehicle Information
  340
- Conversion Table
  341
- Misc. Specifications and Charts
  341
- Standard Torque Specifications
  342
- Metric Tap / Drill Sizes
  343
- Sae Tap / Drill Sizes
  343
- Glossary of Terms
  344
- Break-In Period
  347
- Maintenance Chart Key
  347
- Periodic Maintenance Chart
  347
- Periodic Maintenance Overview
  347
- Pre-Ride - 25 Hour Maintenance Interval
  348
- 50 - 100 Hour Maintenance Interval
  349
- Polaris Lubricants, Maintenance and Service Products
  351
- Service Products and Lubes
  351
- Maintenance References
  352
- Maintenance References, Continued
  353
- Frame, Nuts, Bolts, and Fasteners
  354
- General Vehicle Inspection and Maintenance
  354
- Pre-Ride / Daily Inspection
  354
- Shift Linkage Inspection / Adjustment
  354
- Fuel Filter
  355
- Fuel Lines
  355
- Fuel System
  355
- Fuel System and Air Intake
  355
- Throttle Pedal Inspection
  355
- Vent Lines
  355
- Air Filter Service
  356
- Throttle Freeplay Adjustment
  356
- Air Intake Inspection
  357
- Breather Hose Inspection
  358
- Compression and Leakdown Test
  358
- Engine
  358
- Engine Oil Level
  358
- Engine Oil and Filter Change
  359
- Exhaust Pipe
  360
- Transmission and Gearcases
  361
- Transmission Lubrication
  361
- Front Gearcase Lubrication
  362
- Middle Gearcase Lubrication (6X6)
  363
- Rear Gearcase Lubrication (4X4 Crew)
  364
- Rear Gearcase Lubrication (6X6)
  365
- Coolant Level Inspection
  366
- Cooling System
  366
- Liquid Cooling System Overview
  366
- Coolant Strength / Type
  367
- Cooling System Hoses
  367
- Cooling System Pressure Test
  367
- Radiator Coolant Level Inspection
  367
- Coolant Drain / Radiator Removal
  368
- Radiator
  368
- CV Shaft Boot Inspection
  369
- Final Drive / Wheel and Tire
  369
- Wheel and Hub Torque Table
  369
- Wheel Installation
  369
- Wheel Removal
  369
- Battery Maintenance
  370
- Electrical and Ignition System
  370
- Tire Inspection
  370
- Tire Pressure
  370
- Battery Charging
  371
- Battery Fluid Level (Conventional Battery)
  371
- Battery Installation
  371
- Battery Removal
  371
- Battery Storage
  371
- Engine to Frame Ground
  372
- Spark Plug Service
  372
- Steering
  373
- Steering and Suspension
  373
- Tie Rod End / Steering Inspection
  373
- Front Suspension
  374
- Toe Adjustment
  374
- Rear Spring Adjustment
  375
- Rear Suspension
  375
- Rear Suspension Adjustment (4X4 Crew)
  375
- Brake Fluid Inspection
  376
- Brake Hose and Fitting Inspection
  376
- Brake Pad / Disc Inspection
  376
- Brake System
  376
- Parking Brake Cable Adjustment
  376
- Parking Brake Pad Inspection
  377
- Crankcase Exploded Views
  380
- Engine Specifications
  380
- Engine Fastener Torque Patterns
  387
- Torque Specifications
  388
- 700 EFI Engine Service Specifications
  389
- Accessible Components
  391
- Cooling System Specifications
  391
- General Engine Service
  391
- Piston Identification
  391
- Special Tools
  391
- Cooling System Pressure Test
  392
- Cooling System Bleeding Procedure
  393
- Cooling System Exploded View
  393
- Valve Cover Removal - 6X6 Models (Engine Installed)
  395
- Engine Removal
  396
- Engine Installation Notes
  397
- Engine Lubrication Specifications
  398
- Oil Pressure Test
  398
- Oil Flow Chart
  399
- Cylinder Head Assembly Exploded View
  400
- Engine Disassembly and Inspection
  400
- Cylinder Head Removal
  401
- Rocker Arms / Push Rods
  401
- Cylinder Head Inspection / Warp
  402
- Valve Seal / Spring Service (on Engine)
  402
- Cylinder Head Disassembly
  403
- Valve Inspection
  404
- Combustion Chamber
  405
- Valve Seat Reconditioning
  405
- Cylinder Head Reassembly
  407
- Cylinder Removal
  408
- Valve Lifter Removal / Inspection
  408
- Valve Sealing Test
  408
- Piston Removal
  409
- Cylinder Inspection
  410
- Cleaning the Cylinder after Honing
  411
- Cylinder Hone Selection and Honing Procedure
  411
- Honing to Deglaze
  411
- Piston / Rod Inspection
  412
- Piston-To-Cylinder Clearance
  412
- Piston Ring Installed Gap
  413
- Starter Drive Bendix Removal / Inspection
  413
- Engine Crankcase Disassembly / Inspection
  414
- Flywheel / Stator Removal / Inspection
  414
- Camshaft Inspection
  422
- Crankcase Reassembly
  423
- Engine Reassembly
  423
- Flywheel / Stator Installation
  432
- Cylinder Head Reassembly
  433
- Engine Break-In
  435
- Oil Pump Priming
  435
- Engine
  436
- Troubleshooting
  436
- Cooling System
  437
- General Information
  440
- Special Tools
  440
- Efi Service Notes
  443
- Fuel Tank Exploded View
  444
- Efi System Exploded View
  445
- Efi System Component Locations
  446
- Electronic Fuel Injection
  447
- Fuel Lines - Quick Connect Removal / Installation
  447
- Initial Priming / Starting Procedure
  448
- Principal Components / Efi Operation Overview
  448
- Electronic Control Unit (Ecu)
  449
- Fuel Pump
  450
- Fuel Pump Test
  450
- Fuel Sender Test
  450
- Fuel Pump / Tank Assembly Replacement
  451
- Fuel Pressure Regulator
  452
- Fuel Injectors
  453
- Crankshaft Position Sensor (Cps)
  454
  - Operation Overview
    454
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  455
- Throttle Position Sensor (Tps)
  455
- Engine Coolant Temperature Sensor (Ect)
  458
- Tps Replacement
  458
- Ignition Coil
  459
- Ignition Coil / Ht Lead Replacement
  459
- Ignition Coil Tests
  459
- Diagnostic "Blink Codes
  460
- General Troubleshooting
  460
- Efi Troubleshooting
  461
- Efi System Break-Out Diagrams
  462
- Fuel Injector Circuit (Mag)
  462
- Fuel Injector Circuit (Pto)
  462
- Crankshaft Position Sensor (Cps) Circuit
  463
- Fuel Pump Circuit
  463
- Engine Coolant Temperature Sensor (Ect)
  464
- Temperature Overheat Indicator Lamp Circuit
  464
- Air Temperature / Barometric Air Pressure Sensor (T-Bap) Circuit
  465
- Throttle Position Sensor (Tps) Circuit
  465
- Diagnostic Connector Circuit
  466
- Diagnostic Indicator Lamp Circuit
  466
- Body / Steering / Suspension
  468
- Special Tools
  468
- Torque Specifications
  468
- Body Component Removal
  469
- Removal Procedures
  469
- Lower Body, Floor and Fenders (4X4 Crew)
  470
- Lower Body, Floor and Fenders (6X6)
  471
- Hood / Dash Components
  472
- Dash Instruments and Controls
  473
- Assembly / Removal (6X6)
  474
- Cab Frame
  474
- Assembly / Removal (4X4 Crew)
  475
- Seat / Head Rest
  476
- Chassis / Main Frame (4X4 Crew)
  477
- Chassis / Main Frame (6X6)
  478
- Steering Assembly
  479
- Steering and Suspension
  480
- Front A-Arm
  481
- Front Strut
  482
- Ball Joint Replacement
  483
- Front Strut Cartridge Replacement
  483
- MID Axle A-Arm (6X6)
  484
- Rear A-Arm (4X4 Crew)
  485
- Rear Stabilizer Bar (4X4 Crew)
  487
- Swing Arm (6X6)
  488
- Rear Drive Axle and Swing Arm Exploded View (6X6)
  489
- Cargo Box - Panels
  490
- Rear Cargo Box
  490
- Cargo Box - Tailgate / Box Support
  491
- Decal Replacement
  493
- Storage Box (4X4 Crew)
  493
- Drive Clutch Operation
  496
- General Operation
  496
- Pvt System Fastener Torques
  496
- Pvt System Overview
  496
- Special Tools and Supplies
  496
- Torque Specifications
  496
- Driven Clutch Operation
  497
- Maintenance / Inspection
  497
- Pvt Break-In (Drive Belt / Clutches)
  497
- Overheating / Diagnosis
  498
- Disassembly
  499
- Pvt Sealing, Guard, and Ducting Components
  499
- Pvt System Service
  499
- Assembly
  500
- Belt Removal
  501
- Drive Belt
  501
- Clutch Alignment
  502
- Pvt Break-In (Drive Belt / Clutches)
  502
- Clutch Center Distance
  503
- Drive Clutch Service
  504
- Spring Specifications
  504
- Shift Weights
  505
- Clutch Disassembly
  506
- Exploded View
  506
- Spider Removal
  507
- Button to Tower Clearance Inspection
  508
- Roller, Pin, and Thrust Washer Inspection
  508
- Shift Weight Inspection
  508
- Bearing Inspection
  509
- Clutch Inspection
  509
- Moveable Sheave Bushing Inspection
  510
- Bushing Service
  511
- Clutch Assembly
  513
- Clutch Disassembly / Inspection
  514
- Driven Clutch Service
  514
- Exploded View
  514
- Clutch Assembly
  516
- Troubleshooting
  517
- Front Hub
  521
- Hub Removal / Inspection
  521
- Special Tools
  521
- Torque Specifications
  521
- Wheel, Hub, and Spindle Torque Table
  521
- Hubstrut Bearing Replacement
  522
- Hub Installation
  523
- Front Hub Exploded View
  524
- Front Drive Shaft
  525
- Removal
  525
- Drive Shaft / CV Joint Handling Tips
  526
- Outer CV Joint / Boot Replacement
  526
- Inner Plunging Joint / Boot Replacement
  528
- Exploded View
  529
- Installation
  529
- Front Propshaft
  530
- Front Propshaft Components
  530
- Propshaft U-Joint Service
  531
- Centralized Hilliard Exploded View
  533
- Awd Diagnosis
  535
- Gearcase Removal
  536
- Gearcase Disassembly / Inspection
  537
- Gearcase Reassembly / Inspection
  539
- Backlash Pad (Thrust Pad) Adjustment
  541
- Gearcase Installation
  542
- MID Drive Hub / Bearing Carrier (6X6)
  542
- Removal
  542
- Hub Installation
  544
- Disassembly / Assembly
  545
- MID Drive Exploded View
  545
- MID Drive Shaft (6X6)
  545
- Removal
  545
- Installation
  546
- MID Propshaft (6X6)
  546
- Removal
  546
- Gearcase Removal
  547
- MID Drive Gearcase (6X6)
  547
- Gearcase Disassembly
  548
- Gearcase Assembly
  550
- Gearcase Installation
  553
- MID Gearcase Exploded
  554
- Rear Hub / Bearing Carrier (4X4)
  555
- Hub Assembly
  556
- Hub Disassembly
  556
- Hub Installation
  557
- Exploded View
  558
- Outer CV Joint / Boot Replacement
  559
- Rear Drive Shaft (4X4 Crew)
  559
- Removal
  559
- Inner Plunging Joint / Boot Replacement
  562
- Drive Shaft Exploded View
  564
- Installation
  565
- Installation
  566
- Rear Propshaft (4X4 Crew)
  566
- Removal
  566
- General Operation
  567
- Rear Gearcase (4X4 Crew)
  567
- Operation Modes
  568
- Gearcase Disassembly
  569
- Gearcase Removal
  569
- Rear Gearcase Assembly
  572
- Rear Gearcase Installation
  574
- Rear Gearcase Exploded View (4X4 Crew)
  575
- Rear Axle / Gearcase Service (6X6)
  576
- Rear Axle Removal
  576
- Axle Tube Removal
  577
- Axle Tube Bearing Replacement
  578
- Gearcase Disassembly / Inspection
  578
- Gearcase Assembly
  579
- Gearcase / Axle Installation
  580
  - Rear Gearcase Exploded View (6X)
    583
- Inspection
  586
- Installation
  586
- Removal
  586
- Shift Lever
  586
- Shift Linkage
  586
- Torque Specifications
  586
- Adjustment
  587
- Transmission Removal
  587
- Transmission Service
  587
- Transmission Disassembly
  589
- Transmission Assembly
  594
- Transmission Installation
  598
- Troubleshooting
  599
- Troubleshooting Checklist
  599
- Exploded View
  600
- Transmission Exploded Views
  600
- General Specifications
  604
- Special Tools
  604
- Torque Specifications
  604
- Brake Noise Troubleshooting
  605
- Brake System Service Notes
  605
- Hydraulic Brake System Operation
  606
- Brake System Exploded View
  607
- Foot Brake Pedal
  608
- Master Cylinder
  608
- Brake Bleeding / Fluid Change
  609
- Exploded View (4X4 Crew)
  610
- Parking Brake
  610
- Exploded View (6X6)
  611
- Caliper Removal
  613
- Exploded View
  613
- Parking Brake Caliper Service
  613
- Caliper Disassembly / Inspection
  614
- Caliper Installation
  615
- New Brake Pad Installation
  615
- Parking Brake Disc Service
  615
- Front Brake Pads
  616
- Brake Burnishing Procedure
  617
- Pad Assembly / Installation
  617
- Caliper Removal
  618
- Front Caliper Service
  618
- Caliper Disassembly
  619
- Caliper Installation
  621
- Front Brake Disc
  622
- Rear Brake Pads (6X6)
  623
- Pad Installation
  624
- Pad Removal
  624
- Rear Brake Pads (4X4 Crew)
  624
- Brake Burnishing Procedure
  626
- Caliper Removal
  627
- Rear Caliper Service (6X6)
  627
- Caliper Removal
  630
- Rear Caliper Service (4X4 Crew)
  630
- Caliper Disassembly
  631
- Caliper Installation
  633
- Rear Brake Disc
  634
- Troubleshooting
  635
- Electrical Service Notes
  639
- General Information
  639
- Special Tools
  639
- Under-Hood Components
  639
- Awd / 2Wd / Turf Switch (4X4 Crew)
  640
- Differential Solenoid (4X4 Crew)
  640
- Headlight Switch
  640
- Switches / Controls
  640
- Brake Light Switch
  641
- Parking Brake Switch
  642
- Instrument Cluster
  643
- Rider Information Display
  643
- Diagnostic Display Mode
  644
- Standard Display Modes
  644
- Viewing Diagnostic Codes
  646
- Instrument Cluster Troubleshooting Tests
  648
- Test 1 - no All Wheel Drive
  648
- Test 2 - no Display
  649
- Test 3 - Wheel Speed Sensor
  649
- Test 4 - no Awd Hub Safety Limiter
  650
- Test 5 - Fuel Gauge Display Not Working
  651
- Test 6 - Shift Indicator Not Working (Transmission Switch)
  651
- All Wheel Drive (Awd) Coil
  652
- Gear Position Indicator Switch
  652
- Headlight Housing Removal
  653
  - Lamp Replacement
    654
- Headlights
  653
- Headlight Housing Installation
  654
- Tail Light / Brake Light
  654
- Cooling System
  655
- Cooling System Break-Out Diagram
  655
- Coolant Temperature Sensor
  656
- Efi Diagnostics
  656
- Fuel Sender
  656
- Relays
  657
- Fuses / Circuit Breaker
  658
- Charging System
  659
- Charging System "Break Even" Test
  659
- Current Draw - Key off
  659
- Charging System Alternator Tests
  660
- Charging System Testing Flow Chart
  661
- Battery Activation
  662
- Battery Service
  662
- Battery Inspection
  663
- Battery Testing
  663
- Starter Motor Removal / Disassembly
  665
- Starter System
  665
- Troubleshooting
  665
- Voltage Drop Test
  665
- Brush Inspection / Replacement
  666
- Armature Testing
  667
- Starter Reassembly / Installation
  667
- Starter Drive
  668
- Starter Solenoid Bench Test
  669
- Starter Solenoid Operation
  669
- Starter Exploded View
  670
- Starting System Testing Flow Chart
  671
- Diagnosis (if Equipped)
  672
- Electric Box Lift Actuator
  672
- Electrical Break-Out Diagrams
  673
- Key-On Power Circuit
  673
- Starting Circuit
  673
- Awd Circuit
  674
- Transmission Switch Circuit
  674
- Charging System Circuit
  675
- Speed Sensor Circuit
  675
- Cooling Fan Circuit
  676
- Fuel Display / Fuel Pump Circuit
  676

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