Polaris 4X4 700 EFI Manuals

Manuals and User Guides for Polaris 4X4 700 EFI. We have 5 Polaris 4X4 700 EFI manuals available for free PDF download: Service Manual, Owner's Manual

Polaris 4X4 700 EFI Service Manual (330 pages)

Brand: Polaris | Category: Automobile | Size: 14.28 MB

Polaris

2
- Table of Contents
  2
- Chapter 1
  5
- Engine Designation Number
  5
- Engine Serial Number Location
  5
- Model Identification
  5
- Model Information
  5
- Vin Identification
  5
- Transmission I.D. Number Location
  6
- Unit Serial Number (Vin) Location
  6
- Vehicle Dimensions
  7
  - Vehicle Dimensions Ranger 4X4, 6X6
    8
- General Specifications
  9
  - Model: Ranger Xp 4X4
    9
  - Model: Ranger Xp 6X6
    9
  - Model: Ranger Xp 4X4
    10
  - Model: Ranger Xp 6X6
    11
  - Paint Codes
    12
  - Replacement Keys
    12
- Special Tools
  12
- Misc. Specifications and Charts
  13
  - Conversion Table
    13
  - Standard Torque Specifications
    14
  - Sae Tap / Drill Sizes
    15
  - Metric Tap / Drill Sizes
    15
  - Glossary of Terms
    16
General Information Chapter 2 General Information

17
- Chapter 2
  19
- Maintenance Chart Key
  19
- Periodic Maintenance Chart
  19
- Periodic Maintenance Overview
  19
- Engine
  20
- Pre-Ride - 25 Hour Maintenance Interval
  20
- 50 - 100 Hour Maintenance Interval
  21
- General Component Locations
  23
  - Rh Side and Dash View (4X4)
    23
  - Lh Side and Rear View (4X4)
    24
  - Lh Side and Rh Side Views (6X6)
    25
  - Transmission
    25
- Brakes
  26
  - Maintenance References
    27
    
    Maintenance References, Continued
    28
  - General Vehicle Inspection and Maintenance
    29
    
    Pre-Ride / Daily Inspection
    29
    
    Frame, Nuts, Bolts, and Fasteners
    29
    
    Shift Linkage Inspection / Adjustment
    29
  - Fuel System and Air Intake
    30
    
    Fuel System
    30
    
    Fuel Lines
    30
    
    Fuel Filter
    30
    
    Vent Lines
    30
    
    Throttle Pedal Inspection
    30
    
    Throttle Freeplay Adjustment
    31
    
    Air Filter Service
    31
    
    Air Intake Inspection
    32
  - Engine
    33
    
    Compression and Leakdown Test
    33
    
    Breather Hose Inspection
    33
    
    Engine Oil Level
    33
    
    Engine Oil and Filter Change
    34
    
    Exhaust Pipe
    35
  - Transmission and Gearcases
    36
    
    Transmission Lubrication
    36
    
    Front Gearcase Lubrication (4X4)
    37
    
    Middle Gearcase Lubrication (6X6)
    38
    
    Rear Gearcase Lubrication (4X4)
    39
    
    Rear Gearcase Lubrication (6X6)
    40
  - Cooling System
    41
    
    Liquid Cooling System Overview
    41
    
    Coolant Level Inspection
    41
    
    Radiator Coolant Level Inspection
    42
    
    Coolant Strength / Type
    42
    
    Cooling System Pressure Test
    42
    
    Cooling System Hoses
    42
    
    Radiator
    43
    
    Coolant Drain / Radiator Removal
    43
  - Final Drive / Wheel and Tire
    43
    
    Wheel, Hub, and Spindle Torque Table
    43
    
    CV Shaft Boot Inspection
    44
    
    Wheel Removal
    44
    
    Wheel Installation
    44
    
    Tire Inspection
    44
    
    Tire Pressure
    45
  - Electrical and Ignition System
    45
    
    Battery Maintenance
    45
    
    Battery Fluid Level (Conventional Battery)
    45
    
    Battery Removal
    45
    
    Battery Installation
    46
    
    Battery Storage
    46
    
    Battery Charging
    46
    
    Spark Plug Service
    46
    
    Engine to Frame Ground
    47
  - Steering and Suspension
    47
    
    Steering
    47
    
    Tie Rod End / Steering Inspection
    47
    
    Camber and Caster
    47
    
    Wheel Toe Alignment Inspection
    48
    
    Toe Adjustment
    48
    
    Front Suspension
    49
    
    Rear Suspension
    49
    
    Rear Suspension Adjustment (4X4)
    50
    
    Rear Spring Adjustment
    50
  - Brake System
    50
    
    Brake System Inspection
    50
    
    Brake Pad Inspection
    50
    
    Parking Brake Pad Inspection
    51
    
    Brake Hose and Fitting Inspection
    51
Chapter 3 Engine

52
- Service Products and Lubes
  26
  - Polaris Lubricants, Maintenance and Service Products
    26
- Crankcase Exploded Views
  53
- Engine Specifications
  53
- Fuel Injection
  59
  - Engine Fastener Torque Patterns
    60
    
    Torque Specifications
    61
    
    700 EFI Engine Service Specifications
    62
    
    Special Tools
    64
  - General Engine Service
    64
    
    Accessible Components
    64
    
    Piston Identification
    64
    
    Cooling System Specifications
    64
    
    Cooling System Pressure Test
    65
    
    Cooling System Exploded View
    66
    
    Cooling System Bleeding Procedure
    66
    
    Valve Cover Removal - 6X6 Models (Engine Installed)
    68
    
    Engine Removal
    69
    
    Engine Installation Notes
    70
    
    Cylinder Hone Selection and Honing Procedure
    71
    
    Honing to Deglaze
    71
    
    Cleaning the Cylinder after Honing
    72
    
    Engine Lubrication Specifications
    72
    
    Oil Pressure Test
    72
    
    Oil Flow Chart
    73
  - Engine Disassembly and Inspection
    74
    
    Cylinder Head Assembly Exploded View
    74
    
    Rocker Arms / Push Rods
    75
    
    Cylinder Head Removal
    75
    
    Cylinder Head Inspection
    76
    
    Cylinder Head Warp
    76
    
    Valve Seal / Spring Service (on Engine)
    76
    
    Cylinder Head Disassembly
    77
    
    Valve Inspection
    78
    
    Combustion Chamber
    79
    
    Valve Seat Reconditioning
    79
    
    Cylinder Head Reassembly
    81
    
    Valve Sealing Test
    82
    
    Cylinder Removal
    82
    
    Valve Lifter Removal / Inspection
    82
    
    Piston Removal
    83
    
    Cylinder Inspection
    84
    
    Piston-To-Cylinder Clearance
    85
    
    Piston / Rod Inspection
    85
    
    Piston Ring Installed Gap
    86
    
    Starter Drive Bendix Removal / Inspection
    86
    
    Flywheel / Stator Removal / Inspection
    87
    
    Engine Crankcase Disassembly / Inspection
    87
    
    Camshaft Inspection
    95
  - Engine Reassembly
    96
    
    Crankcase Reassembly
    96
    
    Flywheel / Stator Installation
    105
    
    Cylinder Head Reassembly
    105
    
    Oil Pump Priming
    108
  - Troubleshooting
    109
    
    Engine
    109
    
    Cooling System
    110
Fuel Injection Chapter 4 Fuel Injection

111
- Chapter 4
  112
- Special Tools
  112
- Service Notes
  114
- Efi System Exploded View
  115
- Efi System Component Locations
  116
- Throttle Body
  116
- Fuel Tank
  118
  - Exploded View
    118
  - Fuel Lines - Quick Connect
    119
- Electronic Fuel Injection
  119
  - Principal Components
    119
  - Efi Operation Overview
    119
  - Initial Priming / Starting Procedure
    120
- Electronic Control Unit (Ecu)
  120
  - Operation Overview
    120
  - Ecu Service
    121
  - Ecu Replacement
    121
- Fuel Pump
  121
  - Operation Overview
    121
  - Fuel Pump Test
    122
  - Fuel Pump / Tank Assembly Replacement
    122
- Fuel Injectors
  124
  - Fuel Injector Service
    125
  - Fuel Injector Replacement
    125
- Fuel Pressure Regulator
  124
  - Operation Overview
    124
  - Fuel Pressure Regulator Test
    124
  - Fuel Pressure Regulator Replacement
    124
- Crankshaft Position Sensor (Cps)
  125
  - Operation Overview
    125
  - Cps Test
    126
  - Cps Replacement
    126
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  126
  - Operation Overview
    126
  - T-Bap Test
    126
  - T-Bap Replacement
    126
- Throttle Position Sensor (Tps)
  127
  - Operation Overview
    127
  - Tps Test
    127
  - Tps Initialization
    128
  - Tps Replacement
    129
- Engine Coolant Temperature Sensor (Ect)
  129
  - Operation Overview
    129
  - Ect Sensor Test
    130
  - Ect Sensor Replacement
    130
- Diagnostic "Blink Codes
  131
  - Efi Troubleshooting
    132
- General Troubleshooting
  131
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

133
- Body / Steering / Suspension
  133
  - Torque Specifications
    134
  - Special Tools
    134
  - Body Component Removal
    135
- Chapter 5
  135
- Removal Procedures
  135
- Lower Body Components
  136
- Hood / Dash Components
  137
- Dash Instruments and Controls
  138
- Cab Frame
  139
  - Assembly / Removal
    139
- Chassis / Main Frame (4X4)
  140
  - Exploded View
    140
- Chassis / Main Frame (6X6)
  141
  - Exploded View
    141
- Seat / Head Rest
  142
  - Seat Base / Seat Back / Head Rest Assembly
    142
- Steering Assembly
  143
  - Exploded View
    143
- Steering and Suspension
  144
  - Exploded View
    144
- Front A-Arm
  145
  - Replacement
    145
- Front Strut
  146
  - Exploded View
    146
  - Front Strut Cartridge Replacement
    147
  - Ball Joint Replacement
    147
- MID Axle A-Arm (6X6)
  148
  - Replacement
    148
- Rear A-Arm (4X4)
  149
  - Replacement
    149
- Rear Stabilizer Bar (4X4)
  151
  - Removal / Installation
    151
- Swing Arm (6X6)
  152
  - Removal
    152
  - Installation
    152
- Rear Drive Axle and Swingarm Exploded View (6X6)
  153
- Rear Cargo Box
  154
  - Cargo Box - Panels
    154
  - Cargo Box - Tailgate / Box Support
    155
  - Box Removal
    156
  - Box Installation
    156
- Decal Replacement
  157
- Storage Box
  157
  - Removal
    157
  - Installation
    157
Clutching Chapter 6 Clutching

158
- Clutching
  158
  - Special Tools and Supplies
    159
  - Torque Specifications
    159
- Chapter 6 Pvt System Fastener Torques
  159
- Pvt System Overview
  159
  - General Operation
    159
  - Drive Clutch Operation
    159
  - Driven Clutch Operation
    160
  - Maintenance / Inspection
    160
  - Overheating / Diagnosis
    161
- Pvt System Service
  162
  - Pvt Sealing, Guard, and Ducting Components
    162
  - Disassembly
    162
  - Assembly
    163
- Drive Belt
  164
  - Belt Deflection (Tension)
    164
  - Belt Removal
    164
  - Belt Inspection
    165
  - Belt Installation
    166
- Clutch Alignment / Offset
  166
  - Clutch Alignment
    166
  - Clutch Offset
    167
- Drive Clutch Service
  168
  - Spring Specifications
    168
  - Shift Weights
    169
  - Exploded View
    170
  - Clutch Inspection
    170
  - Clutch Disassembly
    171
  - Spider Removal
    172
  - Roller, Pin, and Thrust Washer Inspection
    172
  - Bushing Service
    173
  - Moveable Sheave - Bushing Removal
    173
  - Moveable Sheave - Bushing Installation
    173
  - Clutch Cover - Bushing Removal
    174
  - Clutch Cover - Bushing Installation
    174
  - Clutch Assembly
    175
- Driven Clutch Service
  176
  - Exploded View
    176
  - Clutch Disassembly / Inspection
    176
  - Clutch Assembly
    178
- Troubleshooting
  179
Chapter 7 Final Drive

181
- Final Drive
  181
  - Special Tools
    183
  - Torque Specifications
    183
- Front Hub
  183
  - Hub Removal / Inspection
    183
  - Hubstrut Bearing Replacement
    184
  - Hub Installation
    185
  - Front Hub Exploded View
    186
- Drive Shaft / Propshaft
  187
  - Exploded View
    187
- Driveshaft / CV Joint Handling Tips
  188
- Front Drive Shaft
  188
  - Removal
    188
  - CV Joint / Boot Replacement
    189
  - Installation
    191
- Front Propshaft Removal
  191
- Propshaft U-Joint Service
  192
  - Disassembly
    192
  - Assembly
    193
- Front Gearcase Centralized Hilliard
  194
  - Awd Operation
    194
  - Centralized Hilliard Exploded View
    195
  - Awd Diagnosis
    196
  - Gearcase Removal
    197
  - Gearcase Disassembly / Inspection
    198
  - Gearcase Reassembly / Inspection
    200
  - Backlash Pad (Thrust Pad) Adjustment
    202
  - Gearcase Installation
    203
- MID Drive Hub / Bearing Carrier (6X6)
  203
  - Removal
    203
  - Hub Disassembly
    204
  - Hub Assembly
    204
  - Hub Installation
    205
  - MID Drive Exploded View
    206
- MID Drive Shaft (6X6)
  207
  - Removal
    207
  - Installation
    207
- MID Drive Gearcase (6X6)
  208
  - Gearcase Removal
    208
  - Gearcase Disassembly
    209
  - Gearcase Assembly
    212
  - Gearcase Installation
    214
- MID Prop Shaft (6X6)
  208
  - Removal
    208
- Rear Drive (4X4)
  216
  - Exploded View
    216
- Rear Hub / Bearing Carrier (4X4)
  216
  - Hub Inspection
    216
  - Hub Removal
    216
  - Hub Disassembly
    217
  - Hub Assembly
    218
  - Hub Installation
    218
- Rear Drive Shaft (4X4)
  219
  - Removal
    219
  - CV Joint / Boot Replacement
    220
  - Installation
    222
- Rear Propshaft (4X4)
  223
  - Removal
    223
  - Installation
    223
- Rear Gearcase (4X4)
  224
  - General Operation
    224
  - Operation Modes
    225
  - Differential Removal
    226
  - Differential Disassembly
    226
  - Differential Assembly
    229
  - Differential Installation
    231
  - Differential Exploded View
    232
- Rear Axle / Gearcase Service (6X6)
  233
  - Rear Axle Removal
    233
  - Axle Tube Removal
    234
  - Axle Tube Bearing Replacement
    235
  - Gearcase Disassembly / Inspection
    235
  - Gearcase Assembly
    236
  - Gearcase / Axle Installation
    237
  - Gearcase Exploded View
    240

Polaris 4X4 700 EFI Service Manual (362 pages)

4X4 CREW / 6X6

Brand: Polaris | Category: Utility Vehicle | Size: 21.4 MB

General Information Chapter 1 1

6
- Table of Contents
  6
- Chapter 1
  7
- Engine Designation Number
  7
- Engine Serial Number Location
  7
- Model Identification
  7
- Model Information
  7
- Vin Identification
  7
- Transmission I.D. Number Location
  8
- Vehicle Identification Number (Vin) Location
  8
- Vehicle Dimensions
  9
- General Specifications
  11
  - General: 2009 Ranger 4X4 Crew
    15
  - General: 2009 Ranger 6X6
    15
- Special Tools
  15
- Vehicle Information
  15
  - Publication Numbers
    15
  - Paint Codes
    15
  - Replacement Keys
    15
- Misc. Specifications and Charts
  16
  - Conversion Table
    16
  - Standard Torque Specifications
    17
  - Sae Tap / Drill Sizes
    18
  - Metric Tap / Drill Sizes
    18
  - Glossary of Terms
    19
  - General Information
    19
Maintenance Chapter 2 Maintenance

20
- Break-In Period
  22
- Chapter 2
  22
- Maintenance Chart Key
  22
- Periodic Maintenance Chart
  22
- Periodic Maintenance Overview
  22
- Pre-Ride - 25 Hour Maintenance Interval
  23
- 50 - 100 Hour Maintenance Interval
  24
- Service Products and Lubes
  26
  - Polaris Lubricants, Maintenance and Service Products
    26
    
    Brakes
    27
- Transmission
  26
- Maintenance References
  27
  - Maintenance References, Continued
    28
- General Vehicle Inspection and Maintenance
  29
- Fuel System and Air Intake
  30
  - Fuel System
    30
  - Fuel Lines
    30
  - Fuel Filter
    30
  - Vent Lines
    30
  - Throttle Pedal Inspection
    30
  - Throttle Freeplay Adjustment
    31
  - Air Filter Service
    31
  - Air Intake Inspection
    32
- Engine
  33
  - Compression and Leakdown Test
    33
  - Breather Hose Inspection
    33
  - Engine Oil Level
    33
  - Engine Oil and Filter Change
    34
  - Exhaust Pipe
    35
- Transmission and Gearcases
  36
- Cooling System
  41
  - Liquid Cooling System Overview
    41
  - Coolant Level Inspection
    41
  - Radiator Coolant Level Inspection
    42
  - Coolant Strength / Type
    42
  - Cooling System Pressure Test
    42
  - Cooling System Hoses
    42
  - Radiator
    43
  - Coolant Drain / Radiator Removal
    43
- Final Drive / Wheel and Tire
  44
  - Wheel and Hub Torque Table
    44
  - CV Shaft Boot Inspection
    44
  - Wheel Removal
    44
  - Wheel Installation
    44
  - Tire Inspection
    45
  - Tire Pressure
    45
- Electrical and Ignition System
  45
  - Battery Maintenance
    45
  - Battery Fluid Level (Conventional Battery)
    46
  - Battery Removal
    46
  - Battery Installation
    46
  - Battery Storage
    46
  - Battery Charging
    46
  - Spark Plug Service
    47
  - Engine to Frame Ground
    47
- Steering and Suspension
  48
  - Steering
    48
  - Tie Rod End / Steering Inspection
    48
  - Wheel Toe Alignment Inspection
    48
  - Front Suspension
    49
  - Toe Adjustment
    49
  - Rear Suspension
    50
  - Rear Suspension Adjustment (4X4 Crew)
    50
  - Rear Spring Adjustment
    50
- Brake System
  51
Chapter 3 Engine

54
- Crankcase Exploded Views
  55
- Engine Specifications
  55
- Engine Fastener Torque Patterns
  62
- Torque Specifications
  63
- 700 EFI Engine Service Specifications
  64
- General Engine Service
  66
  - Accessible Components
    66
  - Piston Identification
    66
  - Cooling System Specifications
    66
  - Cooling System Pressure Test
    67
  - Cooling System Exploded View
    68
  - Cooling System Bleeding Procedure
    68
  - Valve Cover Removal - 6X6 Models (Engine Installed)
    70
  - Engine Removal
    71
  - Engine Installation Notes
    72
  - Engine Lubrication Specifications
    73
  - Oil Pressure Test
    73
  - Oil Flow Chart
    74
- Special Tools
  66
- Engine Disassembly and Inspection
  75
  - Cylinder Head Assembly Exploded View
    75
  - Rocker Arms / Push Rods
    76
  - Cylinder Head Removal
    76
  - Cylinder Head Inspection / Warp
    77
  - Valve Seal / Spring Service (on Engine)
    77
  - Cylinder Head Disassembly
    78
  - Valve Inspection
    79
  - Combustion Chamber
    80
  - Valve Seat Reconditioning
    80
  - Cylinder Head Reassembly
    82
  - Valve Sealing Test
    83
  - Cylinder Removal
    83
  - Valve Lifter Removal / Inspection
    83
  - Piston Removal
    84
  - Cylinder Inspection
    85
  - Cylinder Hone Selection and Honing Procedure
    86
  - Honing to Deglaze
    86
  - Cleaning the Cylinder after Honing
    86
  - Piston-To-Cylinder Clearance
    87
  - Piston / Rod Inspection
    87
  - Piston Ring Installed Gap
    88
  - Starter Drive Bendix Removal / Inspection
    88
  - Flywheel / Stator Removal / Inspection
    89
  - Engine Crankcase Disassembly / Inspection
    89
  - Camshaft Inspection
    97
- Engine Reassembly
  98
  - Crankcase Reassembly
    98
  - Flywheel / Stator Installation
    107
  - Cylinder Head Reassembly
    108
  - Oil Pump Priming
    110
  - Engine Break-In
    110
- Troubleshooting
  111
  - Engine
    111
  - Cooling System
    112
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

114
- Chapter 4
  115
- General Information
  115
- Special Tools
  115
- Efi Service Notes
  118
- Fuel Tank Exploded View
  119
- Efi System Exploded View
  120
- Efi System Component Locations
  121
- Throttle Body
  121
- Electronic Fuel Injection
  122
  - Principal Components / Efi Operation Overview
    123
  - Initial Priming / Starting Procedure
    123
- Fuel Lines - Quick Connect Removal / Installation
  122
- Electronic Control Unit (Ecu)
  124
- Fuel Pump
  125
  - Fuel Sender Test
    125
  - Fuel Pump Test
    125
  - Fuel Pump / Tank Assembly Replacement
    126
- Fuel Pressure Regulator
  127
- Fuel Injectors
  128
- Crankshaft Position Sensor (Cps)
  129
  - Cps Test
    129
  - Cps Replacement
    129
- Temperature / Barometric Air Pressure Sensor (T-Bap)
  130
- Throttle Position Sensor (Tps)
  130
  - Tps Adjustment
    132
  - Tps Replacement
    133
- Engine Coolant Temperature Sensor (Ect)
  133
- Ignition Coil
  134
  - Ignition Coil Tests
    134
  - Ignition Coil / Ht Lead Replacement
    134
- Diagnostic "Blink Codes
  135
  - Efi Troubleshooting
    136
- General Troubleshooting
  135
- Efi System Break-Out Diagrams
  137
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

142
- Body / Steering / Suspension
  142
- Special Tools
  143
- Torque Specifications
  143
- Body Component Removal
  144
- Chapter 5
  144
- Removal Procedures
  144
- Lower Body, Floor and Fenders (4X4 Crew)
  145
- Lower Body, Floor and Fenders (6X6)
  146
- Hood / Dash Components
  147
- Dash Instruments and Controls
  148
- Cab Frame
  149
  - Assembly / Removal (6X6)
    149
  - Assembly / Removal (4X4 Crew)
    150
- Seat / Head Rest
  151
- Chassis / Main Frame (4X4 Crew)
  152
- Chassis / Main Frame (6X6)
  153
- Steering Assembly
  154
- Steering and Suspension
  155
- Front A-Arm
  156
- Front Strut
  157
  - Front Strut Cartridge Replacement
    158
  - Ball Joint Replacement
    158
- MID Axle A-Arm (6X6)
  159
- Rear A-Arm (4X4 Crew)
  160
- Rear Stabilizer Bar (4X4 Crew)
  162
- Swing Arm (6X6)
  163
- Rear Drive Axle and Swing Arm Exploded View (6X6)
  164
- Rear Cargo Box
  165
  - Cargo Box - Panels
    165
  - Cargo Box - Tailgate / Box Support
    166
- Decal Replacement
  168
- Storage Box (4X4 Crew)
  168
Clutching Chapter 6 Clutching

170
- Chapter 6 Pvt System Fastener Torques
  171
- Pvt System Overview
  171
  - General Operation
    171
  - Drive Clutch Operation
    171
  - Driven Clutch Operation
    172
  - Pvt Break-In (Drive Belt / Clutches)
    172
  - Maintenance / Inspection
    172
  - Overheating / Diagnosis
    173
- Special Tools and Supplies
  171
- Torque Specifications
  171
- Pvt System Service
  174
  - Pvt Sealing, Guard, and Ducting Components
    174
  - Disassembly
    174
  - Assembly
    175
- Drive Belt
  176
  - Belt Removal
    176
  - Pvt Break-In (Drive Belt / Clutches)
    177
- Clutch Alignment
  177
- Clutch Center Distance
  178
- Drive Clutch Service
  179
  - Spring Specifications
    179
  - Shift Weights
    181
  - Exploded View
    181
  - Spider Removal
    182
  - Roller, Pin, and Thrust Washer Inspection
    183
  - Button to Tower Clearance Inspection
    183
  - Shift Weight Inspection
    183
  - Bearing Inspection
    184
  - Clutch Inspection
    184
  - Moveable Sheave Bushing Inspection
    185
  - Bushing Service
    186
  - Clutch Assembly
    188
- Driven Clutch Service
  189
  - Exploded View
    189
  - Clutch Disassembly / Inspection
    189
  - Clutch Assembly
    191
- Troubleshooting
  192
Chapter 7 Final Drive

194
- Front Hub
  196
  - Hub Removal / Inspection
    196
  - Hubstrut Bearing Replacement
    197
  - Hub Installation
    198
  - Front Hub Exploded View
    199
- Special Tools
  196
- Torque Specifications
  196
  - Final Drive
    196
- Front Drive Shaft
  200
  - Removal
    200
  - Drive Shaft / CV Joint Handling Tips
    201
  - Outer CV Joint / Boot Replacement
    201
  - Inner Plunging Joint / Boot Replacement
    203
  - Exploded View
    204
  - Installation
    204
- Front Propshaft
  205
  - Front Propshaft Components
    205
- Propshaft U-Joint Service
  206
  - Centralized Hilliard Exploded View
    208
  - All Wheel Drive Operation
    209
  - Awd Diagnosis
    210
  - Gearcase Removal
    211
  - Gearcase Disassembly / Inspection
    212
  - Gearcase Reassembly / Inspection
    214
  - Backlash Pad (Thrust Pad) Adjustment
    216
  - Gearcase Installation
    217
- MID Drive Hub / Bearing Carrier (6X6)
  217
  - Removal
    217
  - Hub Installation
    219
  - MID Drive Exploded View
    220
- MID Drive Shaft (6X6)
  220
  - Removal
    220
  - Disassembly / Assembly
    220
  - Installation
    221
- MID Propshaft (6X6)
  221
  - Removal
    221
- MID Drive Gearcase (6X6)
  222
  - Gearcase Removal
    222
  - Gearcase Disassembly
    223
  - Gearcase Assembly
    225
  - Gearcase Installation
    228
  - MID Gearcase Exploded
    229
- Rear Drive Shaft (4X4 Crew)
  234
  - Removal
    234
  - Outer CV Joint / Boot Replacement
    234
  - Inner Plunging Joint / Boot Replacement
    237
  - Drive Shaft Exploded View
    239
  - Installation
    240
- Rear Propshaft (4X4 Crew)
  241
  - Removal
    241
  - Installation
    241
- Rear Gearcase (4X4 Crew)
  242
  - General Operation
    242
  - Operation Modes
    243
  - Gearcase Removal
    244
  - Gearcase Disassembly
    244
  - Rear Gearcase Assembly
    247
  - Rear Gearcase Installation
    249
  - Rear Gearcase Exploded View (4X4 Crew)
    250
- Rear Axle / Gearcase Service (6X6)
  251
  - Rear Axle Removal
    251
  - Axle Tube Removal
    252
  - Axle Tube Bearing Replacement
    253
  - Gearcase Disassembly / Inspection
    253
  - Gearcase Assembly
    254
  - Gearcase / Axle Installation
    255
  - Rear Gearcase Exploded View (6X)
    258

Polaris 4X4 700 EFI Owner's Manual (134 pages)

Polaris Industries Offroad Vehicle User Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 5.06 MB

Table of Contents
6
Vehicle Identification Numbers
7
Safety
8
- Safety Decals and Locations
  9
- Clutch Cover Warning
  9
- Operator Safety
  11
- Know Your Vehicle
  11
- Equipment Modifications
  16
Features and Controls
25
- Component Locations
  26
- Instrument Cluster
  28
- Rider Information Center
  29
- Clock Mode
  30
- Diagnostic Mode
  33
- Seat Removal
  36
- Seat Belts
  36
- Auxiliary Outlet
  37
- Mode Button
  37
- Gear Selector
  38
- Brake Pedal
  39
- Throttle Pedal
  39
- Ignition Switch
  40
- Light Switch
  40
Operation
41
- Starting the Engine
  43
- Stopping the Engine
  44
- Driving Safely
  45
- Driving on Slippery Surfaces
  46
- Driving Uphill
  47
- Driving Downhill
  48
- Driving through Water
  49
- Driving over Obstacles
  50
- Driving in Reverse
  51
- Parking on an Incline
  52
- Hauling Cargo
  53
- Dumping the Cargo Box
  55
- Towing Loads
  56
- Belt Life
  56
- Parking the Vehicle
  57
- Locking the Differential
  58
- Disengaging Awd
  59
Emission Control Systems
60
Severe Use Definition
61
Maintenance
61
- Periodic Maintenance Chart
  62
- Maintenance Chart Key
  62
- Lubrication Recommendations
  66
- Engine Oil
  68
- Oil Check
  69
- Oil and Filter Change
  70
- Gearcase Specification Chart
  71
- Rear Gearcase
  76
- Spark Plugs
  78
- Spark Plug Condition
  79
- Cooling System
  80
- Coolant Level
  81
- Radiator Coolant Level
  82
- Pvt System
  84
- Pvt Drying
  85
- Fuel Filter
  86
- Air Filter
  86
- Filter Systems
  86
- Spark Arrestor
  87
- Throttle System
  88
- Throttle Freeplay Adjustment
  89
- Brake Fluid
  90
- Brake Inspection
  91
- Steering Wheel Inspection
  92
- Tire Tread Depth
  94
- Wheel Removal
  95
- Wheel Installation
  95
- Headlight Lamp Replacement
  96
- Headlight Beam Adjustment
  97
- Vehicle Immersion
  98
- Conventional Battery
  99
- Battery Removal
  100
- Battery Installation
  101
- Battery Storage
  102
- Cleaning and Storage
  105
- Washing the Vehicle
  106
- Polishing the Vehicle
  106
- Fluid Levels
  108
- Oil and Filter
  108
- Battery Maintenance
  109
- Removal from Storage
  110

Polaris 4X4 700 EFI Owner's Manual (121 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 6.47 MB

Table of Contents
5
Know Your Vehicle
6
Vehicle Identification Numbers
6
Safety
7
- Operator Safety
  8
- Equipment Modifications
  12
Features and Controls
20
- Component Locations
  21
- Run-Flat Tires
  22
- Trailer Hitch Bracket
  22
- Fuel Cap
  23
- Fuel Requirements
  23
- Rear Box/Flatbed Conversion
  23
- Seat Belts
  24
- Seat Removal
  24
- Mode Button
  26
  - Slave Receptacles
    27
  - Steering Lock
    27
- Gear Selector
  28
- Headlight/Taillight Switch
  31
  - Winch Operation Switch
    31
  - Brake Pedal
    32
  - Throttle Pedal
    32
  - Park Brake Lever
    33
- Instrument Cluster
  34
- Rider Information Center
  35
- Programmable Service Interval
  39
Operation
42
- Pre-Ride Inspection
  43
  - Starting the Engine
    44
  - Stopping the Engine
    45
- Driving Procedure
  46
- Driving Safely
  46
- Driving on Slippery Surfaces
  47
- Driving Uphill
  48
- Driving Downhill
  49
- Driving through Water
  50
- Driving over Obstacles
  51
- Driving in Reverse
  52
- Parking on an Incline
  53
- Hauling Cargo
  54
- Dumping the Cargo Box
  56
- Towing Loads
  57
- Parking the Vehicle
  58
- Disengaging Awd
  59
- Locking the Differential
  60
- Severe Use Definition
  61
Maintenance
61
- Maintenance Chart Key
  62
- Lubrication Recommendations
  65
- Engine Oil
  67
- Oil Check
  68
- Oil and Filter Change
  69
- Gearcase Specification Chart
  70
- Rear Gearcase
  75
  - Spark Plug Inspection
    77
  - Spark Plugs
    77
  - Spark Plug Condition
    78
  - Cooling System
    79
- Radiator Coolant Level
  81
- Pvt System
  83
- Pvt Drying
  84
- Air Filter
  85
- Filter Systems
  85
- Fuel Filter
  85
- Spark Arrestor
  86
- Throttle Freeplay
  87
  - Throttle System
    87
  - Throttle Freeplay Adjustment
    88
  - Brake Inspection
    90
- Park Brake Cable Tension
  90
- Park Brake Inspection
  90
- Steering Wheel Inspection
  91
- Rear Spring Adjustment
  92
  - Suspension Adjustment
    92
  - Tire Tread Depth
    93
  - Wheel Installation
    94
  - Wheel Removal
    94
  - Vehicle Immersion
    95
- Headlight Lamp Replacement
  96
- Headlight Beam Adjustment
  97
  - Conventional Battery
    98
  - Battery Removal
    99
  - Battery Installation
    100
  - Battery Storage
    101
  - Cleaning and Storage
    104
- Polishing the Vehicle
  105
- Storage Tips
  106
- Battery Maintenance
  107
- Removal from Storage
  108
- Transporting the Vehicle
  109

Polaris 4X4 700 EFI Owner's Manual (131 pages)

Polaris Sales Ranger 4x4 700 EFI ATV Owner's manual

Brand: Polaris | Category: Motorcycle | Size: 8.68 MB

Table of Contents
6
Vehicle Identification Numbers
7
Safety
8
- Know Your Vehicle
  11
- Equipment Modifications
  16
Features and Controls
25
- Component Locations
  26
- Mode Button
  27
- Gear Selector
  28
- Ignition Switch
  29
- Light Switch
  30
- Seat Belts
  32
- Seat Removal
  33
- Storage Box
  33
- Fuel Cap
  33
- Brake Pedal
  34
- Instrument Cluster
  35
- Diagnostic Mode
  38
Operation
43
- Pre-Ride Inspection
  45
- Starting the Engine
  46
- Stopping the Engine
  47
  - Driving Procedure
    49
  - Driving on Slippery Surfaces
    50
  - Driving Uphill
    51
  - Driving Downhill
    52
  - Driving through Water
    53
  - Driving over Obstacles
    54
  - Driving in Reverse
    55
- Parking on an Incline
  56
  - Hauling Cargo
    57
  - Dumping the Cargo Box
    59
  - Towing Loads
    60
- Parking the Vehicle
  61
Disengaging Awd
63
Emission Control Systems
64
Maintenance
65
- Severe Use Definition
  65
- Periodic Maintenance Chart
  66
Engine Oil
71
Specifications
75
Gearcase Specification Chart
75
Polaris Products
77
- Spark Plugs
  79
- Cooling System
  81
- Radiator Coolant Level
  83
- Pvt Drying
  86
  - Vehicle Immersion
    87
  - Air Filter
    88
  - Fuel Filter
    88
  - Throttle Freeplay
    91
  - Throttle Freeplay Inspection
    91
  - Throttle System
    91
  - Throttle Freeplay Adjustment
    92
  - Brake Fluid
    93
  - Brake Inspection
    94
- Park Brake Adjustment
  95
- Steering Wheel Inspection
  95
  - Tire Tread Depth
    97
  - Wheel Installation
    98
  - Wheel Removal
    98
  - Headlight Lamp Replacement
    99
  - Headlight Beam Adjustment
    100
  - Battery Removal
    102
  - Battery Installation
    103
  - Battery Storage
    104
  - Cleaning and Storage
    107
- Polishing the Vehicle
  108
- Battery Maintenance
  110
- Oil and Filter
  110
- Fluid Levels
  111

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Polaris 4X4 700 EFI Service Manual (362 pages)

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