Polaris 4X4 700 EFI Service Manual

Text of Polaris 4X4 700 EFI User Guide:

• Polaris 4X4 700 EFI, FINAL DRIVE 7.1 CHAPTER 7 FINAL DRIVE 7 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 HUB REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• Polaris 4X4 700 EFI, 6.17 CLUTCHING 6 4. Install nut on puller rod and hand tighten. Turn barrel to apply additional tension if needed. 5. Turn sheave and barrel together counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7. Remove sheave from puller. 8. Remove installation tool. Clutch Cover - Bushing Removal 1. Install the Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386). 2. From outside of clutch cover, insert the Drive Cover Bushing Remover (#3) (PN 5020629) into cover bushing. 3. With inside of cover toward vise, slide cover onto puller. 4. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as n

• Polaris 4X4 700 EFI, 3.44 ENGINE 40. Remove balance shaft and crankshaft. 41. Remove and inspect crankshaft main journal bearings for abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled. Camshaft Inspection 1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing or damage. 3. Measure height of each cam lobe using a micrometer. Compare to specification. 4. Measure camshaft journal outside diameters (O.D.). = In. / mm. Cam Lobe Height (Intake & Exhaust): Std: 1.3334" (33.8674 mm) = In. / mm. Camshaft Journal O.D. : A. (Mag): 1.654" ± .00039" (42 ± .010 mm) B. (Ctr.): 1.634" ± .00039" (41.

• Polaris 4X4 700 EFI, 4.11 FUEL INJECTION 4 RANGER 700 EFI RPM Limit: Hard Limit - Injector suppression occurs • High: 6200 • Low: 6200 • Neutral: 6200 • Reverse: 6200 Soft Limit - Timing suppression occurs • High: None • Low: 5900 • Neutral: 5900 • Reverse: 5900 ECU Service Never attempt to disassemble the ECU. It is sealed to prevent damage to internal components. Warranty is void if the case is opened or tampered with in any way. All operating and control functions within the ECU are pre-set. No internal servicing or readjustment may be performed. If a problem is encountered, and you determine the ECU to be faulty, contact the Polaris Service Depart

• 9.19 BRAKES 9 3. Clean caliper area before removal. 4. Remove caliper mounting bolts and lift caliper off of disc. NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 5. Push caliper piston into caliper bore slowly with pads installed. NOTE: Brake fluid will be forced through compensating port into master

• Polaris 4X4 700 EFI, 5.20 BODY / STEERING / SUSPENSION SWING ARM (6X6) Removal 1. Support machine on a level surface. 2. Remove rear wheels. NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, “REAR AXLE HOUSING REMOVAL/INSPECTION”. 3. Support swing arm, remove rear axle shocks. 4. Drive spring pin out of rear propshaft at middle angle drive using the Roll Pin Removal Tool (PN 2872608). NOTE: Use jacks and jackstands to help remove the swing arm assembly. 5. Remove the pivot bolt lock brackets (A), swing arm pivot bolts (B), bolts swing arm bushings, lower swing ar

• Polaris 4X4 700 EFI, 4.18 FUEL INJECTION 3. If voltage varies with throttle movement, continue on to step 3 and measure the idle air flow reading. If the sensor does not function correctly, replace it. 4. With voltmeter still attached to the TPS Test Adapter Harness (PU-47082) as shown below, the voltmeter should read .710 ± .01 volts at idle position. 5. If the voltage does not read within the specification, “TPS Initialization” will need to be performed. TPS Initialization NOTE: The correct position of the TPS is established and set at the factory. Use this procedure only if the TPS was repositione

• Polaris 4X4 700 EFI, 3.23 ENGINE 3 ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Push Rods Hydraulic Lifters Valves Cylinder Head Valve Seals Springs Spring Retainers Rocker Arms Retainer Locks (keepers) Valve Spring Seats

• Polaris 4X4 700 EFI, 9.8 BRAKES PARKING BRAKE Exploded View Mount Cotter Pin Washer Spring Washer Bushings Pin Park Brake Sensor Switch Park Brake Lever Spring Latch Washer Brake Release Grommet Handle Nut Pin Clip Bolt Parking Brake Assembly Clip Pin Cable Park Brake Caliper Assembly Mount Bolt Rear Prop Shaft / Park Brake Disc Clip Pin Washer Pin Park Brake Handle / Lever Park Brake Assembly

• 2.29 GENERAL INFORMATION 2 Tire Pressure ELECTRICAL AND IGNITION SYSTEM Battery Maintenance Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric gre

• Polaris 4X4 700 EFI, 4.4 FUEL INJECTION Service Notes • For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench ™ Diagnostic Software (dealer only), or testing may be done manually using the procedures provided. • 80% of all EFI problems are caused by wiring harness connections. • For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris RANGER XP EFI of the same model may be used without damaging system or engine component

• 7.31 FINAL DRIVE 7 9. Inspect the pinion gear (K) and 26T output gear (L) for nics or uneven wear. Inspect the bearing (M), the bearing should spin smoothly. Replace the parts as needed. 10. Remove the rear output seal (N). 11. Remove the retaining ring (O) and shim (P) from the rear output thru shaft. 12. Carefully pull the output thru shaft (Q) through th

• Polaris 4X4 700 EFI, 3.5 ENGINE 3 Oil Filter / Pressure Relief / Dipstick Assembly Exploded View A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I . G a l l e y P l u g As m . J. Screw K. Relief Spring A B C D E F G H I J K 50  5 in. lbs. (5.65 0.56 Nm) 22  2 ft. lbs. (30  3 Nm) 18  2 ft. lbs. (24.4  2.71 Nm) 35  4 ft. lbs. (47.5  5.4 Nm) 50  5 in. lbs. (5.65  0.56 Nm)

• Polaris 4X4 700 EFI, 10.38 ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test With the tester on the VDC position, place the tester's black lead on the battery negative and the red lead on the battery positive. Reading should be 12.4 V D. C. or greater. Remove battery and properly service. Install fully charged shop battery to continue test. Disconnect coil engagement wire from the starter solenoid.

• Polaris 4X4 700 EFI, 9.23 BRAKES 9 Caliper Removal (6x6) 1. Safely support the rear of the machine. 2. Use a wrench to remove the brake line. Place a container to catch brake fluid draining from brake lines. 3. After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper. 4. Clean disc, caliper body, and pistons with brake cleaner or alcohol. Caliper Disassembly 1. Remove brake pad adjuster screw (A). 2. Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed. 3. Remove mounting bracket (B) and dust boot (C) 4. Remove piston (D) and square O-rings (E) from the caliper body (F). 5. Clean the caliper body, pis

• Polaris 4X4 700 EFI, 7.17 FINAL DRIVE 7 5. Inspect the rollers for nics and scratches. The rollers must slide up and down and in and out freely within the roll cage sliding surfaces. Gearcase Removal 1. Stop engine, place machine in gear and set parking brake. 2. Loosen right front wheel nuts slightly. 3. Elevate and support machine under footrest/frame area. 4. Remove right wheel nuts and wheel. 5. Remove cotter pin, lower ball joint nut, and A-arm from ball joint. 6. Repeat Step 1 through Step 5 on the opposite side. 7. Pull each axle out from the front gearcase, refer to the "FRONT DRIVE SHAFT REMOVAL" procedure earlier in this chapter. 8. The front gearcase and drive shafts can be

• Polaris 4X4 700 EFI, 10.18 ELECTRICAL 3. Remove the O-ring (A) from the headlamp brackets (both sides) 4. After the O-rings are removed from the headlamp, Remove the adjustment screw (B) and pull the headlamp from the brackets. Headlamp Housing Installation 1. To install the headlamp housing, press the headlamp tabs back into the brackets. 2. Secure the headlamp housing with the rubber O-rings on each side (A). Install the adjustment screw (B). 3. Reconnect wire harness or re-insert bulb if previously removed. 4. A

• Polaris 4X4 700 EFI, 3.3 ENGINE 3 Oil Pump / Water Pump / Engine Cover Exploded View A. Split Gear B. Washer C. Bolt D. Oil Rotor E. Oil Pump F. Mag Gasket Cover G. Impeller H. Washer I. Nut J. Counterbalance Gear K. Washer L. Bolt M. Oil Pump Bolts N. Engine Cover O. Wire Hold down P. Stator Housing Bolts A B C D E F G H J K L M N P 22  2 ft. lbs. (30  3 Nm) 84  8 in. lbs. (9.5 

• 3.33 ENGINE 3 Cylinder Inspection 1. Remove all gasket material from the cylinder sealing surfaces. 2. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. 3. Inspect cylinder for wear, scratches, or damage. 4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.

• Polaris 4X4 700 EFI, 10.14 ELECTRICAL TEST 4 - No AWD Hub Safety Limiter  5$,6( $79 :+((/6 2)) *5281' $1' 6833257 ,1 $ 6$)( 0$11(5  021,725 92/7$*( $7 +8% &2,/ &211(&725 %(7:((1 %52:1:+,7( $1' *5281' ,1 1(875$/ 72**/( 72 7$&+20(7(5 6(77,1*  5(9 (1*,1( +2/' 817,/ ',63/$< 67$%,/,=(6 '2(6 ,7 $33($5 $&&85$7(" ,6 63(('2 )81&7,21,1* &255(&7/<" < &+(&. 63(('2 7(67   5(029(  3,1 &211(&725 )520 %$&

• 7.55 FINAL DRIVE 7 Axle Tube Bearing Replacement 1. Remove the retaining ring from the axle tube. 2. Remove the bearings from the axle tube with a bearing puller. Inspect the bearing contact surfaces in the axle tube. 3. Install the new bearing using a press. NOTE: The bearing should be properly lubricated before installation. 4. Reinstall the retaining ring. Gearcase Disassembly / Inspect

• Polaris 4X4 700 EFI, 1.9 GENERAL INFORMATION 1 V P NOTE: NOTE: www.purepolaris.com. Paint Codes Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX

More Instructions:

	Polaris 4X4 700 EFI Owner's manual 29-09-2022 134	DOWNLOAD
	Polaris 4X4 700 EFI Owner's manual 09-02-2024 121	DOWNLOAD

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