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8.1

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

TRANSMISSION

CHAPTER 8

TRANSMISSION

TRANSMISSION - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

LUBRICATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

TRANSMISSION FRAME MOUNTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

TRANSMISSION UPPER FRAME MOUNT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

TRANSMISSION REAR STABILIZER MOUNTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

TRANSMISSION CONTROL ARM BRACKET MOUNTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

SHIFT LINKAGE INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7

GEAR SELECTOR REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

TRANSMISSION REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

TRANSMISSION INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

TROUBLESHOOTING CHECKLIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9

TRANSMISSION DISASSEMBLY / ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10

TRANSMISSION DISASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10

SNORKEL / OUTPUT GEAR BACKLASH PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16

TRANSMISSION ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18

SPORTSMAN TRANSMISSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.25

Summary of Contents for 2014 Sportsman 570 EF

Page 1: ...orized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manua...

Page 2: ...rmation by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCT S MENTIONED...

Page 3: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEM GENERAL 5 BODY STEERING SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION 9 BRAKES 10 ELECTRICAL...

Page 4: ......

Page 5: ...ICLE INFORMATION 1 5 PUBLICATION PART NUMBERS 1 5 REPLACEMENT KEYS 1 5 SPECIAL TOOLS 1 5 VEHICLE SPECIFICATIONS 1 6 2014 SPORTSMAN 570 EFI EPS 1 6 2014 SPORTSMAN FOREST 570 EFI EPS 1 7 2014 SPORTSMAN...

Page 6: ...used on color featured versions of models not including the base First 3 digits and 9th digit are used in model number only They are not used with the 17 digit VIN Digits 1 through 8 determine Digital...

Page 7: ...l number and serial number are important for vehicle identification Be sure to refer to the engine model number and serial number whenever corresponding about an engine This information can be found o...

Page 8: ...portsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc Transmission I D Location The Transmission I D number is located on the RH side of the transmission case visible from the RH side of th...

Page 9: ...riginal 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 Should both keys become lost ignition switc...

Page 10: ...imum Turning Radius 65 in 165 cm unloaded Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc SPORTSMAN 570 EFI EPS CATEGORY DIMENSION CAPACITY Bore x Stroke 99mm x 73 6mm Al...

Page 11: ...nder Displacement 567 cc SPORTSMAN FOREST 570 EFI EPS CATEGORY DIMENSION CAPACITY Bore x Stroke 99mm x 73 6mm Alternator Output 560 W 7000 RPM Idle RPM 1200 100 Compression Ratio 10 1 Starting System...

Page 12: ...Radius 82 in 208 3 cm unloaded Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73 6mm Alternator Output 560 W 7000 RPM SPORTSMAN TOURING 570 EFI EPS...

Page 13: ...NG 570 EFI EPS CATEGORY DIMENSION CAPACITY Minimum Turning Radius 82 in 208 3 cm unloaded Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73 6mm Alte...

Page 14: ...ING DRIVEN CLUTCH SPRING HELIX Meters Feet 0 1800 0 6000 25 52G PN 5632409 Black PN 7043594 Non EBS Black PN 7041782 EBS Red PN 3234451 EBS PN 3234356 Non EBS PN 5132344 1800 3700 6000 12000 25 48 PN...

Page 15: ...h inch x 2 54 cm mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb...

Page 16: ...69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Metric Bolt Torque Specification BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LBS NM DRY THREADS M3 3 5 5 7...

Page 17: ...56 45 3 4 10 21 32 4 40 43 3 4 16 11 16 4 48 42 7 8 9 49 64 5 40 38 7 8 14 13 16 5 44 37 1 8 7 8 6 32 36 1 12 59 64 6 40 33 1 1 8 7 63 64 8 32 29 1 1 8 12 1 3 64 8 36 29 1 1 4 7 1 7 64 10 24 24 1 1 4...

Page 18: ...0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 11 64 5 x 90 20 0 161 5 32 6 x 1 00 9 0 196 13 64 7 x 1 00 16 64 0 234 15 64 8 x 1 00 J 0 277 9 32 8 x 1 25 17 64 0 265 17 64 9 x 1...

Page 19: ...16 0 1875 5 mm 0 1969 13 64 0 2031 7 32 0 2188 15 64 0 2344 6 mm 0 2362 1 4 0 25 17 64 0 2656 7 mm 0 2756 9 32 0 2813 19 64 0 2969 5 16 0 3125 8 mm 0 3150 21 64 0 3281 11 32 0 3438 9 mm 0 3543 23 64 0...

Page 20: ...6 0 6875 45 64 0 7031 18 mm 0 7087 23 32 0 7188 47 64 0 7344 19 mm 0 7480 3 4 0 750 49 64 0 7656 25 32 0 7813 20 mm 0 7874 51 64 0 7969 13 16 0 8125 21 mm 0 8268 53 64 0 8281 27 32 0 8438 55 64 0 8594...

Page 21: ...TEM TRS SWITCH ADJUSTMENT 2 12 AIR FILTER PRE FILTER SERVICE 2 13 AIR BOX SEDIMENT DRAIN 2 14 CRANKCASE BREATHER VALVE HOSE 2 15 ENGINE 2 16 ENGINE OIL LEVEL 2 16 OIL AND FILTER CHANGE 2 16 COMPRESSIO...

Page 22: ...N 2 30 BRAKE PAD INSPECTION 2 30 HOSE FITTING INSPECTION 2 30 AUXILIARY BRAKE TESTING 2 31 AUXILIARY BRAKE ADJUSTMENT HYDRAULIC 2 31 ELECTRICAL AND IGNITION SYSTEM 2 32 BATTERY MAINTENANCE 2 32 BATTER...

Page 23: ...9924871 R03 2014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc SPECIAL TOOLS Bosch Automotive Service Solutions 1 800 328 6657 or http polaris service solutions com MAINTE...

Page 24: ...aner element check for dirt or water clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolt...

Page 25: ...oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Ch...

Page 26: ...heck often if operating in wet conditions D Brake pad wear 10 H Monthly 100 160 Inspect periodically Battery 20 H Monthly 200 320 Check terminals clean test E Engine breather filter if equipped 25 H M...

Page 27: ...park plug 100 H 12 M 1000 1600 inspect replace as needed Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive...

Page 28: ...tank fuel lines and injectors should be completely drained of gasoline Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never st...

Page 29: ...Oil Pump for 1 Gallon Jug Coolant 2871323 60 40 Coolant 1 Gallon 3 8 l 6 Count 2871534 60 40 Coolant Quart 95 l 12 Count Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Seaso...

Page 30: ...nd grease Semi annually A 6 Rear A Arm Polaris All Season Grease Locate fitting and grease Semi annually A 7 Propshafts Polaris U Joint Grease C Locate fitting and grease Semi annually A Perform more...

Page 31: ...components when removing fuel filter Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is perform...

Page 32: ...ver starting on the 1 position 7 Twist screwdriver slightly while lifting on the cover to release snap 8 Repeat procedure at the other five locations as shown NOTE Do not attempt to remove cover until...

Page 33: ...e sure the slots in the seat engage the tabs in the fuel tank 3 Remove clips 1 from air box cover and remove cover 2 Inspect the gasket It should adhere tightly to the cover and seal all the way aroun...

Page 34: ...1 2 Proper placement of the air filter is important to prevent rattles and air leaks See Illustration above 11 Install air box cover and secure with the clips Air Box Sediment Drain Periodically check...

Page 35: ...ntly through the valve to check for clogging Replace a damaged or clogged valve NOTE In line breather filter service life is extended when the foam air box pre filter is in place and maintained proper...

Page 36: ...l between checks in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is over the full mark change the oil Oil and Filter Change Always change the oil and fil...

Page 37: ...y cloth clean filter sealing surface on the crankcase 13 Lubricate the o ring on new filter with a thin film of engine oil Check to make sure the O ring is in good condition 14 Install the new filter...

Page 38: ...on should be performed on a cold engine at room temperature 1 Remove the seats and disconnect the negative battery cable 2 Remove the air box cover and PVT ducting tubes Non Touring models require fue...

Page 39: ...earance is out of specification proceed to Valve Clearance Adjustment see Chapter 3 Intake Valve Clearance cold 006 002 in 0 152 050 mm Exhaust Valve Clearance cold 008 002 in 0 203 050 mm 10 Repeat s...

Page 40: ...ve the clean out plugs located on the bottom of the muffler 2 Place the transmission in Park and start the engine Purge accumulated carbon from the system by momentarily revving the engine several tim...

Page 41: ...from the left side of transmission and visually inspect the oil level Level is correct when it reaches the bottom of the fill hole threads NOTE The check fill plug is a 5 16 hex To Change Lubricant 2...

Page 42: ...icle is level before proceeding and in PARK Check vent hose to be sure it is routed properly and unobstructed The correct front gearcase lubricant to use is Polaris Demand Drive PLUS Hub Fluid Specifi...

Page 43: ...nd drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug A using a new sealing washer B Torque to specification 3 Remove fi...

Page 44: ...ottle With the engine at operating temperature the coolant level should be between the upper and lower marks on the coolant reservoir If not 1 Remove reservoir cap Inner splash cap vent hole must be c...

Page 45: ...using a restriction to coolant flow Radiator hose clamp torque is 36 in lbs 4 Nm Cooling System Pressure Test System Pressure Test 1 Remove radiator cap cover located under the storage box access pane...

Page 46: ...em to freeze corrode or overheat Polaris 60 40 Anti Freeze Coolant PN 2871323 Coolant Drain Fill Coolant Drain 1 Remove the front cover located under the front rack right inner fender and footwell pla...

Page 47: ...9 Remove the pressure cap Using a funnel add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level 10 Refer to Chapter 3 for the Cooling System Bleeding...

Page 48: ...30 ft lbs 1 4 Turn 41 Nm 1 4 Turn Aluminum Rear Wheel Nuts 30 ft lbs 1 4 Turn 41 Nm 1 4 Turn Front Hub Retaining Nut 60 ft lbs 81 Nm Rear Hub Retaining Nut 80 ft lbs 109 Nm Tire Pressure CAUTION Main...

Page 49: ...d Depth Always replace tires when tread depth is worn to 1 8 3 mm or less WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily with possible loss of co...

Page 50: ...ervoir to the indicated level inside reservoir Use Polaris DOT 4 Brake Fluid Use Polaris DOT 4 Brake Fluid Check brake for excessive travel or spongy feel Check brake system for fluid leaks Check fric...

Page 51: ...ulic auxiliary foot brake system and adjust or bleed if necessary First check foot brake effectiveness by applying 50 lb approx downward force on the pedal The top of the pedal should be at least 1 in...

Page 52: ...edical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT O...

Page 53: ...fe It can also hinder vehicle performance Follow the battery charging procedure in Chapter 10 Electrical before installing the battery CAUTION To reduce the chance of sparks Whenever removing the batt...

Page 54: ...ative battery cable from the battery WARNING A hot exhaust system and engine can cause serious burns Allow engine to cool or wear protective gloves when removing the spark plugs 2 Clean top of engine...

Page 55: ...k plug threads 10 Install spark plugs and torque to specification Recommended Spark Plug Champion RG6YC Spark Plug 7 ft lbs 10 Nm Apply Anti seize 11 Install spark plug wire into spark plug engine 12...

Page 56: ...nent repair and adjustment be performed by an authorized MSD certified technician when replacing worn or damaged steering parts Use only genuine Polaris replacement parts Tie Rod End Steering Inspecti...

Page 57: ...llowing precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold tie rod end to keep it from rota...

Page 58: ...the measurement Call this measurement A 5 Rotate the tires 180o by moving vehicle forward or backward Position chalk marks facing rearward even with the hub axle centerline 6 Again measure the distan...

Page 59: ...TEM SPECIFICATIONS 3 15 COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM 3 16 COOLING SYSTEM PRESSURE TEST 3 17 PRESSURE CAP TEST 3 17 RADIATOR 3 18 COOLANT DRAIN RADIATOR REMOVAL 3 18 THERMOSTAT...

Page 60: ...VALVE SEALING TEST 3 57 VALVE CLEARANCE CHECK ADJUSTMENT 3 58 INTAKE VALVE LASH TAPPET SELECTION MATRIX 3 61 EXHAUST VALVE LASH TAPPET SELECTION MATRIX 3 62 CAMSHAFT INSTALLATION TIMING 3 63 CAMSHAFT...

Page 61: ...EFI Service Manual Copyright 2013 Polaris Sales Inc ENGINE ASSEMBLY LOWER END 3 83 CRANKCASE ASSEMBLY PTO SIDE 3 83 BALANCE SHAFT INSTALLATION TIMING 3 85 FINAL CRANKCASE ASSEMBLY 3 85 TROUBLESHOOTING...

Page 62: ...er Use With 2 375 Bore Stand PA 49316 Flywheel Puller PU 50105 Oil Filter Wrench PV 43531 Oil Pressure Gauge PU 50569 Oil Pressure Gauge Adapter PA 49317 Stator Cover Removal Handles PV 1253 or PV 401...

Page 63: ...sure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 at operating tempe...

Page 65: ...inder Head Standard Height 4 745 0 0020 120 53 0 05 mm Valve Seat Contacting Width Intake Standard 0 0393 0 0039 1 0 0 10 mm Contacting Width Intake Service Limit 0 0551 1 4 mm Contacting Width Exhaus...

Page 66: ...Ring Installed Gap Top Ring Standard 0 0059 0 0122 0 15 0 31 mm Top Ring Service Limit 0 0137 0 35 mm Second Ring Standard 0 0094 0 0196 0 24 0 50 mm Second Ring Service Limit 0 0220 0 56 mm Oil Contr...

Page 67: ...924871 R03 2014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc ENGINE DETAIL TORQUE VALUES SEQUENCES ASSEMBLY NOTES Main Engine Components Torque Specification and Sequence...

Page 73: ...utdown 257 F 125 C ITEM SPECIFICATION Cooling System Capacity 4 25 qts 4 l Pressure Cap Relief 13 PSI Polaris Premium Antifreeze 2871534 Quart 2871323 Gallon Recommended Coolant Use only high quality...

Page 74: ...E ENGINE LOWER 20 FITTING BARBED 90 DEG 5 HOSE BYPASS FORMED 21 HOSE CLEAR 6 CONNECTOR TEE 22 LINE FUEL 7 CLAMP SPRINGBAND BLACK 23 SPRING COOLANT HOSE GUIDE 8 CLAMP HOSE SPRING 24 BUSHING MOUNT LOWER...

Page 75: ...ure cap and pressure test the cooling system using a commercially available pressure tester 3 The system must maintain 10 psi for five minutes or longer If pressure loss is evident within five minutes...

Page 76: ...and radiator are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 2 Slowly remove the pressure cap 1 to relieve any cooling system pressure 3 Place a suitable drain pan...

Page 77: ...e cooling system is under pressure and serious burns may result Allow the engine to cool before servicing 2 Remove front rack front cab and fuel tank not required for touring models 3 Remove the press...

Page 78: ...engine has cooled and no pressure is built up in the cooling system before removing the pressure cap The coolant may be hot and could cause severe injury or burns 2 Remove Left side panel required PVT...

Page 79: ...12 Open the bleed screw to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 13 Tighten the bleed screw to specification top off coolant and pro...

Page 80: ...2 and water pump cover gasket 3 Discard the water pump gasket 3 10 Using an 8mm socket remove the water pump impeller 4 NOTE The water pump impeller 4 uses reverse LH threads 11 Inspect the water pump...

Page 81: ...ter pump cover gasket 3 Discard the water pump gasket 3 13 Remove the water pump impeller 4 NOTE The water pump impeller 4 uses reverse LH threads 14 Remove the bolts 5 securing the stator cover 6 to...

Page 82: ...ift remove the water pump drive shaft Be sure not to damage the threads Inspect shaft for wear or damage replace if necessary 19 Extract the mechanical seal E and the oil seal F from the stator cover...

Page 83: ...clean the stator cover 2 Press in a new water pump drive shaft bearing G until it is fully seated in the cover CAUTION Be sure bearing is fully seated in cover or severe engine damage may result 3 Cle...

Page 84: ...6 Lubricate the new water pump oil seal with clean engine oil 7 Use the water pump oil seal installation tool in kit PU 50869 to fully install the new water pump oil seal I CAUTION Be sure the oil se...

Page 85: ...d in stator cover installation 14 While installing the stator cover to the engine slightly rotate the water pump impeller to verify the crankshaft slot and the water pump drive shaft blade are properl...

Page 86: ...ure the installed height of the new mechanical seal as shown below If not within specification remove and discard the mechanical seal and properly install new mechanical seal as outlined in this chapt...

Page 87: ...wire connector and securing the wiring to the front engine mount bracket 23 Install the CPS sensor into the stator cover Inspect CPS O ring and replace if needed 24 Install the seat right side panel...

Page 88: ...nd Rings Flywheel Starter Motor Idler Gear Asm Stator Alternator Thermostat Valve Cover Water Pump Camshaft Timing Chain and Guides Crankshaft Seal PTO Oil Pump Oil Pump Sprocket or Chain The followin...

Page 89: ...o perform any work 2 Thoroughly clean the engine and chassis 3 Disconnect the negative battery cable from the battery prior to engine removal see Battery Removal page 2 32 4 Drain the engine oil See O...

Page 90: ...jector harness lead 7 from the fuel injector 14 Properly relieve fuel pressure from the fuel rail 15 Place a shop to beneath the fuel line quick connector to catch any excess fuel Disconnect the fuel...

Page 91: ...the top of the engine forward until the top of the cylinder head is facing the front of the vehicle 29 With the help of an assistant lift the engine and rotate it out the frame opening at the left sid...

Page 92: ...t previously installed under the transmission case during the engine removal process 5 Have an assistant help lift and rotate the engine into the frame 6 Install the rear engine mount fasteners IMPORT...

Page 93: ...the head pipe assembly in the chassis and install new exhaust seals Install the head pipe bolts and torque to specification if removed Exhaust Head Pipe Bolts 18 ft lbs 24 5 Nm 15 Install the springs...

Page 94: ...o specification as outlined in Chapter 6 See CLUTCH ALIGNMENT page 6 13 29 Install the PVT inlet exhaust ducts and the airbox top 30 Remove the pressure cap and fill the cooling system through the fil...

Page 95: ...n build up and cause damage to close fitted engine parts 1 Fill fuel tank with unleaded fuel which has a minimum pump octane number of 87 R M 2 2 Refer to Chapter 2 Engine Oil Level Check oil level in...

Page 96: ...NE REAR 2 ISOLATOR Replace if excessively worn or damaged 3 TUBE ISOLATOR REAR 4 ISOLATOR RUBBER Replace if excessively worn or damaged 5 MOUNT ENGINE FRONT LH CAST 6 MOUNT ENGINE REAR CAST 7 MOUNT EN...

Page 97: ...tat housing removed rotate the engine so the cam lobes are facing outward and the Cylinder Holding and Camshaft Timing Plate PU 50563 can be installed into the slots of the camshafts as shown below Th...

Page 98: ...over from the engine and remove it out of the right hand rear wheel well area 5 Replace isolators B and valve cover seal C if oil leaks are evident 6 Remove the spark plug D Stuff spark plug hole with...

Page 99: ...camshafts NOTE The crankcase has a lower guide to prevent the chain from falling off the crankshaft 5 Attach a hook or other tool to the camshaft chain to prevent it from dropping down into the engine...

Page 100: ...haft Sprocket Bolt 33 ft lb 45 Nm Camshaft Inspection Inspect all main journals and cam lobes as described below and compare to specifications Replace camshafts or cylinder head if worn beyond service...

Page 101: ...cover flywheel cam chain tensioner cam carrier and camshafts as outlined in this chapter 2 Remove the two fasteners 1 that secure the cam chain guides 2 to the crankcase 3 Remove the fastener 3 that s...

Page 102: ...n working with the valve springs NOTE Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes It is important to install cylinder head componen...

Page 103: ...us steps to remove the remaining valves 8 Clean the combustion chamber and head gasket surface Cylinder Head Inspection Thoroughly clean cylinder head surface to remove all traces of gasket material a...

Page 104: ...NOTE The valves can be re faced or end ground if necessary They must be replaced if extensively worn burnt bent or damaged 6 Measure diameter of valve stem with a micrometer in three places then rotat...

Page 105: ...ovided by the valve reconditioning equipment manufacturer Do not grind seats more than necessary to provide proper seat surface width and contact point on valve face WARNING Wear eye protection or a f...

Page 106: ...e seat If using an interference angle 46 apply black permanent marker to the entire valve face A 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where t...

Page 107: ...to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five ti...

Page 108: ...inder Taper Limit 001 Max 0 025 mm Cylinder Out of Round Limit 001 Max 025 mm Standard Bore Size 3 8976 0 0003 99 0 0 008 mm Piston Removal 1 Note piston directional indicator EX positioned toward the...

Page 109: ...ton O D 3 8957 3 8968 98 953 98 980 mm Piston Rod Inspection 1 Measure piston pin bore inside diameter I D Item 1 Piston Pin Bore Std 0 8662 0 8665 22 004 22 010 mm Service Limit 0 8651 21 975 mm 2 Me...

Page 110: ...0 0007 0 0029 020 0 076 mm Service Limit 0 0035 0 89 mm Piston Ring Installed Gap 1 Place each piston ring inside cylinder Use a piston to push the ring squarely into place 1 25 4 mm down from the cyl...

Page 111: ...red or cylinder centered on arbor and to bring the stone approximately 1 2 1 3 cm beyond the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if i...

Page 112: ...r in oil ring groove Rotate expander in groove until butt ends are on PTO side of piston see illustration 1 NOTE Ends must butt squarely together and must not overlap 2 Install lower rail with end gap...

Page 113: ...A on connecting rod B Push piston pin C through rod and piston until it seats against the installed circlip NOTE Do not tap on pin or cause any sideways force to connecting rod Warm piston crown with...

Page 114: ...he engine to avoid damage to the chain drive sprocket teeth or tensioner blade Cylinder Head Installation NOTE Head gasket and surfaces must be DRY and oil free Use care during assembly to keep oil an...

Page 115: ...c Valve Sealing Test 1 Clean and dry the combustion chamber area A 2 Pour a small amount of clean solvent into each intake port B and check for leakage around the valves The valve seats should hold fl...

Page 116: ...during disassembly If installing new camshafts or if camshafts were not marked you can reference the part number stamped on the end of the shafts 3 Lubricate the camshaft bearing journal surfaces with...

Page 117: ...e the valve tappet Item 1 from a valve that was out of specification NOTE Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes Mark each com...

Page 118: ...Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc 20 If all valve clearance measurements are now within specification remove the camshaft carriers and proceed to Camshaft Insta...

Page 119: ...525 528 530 532 535 538 540 542 545 0 376 0 400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 401 0 425 468 470...

Page 120: ...515 518 520 522 525 528 530 532 535 538 540 542 0 401 0 425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545...

Page 121: ...aris PS 4 Plus engine oil prior to installation 4 Place the exhaust cam into the cylinder head and align the timing marks as shown below 5 Wrap the cam chain around the exhaust cam sprocket and hold t...

Page 122: ...g Plate PU 50563 into the end of camshafts as shown 10 Verify cam timing is correct and the piston is a TDC 11 If timing marks are not aligned Remove the Camshaft Timing Plate PU 50563 from the end of...

Page 123: ...s in sequence to specification Camshaft Carrier Bolts 8 ft lb 11 Nm 15 Insure the new sealing washer G is in place 16 Install the hydraulic cam chain tensioner H into the cylinder and torque to specif...

Page 125: ...t lbs 19 Nm 2 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 3 Apply a small amount of crankcase sealant to the cylinder head half moon cutouts E as shown Crankcase...

Page 126: ...cover service 2 Remove starter drive gear and shaft 4 Inspect gear teeth for damage Inspect fit of shaft inside gear and replace gear assembly if clearance is excessive Inspect shaft and shaft bearin...

Page 127: ...heel assembly 7 Remove the 3 one way clutch retaining bolts 8 Remove clutch and inspect both sides of drive rollers B and roller contact surface C inside hub for wear damage or uneven surface 9 Inspec...

Page 128: ...to remove all oil or grease 3 Apply Loctite 272 on the 3 bolts Place hub on flywheel and install 3 bolts 4 Torque screws to specification One Way Clutch Retaining Bolts 9 ft lbs 12 Nm Apply Loctite 27...

Page 129: ...e continuity before removing it from the housing 1 Remove the stator cover as outlined in the Water Pump Mechanical Seal Oil Seal Replacement procedure in this chapter CAUTION The flywheel contains po...

Page 130: ...9 Nm Apply Loctite 242 7 Install a new stator cover gasket into the engine 8 Install the stator cover as outlined in this chapter CAUTION The flywheel contains powerful magnets Use caution when insta...

Page 131: ...ets if sprocket teeth are worn NOTE The larger oil pump sprocket mounts to the balance shaft extension the smaller oil pump sprocket mounts to the oil pump shaft 5 Remove the upper oil pump sprocket s...

Page 132: ...engine oil to all parts Do not use gasket sealer on the pump cover mating surfaces 2 Align the gerotor according to the orientation dots 3 Place the drive pin A through the oil pump drive shaft 4 Sli...

Page 133: ...de crank case by clean all mating surfaces 13 Apply a thin film of Crankcase Sealant PN 2871557 evenly to a clean and oil free MAG crankcase mating surface 14 Install the inter mag crankcase bolts fin...

Page 134: ...rated be sure the entire top end water pump stator flywheel and oil pump assembly are removed from the engine as outlined in this chapter 1 Remove the engine from the engine stand and lay it on a tabl...

Page 135: ...place the balance shaft bearings in both crankcase halves See Crankcase Bearing Inspection Removal procedure in this chapter NOTE Due to extremely close tolerances and minimal wear counterbalance shaf...

Page 136: ...crew C into adapter B 5 With the help of an assistant holding the crankshaft slowly tighten the screw C until the crankcase is completely separated from the crankshaft 6 Remove all special tools from...

Page 137: ...is not groved pitted damaged or excessively worn PTO Side Crankcase Bearing Service WARNING Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel Look...

Page 138: ...s 1 Clean all bearing bores and inspect for excessive wear 2 Lubricate all bearing bores with clean engine oil 3 Fully seat the new balance shaft bearing until bottomed in the bearing bore 4 Install t...

Page 139: ...nner race should be firm with minimal side to side movement and no detectable up and down movement Bearings are stressed during the removal process and must not be re used Installation 2 Clean all bea...

Page 140: ...e the O ring and lubricate with clean engine oil 7 Install the oil pressure valve into the crankcase torque to specification Oil Pressure Regulator 20 ft lbs 2 ft lbs 27 Nm 3 Nm 8 Install the oil pres...

Page 141: ...the PTO side crankcase Install plate A over adapter B Evenly attach the assembly onto the PTO side crankcase using the four bolts as shown Place the nut and large washer onto the crankshaft installati...

Page 142: ...fold back when moving over the crankshaft flange 10 Use the crankshaft removal installation tool PU 50784 to properly drive the crankshaft seal into the crankcase Center plate A over the crankshaft s...

Page 143: ...crankcase by cleaning sealing surface Be sure the oil pickup and oil pressure valve are fully installed 2 Apply a thin film of Crankcase Sealant PN 2871557 evenly to a clean and oil free MAG crankcase...

Page 144: ...30 Nm 8 Install the engine stand adapter PU 50824 A onto the engine ears as shown below 9 Select the proper engine stand sleeve adapter and install it onto the engine stand adapter Sleeve adapter for...

Page 145: ...Will Not Idle Restricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Ai...

Page 146: ...ections in ignition system Ignition timing incorrect Sheared flywheel key Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system lea...

Page 147: ...SENDER TANK LINES 4 13 OPERATION OVERVIEW 4 13 FUEL PUMP TEST 4 14 FUEL PUMP REPLACEMENT 4 15 FUEL TANK EXPLODED VIEW 4 19 FUEL SENDER TEST 4 20 FUEL TANK REMOVAL 4 20 FUEL TANK INSTALLATION 4 21 FUEL...

Page 148: ...DIAGNOSTICS 4 34 INSTRUMENT CLUSTER TROUBLE CODE DISPLAY 4 34 EFI TROUBLESHOOTING 4 37 DIGITAL WRENCH OPERATION 4 39 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 39 SPECIAL TOOLS 4 39 DIAGNOSTIC SOFT...

Page 149: ...same model and year may be used without damaging system or engine components Never attempt to service any fuel system component while engine is running or ignition switch is on Cleanliness is essenti...

Page 152: ...olute Pressure Sensor T MAP Located in the rubber intake boot between the throttle body and the cylinder head 3 Crankshaft Position Sensor CPS Located in the magneto cover on the right hand side of th...

Page 153: ...essed with the left seat side panel and the PVToutlet ducting removed 10 Ignition Coil located behind the left side panel Special Tools PART NUMBER TOOL DESCRIPTION PU 43506 A Fuel Pressure Gauge Kit...

Page 154: ...e even when the engine is not running Before attempting to service any part of the fuel system pressure must be relieved if applicable The Fuel Pressure Gauge Kit has an integrated pressure relief val...

Page 155: ...ule Kit PU 47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the followi...

Page 156: ...e controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cylinder is injected during each cycle W...

Page 157: ...is exceeded the ECU suppresses the injection signals cutting off the fuel flow and retards the ignition timing This process repeats it self in rapid succession limiting operation to the preset maximum...

Page 158: ...he connector locking lever and rotate it up until the connector is free from the ECU NOTE Upon removing the ECU connector you should hear a click when the connector is fully open 5 To install reverse...

Page 159: ...s two non serviceable fuel filters When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off the pump preventing the continued...

Page 160: ...tor PV 48656 Route the clear hose into a portable gasoline container or the vehicle s fuel tank 5 Turn on the key switch to activate the pump and check the system pressure on the gauge If system press...

Page 161: ...e 3 Ensure that static has been discharged from you by touching a ground source such as the engine or frame 4 Disconnect the fuel pump electrical harness 1 5 While holding a shop towel over the fuel l...

Page 162: ...ure that the float arm is not bent when removed from the tank 9 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 10 Inspect the inside...

Page 163: ...does not get caught or bent during installation 15 Gently push down on fuel pump flange ensuring flange is centered 16 Roughly align orientation mark on fuel pump between the orientation marks on fuel...

Page 164: ...fuel pump and tank orientation marks 20 Connect the fuel line to the fuel pump outlet NOTE Be sure to engage the retainer on fuel line until it snaps into place Pull on fuel line lightly to confirm c...

Page 166: ...stance If out of specification replace the fuel pump assembly Fuel Sender Resistance Specifications Full 6 1 Empty 90 4 5 Fuel Tank Removal NOTE Syphon as much fuel from the tank as possible before at...

Page 167: ...ling out the top inlet Fuel Tank Installation 1 Carefully reinstall the fuel tank assembly 2 Reinstall the fuel tank brackets and fasteners 3 Install the fuel line vent hose and clamp Verify they are...

Page 168: ...he T MAP sensor provides the ECU with engine load data T MAP Sensor Test The T MAP sensor is a non serviceable item If it is faulty it must be replaced NOTE This sensor should only be tested using the...

Page 169: ...and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for...

Page 170: ...CPS Test 2 Using an 8mm socket remove the CPS retaining bolt and remove the sensor from the stator cover 3 Install new sensor using a light coating of oil on the O ring to aid installation 4 Torque t...

Page 171: ...t touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only run...

Page 172: ...lean the fuel injector area if all dirt and debris 5 Disconnect the fuel injector harness lead 6 Hold a shop towel over the fuel line fittings and remove the fuel supply line from the fuel rail 7 Remo...

Page 173: ...or O rings and reinstall the fuel rail injector assembly into the cylinder head 14 Install the fuel rail mounting screws and torque to specification Fuel Rail Mounting Screws 7 ft lbs 10 Nm 15 Reinsta...

Page 174: ...ch tested using the following method Set your meter to read Ohms Check the resistance values at each of the following pin locations of the IAC If any of the readings are out of specification replace t...

Page 175: ...screw controls the air flow calibration of the throttle body If the stop screw is repositioned or adjusted the throttle body assembly must be replaced TPS Resistance Tests The TPS is a non serviceabl...

Page 176: ...face cable to the vehicle to allow Digital Wrench use see Digital Wrench Diagnostic Connector 6 Select the appropriate vehicle and open the data display grid Click on the meter icon next to TPS Volts...

Page 177: ...ts during operation The ECU also uses this signal to determine when to activate the fan during operation ECT Sensor Test To quickly rule out other components and wiring related to the ECT disconnect t...

Page 178: ...et ducting to access the ECT sensor 3 Drain coolant to level below sensor 4 Disconnect sensor from engine harness 1 5 Using a wrench remove and replace the sensor 2 applying a light coating of thread...

Page 179: ...s signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces...

Page 180: ...code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three number...

Page 181: ...aft Position Sensor CPS Plausibility Fault 636 2 P0335 Injector 1 MAG Driver Circuit Open Grounded 651 5 P0261 Driver Circuit Short to B 3 P0262 Driver Circuit Grounded 4 P1262 Rear Differential Outpu...

Page 182: ...1519 Driver Circuit Grounded 4 P1518 Idle Air Control Valve IAC M17 IAC Stepper Pin 4 Driver Circuit Open Grounded 520269 5 P1525 Driver Circuit Short to B 3 P1529 Driver Circuit Grounded 4 P1528 Idle...

Page 183: ...ouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirt...

Page 184: ...38 9924871 R03 2014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc Engine worn Spark Plug fouled Throttle stop screw set incorrectly out of sync with ECU FUEL SYSTEM GENERA...

Page 185: ...RS 232 Commercially Available refer to diagnostic software user manual or HELP section for minimum requirements Diagnostic Software Version Always use the most current version of the Digital Wrench s...

Page 186: ...e diagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble the SmartLink Module and attach the PC Interface Cable to your laptop see page 4 3 2 Remove the protective cap from t...

Page 187: ...h see Digital Wrench Updates NOTE Always operate with the latest update Digital Wrench Updates Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench w...

Page 188: ...e link shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or open the file from where they are Select save and download them to your...

Page 190: ...ast 12 5 volts with the key ON Connect a battery charger if necessary to bring voltage level above minimum Fully charge the battery before you attempt to reprogram DEDICATED LAPTOP Best results are ob...

Page 191: ...not familiar with the reprogramming process review the Reprogramming Reflash Tips before you begin Follow the on screen instructions as you progress through the steps If you encounter a problem alway...

Page 192: ...I Service Manual Copyright 2013 Polaris Sales Inc 4 Select the model year product line and vehicle description by selecting the Change Vehicle Type icon 5 Select the Special Tests icon 6 Select Engine...

Page 193: ...CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be invalid NOTE All characters are letters there are no number...

Page 194: ...upper left corner of the screen Copy CTRL C this key exactly as it appears 14 Enter or paste CTRL C the Authorization Key in the box located on the Digital Wrench screen Click the Continue button and...

Page 195: ...ER ASSEMBLY 5 9 FRONT CAB ASSEMBLY 5 10 REAR RACK ASSEMBLY 5 12 REAR CAB SEAT AND FOOTWELL ASSEMBLY 5 16 REAR STORAGE BOX ASSEMBLY 5 22 WINCH AND FRONT BUMPER MOUNTING 5 23 HEADLIGHT POD EXPLODED VIEW...

Page 196: ...lt 17 27 Tie Rod End Jam Nut 12 17 Tie Rod End Castle Nut 45 61 Tie Rod End Attaching Bolt 24 33 Upper Shock Mounting Bolt 37 50 Lower Shock Mounting Bolt 37 50 NOTE Refer to exploded views throughout...

Page 197: ...firm motion pull the side panel outward to remove the side panel 6 Reinstall the side panel by reversing the removal procedure Front Storage Box Lid Front Rack and Access Panel Removal Installation 1...

Page 198: ...Removal Installation 1 Remove the plastic inserts 2 that secure the footwell to the front fenders 2 Remove the screws 11 that secure the footwell to the rear fenders 3 Remove the screws 5 from the bo...

Page 199: ...the front fenders 5 Remove to 2 T27 bolts that attache the upper front bumper to the frame 6 Disengaged the 4 plastic tabs from the front fender that engage into the upper front bumper by gently pres...

Page 200: ...screws C that attach the front cab to the frame in the front rack area 5 Remove the seat and side panels refer to the SIDE PANEL REMOVAL section 6 Remove the plastic inserts D that secure the front o...

Page 201: ...bumper as outline in this chapter 2 Locate the mud guards in the front wheel area 3 Remove the 1 T27 bolt and the 3 plastic rivets per side 4 Remove the wheel well from the vehicle frame 5 Reverse th...

Page 205: ...TES 1 ASM CAB FRONT 2 PANEL SIDE LH 3 COVER FRONT 4 ASM PANEL FOIL RH 5 FOIL SIDE PANEL 6 SCREW 7 CLIP 8 SCREW 9 GUARD SPLASH RH 10 SCREW 11 GUARD SPLASH LH 12 RIVET 13 WASHER FLAT 14 SEAL BULB 15 PLU...

Page 207: ...aris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc RE F PART DESCRIPTION NOTES 1 ASM RACK REAR 2 TUBE SUPPORT FRONT 3 TUBE SUPPORT REAR 4 CLIP U SPEED NUT 5 SCREW 6 NUT FLANGE NYLO...

Page 209: ...t 2013 Polaris Sales Inc RE F PART DESCRIPTION NOTES 1 ASM RACK REAR 2 TUBE SUPPORT FRONT 3 TUBE SUPPORT REAR 4 CLIP U SPEED NUT 5 SCREW Torque fastener until fully seated 6 NUT FLANGE NYLOK 7 ASM HAN...

Page 211: ...anual Copyright 2013 Polaris Sales Inc REF PART DESCRIPTION NOTE 1 ASM SEAT 2 RIVET 3 FOOTWELL BLACK LH 4 FOOTWELL BLACK RH 5 SCREW 6 NUT NYLOK 7 BUMPER RUBBER 8 ASM CAB REAR 9 BUMPER SEAT 10 GROMMET...

Page 213: ...nc REF PART DESCRIPTION NOTE 1 ASM SEAT OPERATOR 2 BUMPER RUBBER 3 ASM COVER W DECAL 4 GROMMET SEAT LATCH 5 SUPPORT SEAT BACK BLACK 6 ASM PASSENGER SEAT BACK 7 ASM PASSENGER SEAT BACK COVER 8 PLATE SE...

Page 215: ...Inc REF PART DESCRIPTION NOTE 1 ASM CAB REAR 2 FOIL CAB REAR 3 FOOTWELL BLACK LH 4 FOOTWELL BLACK RH 5 SCREW Torque until full seated 6 NUT NYLOK Torque until full seated 7 RIVET 8 FOOTWELL PASSENGER...

Page 218: ...tion switch C and choke cable D Remove headlight F with adjuster Remove two screws securing bottom half of pod E Assembly Install bottom of pod onto handlebar and secure to brackets Install key switch...

Page 219: ...ING POST AND LOCK INTL Steering Assembly Exploded View International units are equipped with a steering locking mechanism to prevent theft or unauthorized use Refer to the standard torque specificatio...

Page 220: ...side of the blocks after the procedure is performed Steering Post Removal 1 Remove the front cab 2 Remove the handle bar pod 3 Remove the handle bar 4 Remove the fuel tank bracket assembly 5 Remove th...

Page 221: ...esses from the power steering unit 6 Remove the fasteners retaining the upper steering post bushing bracket 7 Lift the upper steering post up from the power steering unit 8 Remove the 4 mounting faste...

Page 222: ...hand but do not torque fasteners at this time 6 Reconnect the 2 electrical harnesses to the power steering unit 7 Align the mark on the upper steering post nut side with the skip tooth spline on the u...

Page 223: ...ation Steering Post to Bulkhead Bolts 20 ft lbs 27 Nm 13 Turn the ignition key to the ON position and move the handlebar from left to right several times to ensure the power steering doesn t bind If b...

Page 225: ...G 6 BUSHING UPPER STEERING 7 SCREW 8 SCREW 9 BOLT CARRIAGE 10 BOLT 30 ft lbs 10 41 Nm 10 11 NUT FLANGE NYLOK 18 ft lbs 10 24 Nm 10 20 ft lbs 10 27 Nm 10 at joint attaching EPS mount to frame 12 NUT FL...

Page 227: ...teering A arm Exploded View NOTE To avoid damage to tie rods and other steering components be sure to install tie rod end bolts in the proper direction The steering post arm bolt B points up the rod e...

Page 228: ...lbs 50 Nm WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 9 Attac...

Page 229: ...and turn nut I clockwise until ball joint is removed from strut housing 13 To install a new ball joint Remove extension cap and attach puller guide using short bolts provided in the kit 14 Remove ext...

Page 230: ...n Bar Exploded View REF DESCRIPTION NOTE 1 BOLT FLANGE 2 NUT FLANGE 17 ft lbs 23 Nm 3 WASHER 4 BUSHING STABILIZER TUBE BLACK 5 BAR STABILIZER TUBE BLACK 6 ARM STABILIZER BAR BLACK 7 SCREW 30 ft lbs 40...

Page 233: ...ercially available spring compressor tool and remove the spacer nut 4 Remove coil spring and collapse strut cartridge 5 Remove two pinch bolts from strut casting 6 Remove strut cartridge 7 Install car...

Page 234: ...The following procedure involves the use of an open flame Wear the appropriate safety equipment at all times Perform this procedure in a well ventilated area away from gasoline or other flammable mat...

Page 235: ...MBLY 6 10 ASSEMBLY 6 11 DRIVE BELT 6 12 BELT REMOVAL 6 12 BELT INSPECTION 6 12 BELT INSTALLATION 6 12 PVT BREAK IN DRIVE BELT CLUTCHES 6 12 CLUTCH ALIGNMENT 6 13 CLUTCH ALIGNMENT TOOL USE 6 13 BELT DE...

Page 236: ...ING SERVICE 6 30 MOVEABLE SHEAVE BUSHING INSTALLATION 6 32 CLUTCH ASSEMBLY 6 33 DRIVEN CLUTCH SERVICE EBS 6 35 EXPLODED VIEW 6 35 CLUTCH DISASSEMBLY 6 36 BUSHING SERVICE 6 39 CLUTCH ASSEMBLY 6 41 DRIV...

Page 237: ...nch 2871358 Clutch Holding Fixture 2870341 Drive Clutch Spider Removal and Install Tool 2870910 Roller Pin Tool 2871226 Clutch Bushing Replacement Tool Kit 2870386 Piston Pin Puller PU 50518 Universal...

Page 238: ...ward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low...

Page 239: ...ges The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area in the crankcase casting drawing air into the system through an intake duct The openi...

Page 240: ...and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in m...

Page 241: ...6 6 7 9924871 R03 2014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc PVT EXPLODED VIEWS Drive Clutch Exploded Views EBS vs Non EBS NON EBS Clutch EBS Clutch CLUTCHING...

Page 243: ...tener Until Fully Seated 7 Washer Inner clutch Cover 8 Outer Clutch Cover 9 O ring Replace if cracked or damaged 10 Clutch cover Drain Plug 12 Outer Clutch Cover Baffle WARNING Do not operate the vehi...

Page 244: ...ews 4 Mark the drive belt direction of rotation and remove drive belt See Drive Belt Removal Drive Clutch Puller PN 2870506 Drive Clutch Holder PN 9314177 A 5 Install the Drive Clutch Holder PN 931417...

Page 245: ...ines inside driven clutch and on the transmission input shaft 8 Apply a light film of grease to the splines on the shaft 9 Install the driven clutch washer lock washer and retaining bolt Torque to spe...

Page 246: ...thin spots or excessive wear Compare belt measurements with a new drive belt Replace if necessary 3 Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT...

Page 247: ...clearance of roughly 020 between the tool and stationary sheave of the drive clutch 9 If the alignment tool hits the stationary sheave before it reaches the shaft bearing the driven clutch will need t...

Page 248: ...eflection Add shims to increase belt deflection Refer to Driven Clutch Service section At least one shim must remain between the inner and outer sheave of the driven clutch If proper belt deflection c...

Page 250: ...r bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more...

Page 251: ...ee length from the outer coil surfaces Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requiring replacement Drive Clutch Spring Speci...

Page 252: ...lon is visible on the bushing Refer to bushing replacement in this chapter Roller Pin and Thrust Washer Inspection Inspect all rollers bushings and roller pins by pulling a flat metal rod across the r...

Page 253: ...clockwise and counter clockwise directions Non EBS The non braking bearing should rotate both directions on the shaft with only a slight amount of drag EBS The one way bearing should rotate clockwise...

Page 254: ...ted 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged Shaft Diameter Sta...

Page 255: ...Tool all clutches 5020629 5 1 P 90 Driven Clutch Cover Bushing Removal Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 NOTE Bushings ar...

Page 256: ...place on sheave 15 Insert installation puller tool Item A B with A side down into center of bushing 16 NOTE 800 EFI Clutch Use Bushing Tool PA 47336 17 With towers pointing upward slide sheave bushing...

Page 257: ...y oil or grease to the bushings Reassemble the drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly 1 Install the VESPEL w...

Page 259: ...oval Installation Tool all clutches 5 1 5020631 P 90 Driven Clutch Cover Bushing Removal Tool 8 1 5020632 Main Puller Adapter 9 1 5010279 Adapter Reducer 10 1 5020633 Number Two Puller Adapter Bosch A...

Page 260: ...eave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Drive Clutch Bushing Installation 12 Place mai...

Page 261: ...oved and cover comes free 29 Remove nut from puller rod and set aside 30 Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 31 Apply Loctite 648 evenly to b...

Page 263: ...elease the assembly CAUTION Wear eye protection when removing snap ring to prevent serious personal injury 2 Remove snap ring retainer 3 Note the location of the spring and remove helix 4 Note the loc...

Page 264: ...o the Bushing Service section 9 Inspect driven clutch faces for wear or damage 10 Clean and inspect splines on helix and transmission input shaft 11 Lube splines with a light film of grease Do not lub...

Page 265: ...rious burns wear heat resistant insulated gloves for the rest of the removal process 5 Working from the top install Driven Clutch Bushing Removal Tool 5 PN 5020631 into the center of clutch sheave wit...

Page 266: ...eave onto puller with new bushing upward as shown Install Puller Adapter 10 PN 5020633 4 Install nut onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclockwise un...

Page 267: ...o proper hole in helix The driven clutch helix moveable assembly has several different spring locations which affect clutch shifting and RPMs The greatest amount of spring tension will raise engine RP...

Page 268: ...ice Manual Copyright 2013 Polaris Sales Inc 6 Place the clutch into the Universal Clutch Compressor Tool PU 50518 Press down on the top of the spider assembly pushing the spider onto the shaft Install...

Page 270: ...x side 2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in assembly and maintains clutch balance...

Page 271: ...e D and spider dampener E Inspect the spider dampener E for wear and replace if needed 8 Remove the E clips F washers G and the clutch rollers H Inspect the rollers for wear replace if worn 9 Remove t...

Page 272: ...ng does not spin smoothly replace it To replace the bearing remove the snap ring from the end of the shaft and press the bearing off the shaft 14 Inspect the cam helix assembly bushing for wear If the...

Page 273: ...0 Driven Clutch Cover Bushing Removal Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 NOTE Bushings are installed at the factory using L...

Page 274: ...apter Item 9 onto puller 13 Apply Loctite 609 evenly to bushing bore inside moveable sheave 14 Install sheave face down on puller 15 Install new bushing on installation tool Item 2 and install assembl...

Page 275: ...ly seated install a new snap ring 2 Install the shaft and bearing assembly into the outer sheave NOTE Press only on the outer race of the bearing during installation to prevent damaging the bearing 3...

Page 276: ...shaft 8 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should spin freely 9 Install the spider dampener G insi...

Page 277: ...retaining ring 14 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam...

Page 278: ...all clutches 5020629 5 1 P 90 Driven Clutch Cover Bushing Removal Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 Bosch Automotive Servi...

Page 279: ...Discard bushing Clutch Bushing Installation 11 Install puller adapter Item 10 onto puller 12 Install adapter Item 9 onto puller 13 Apply Loctite 648 evenly to bushing bore inside moveable sheave 14 I...

Page 280: ...clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct recommende...

Page 281: ...errain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation...

Page 283: ...OTING FRONT GEARCASE NON ADC 7 15 SETTING RING GEAR BACKLASH NON ADC 7 16 FRONT DRIVE CV SHAFT 7 17 INSPECTION 7 17 REMOVAL 7 17 INSTALLATION 7 19 REAR HUB 7 20 REMOVAL 7 20 DISASSEMBLY 7 21 ASSEMBLY...

Page 284: ...ICATION Steel Front and Rear Wheel Nuts 27 ft lbs 37 Nm Aluminum Front and Rear Wheel Nuts 30 ft lbs 1 4 Turn 41 Nm 1 4 Turn Front Hub Retaining Nut 60 ft lbs 81 Nm Rear Hub Retaining Nut 80 ft lbs 10...

Page 285: ...imal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no d...

Page 286: ...nt wheel nuts and wheel 4 Remove cotter pins lower ball joint nuts and A arms from the ball joints 5 Pull the hub and strut assembly out and pull the drive shaft out of the gearcase 6 Remove the rolle...

Page 287: ...tall gearcase reverse removal procedures Use a new roll pin in front prop shaft 2 Torque mounting bolts in skid plate to specification Gearcase Mounting Bolt 37 ft lbs 50 Nm 3 Add the proper lubricant...

Page 289: ...11 Gear Spacer 1 31 Screw 1 12 Ring Gear Assembly 1 32 Oil Seal 2 13 Bushing non serviceable see parts book 1 33 Roller 20 14 Input Cover 1 34 H Clip 20 15 O ring square style 1 35 Roll Cage 1 16 Reta...

Page 290: ...input which creates a magnetic field This magnetic field attracts an armature plate that is keyed to the roll cage When the ring gear and roll cage are spinning vehicle is moving the energized coil an...

Page 291: ...the outer cover plate Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or damaged 5 Remove and inspect the armature plate Re...

Page 292: ...ughly clean all parts Inspect the bearing surfaces of the output hub Inspect the rollers A for nicks scratches and flat spots Inspect the roll cage B for damage or cracks The rollers must slide up and...

Page 293: ...t Gearcase NON ADC later in this chapter for more details on the coil The backlash for the centralized hilliard is set at the factory No adjustment is required unless the front cover is replaced or th...

Page 294: ...tput and pinion shafts To replace press new bearing onto shaft NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by ha...

Page 295: ...rollers and roll cage into the ring gear Insert the rollers as the roll cage is installed 8 Install the ring gear and roll cage assembly into the gearcase housing 9 Install the torsion spring by wrapp...

Page 296: ...sting on the cut grooves of the ring gear NOTE Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves 13 Install the output hub and cover plate assembly...

Page 297: ...80 12 0 Vdc 3 Inspect the armature plate for a consistent wear pattern There should be two distinct wear bands one band inside the other If only one band of wear is present or if there is wear between...

Page 298: ...that holds it into place Use a heat gun to lightly heat up the locking agent on the screw 2 Using a hex wrench turn the back lash screw out 3 4 turns Re apply Loctite 262 onto the bottom screw threads...

Page 299: ...cap if equipped 2 Remove cotter pin 3 Loosen but do not remove the hub retaining nut 4 Loosen but do not remove the wheel nuts 5 Safely lift and support the front of the ATV CAUTION Serious injury co...

Page 300: ...l joint fork tool 11 Pull strut assembly out while pivoting the CV drive shaft away until it clears the strut assembly 12 Pull outward sharply on CV shaft assembly to remove it from the gearcase In so...

Page 301: ...with soft faced hammer 2 Install drive shaft in strut 3 Install lower ball joint torque nut to specification and install new cotter pin Ball Joint Retaining Nut 30 ft lbs 41 Nm 4 Install hub and tigh...

Page 302: ...ear hub cap 2 Remove cotter pin A 3 Loosen the hub retaining nut B 4 Loosen the wheel nuts C 5 Safely support the rear of the ATV 6 Remove wheel nuts and wheel 7 Remove the rear brake caliper and safe...

Page 303: ...by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 3 Inspect bearing NOTE Due to extremely close tolerances and minimal wear th...

Page 304: ...ing 3 Press bearing into place until outer race bottoms on housing CAUTION Use an arbor press only on the outer race to avoid bearing damage 4 Install snap ring into groove Installation 1 Insert beari...

Page 305: ...on Upper Control Arm Bolt 37 ft lbs 50 Nm 5 Pull drive shaft outward and install hub onto driveshaft splines Apply anti seize to the splines 6 Install cone washers with domed side facing outward 7 Ins...

Page 306: ...Remove upper carrier bolt Tip hub outward and remove shaft from carrier 3 Pull sharply outward to remove shaft from transmission Install a new compression ring and apply an anti sieze compound to the...

Page 307: ...ification Install new cotter pin and hub cap Rear Hub Nut 80 ft lbs 109 Nm 6 Install brake caliper and tighten bolts to specification Refer to Chapter 9 7 Install rear wheel and torque wheel nuts to s...

Page 308: ...2014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc CV DRIVE SHAFT SERVICE Drive Shafts and Propshafts Components NOTE Refer to your parts manual for the proper replacement...

Page 309: ...n components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots...

Page 310: ...the joint should be replaced 8 Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 9 Visually inspect...

Page 311: ...soft faced hammer to tap the joint onto the drive shaft until it locks into place 16 Pull on the joint to make sure it is securely locked in place 17 Remove excess grease from the CV joint s external...

Page 312: ...om the plunging joint and slide the boot down the shaft 3 Clean the grease from the face of the joint 4 Place the drive shaft in a soft jawed vise 5 Using a soft faced hammer or brass drift strike the...

Page 313: ...roove machined in the shaft 12 Install a NEW circlip on the end of the shaft 13 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls...

Page 314: ...ed or collapsed 20 Install and tighten the small clamp using the Axle Boot Clamp Tool 8700226 or PU 48951 Axle Boot Clamp Tool 8700226 or PU 48951 21 Pull out on the drive shaft to center the joint in...

Page 316: ...from prop shaft at rear of housing front only or transmission output shaft rear only Slide prop shaft back and away from housing then pull sharply forward to remove from transmission shaft 2 For inst...

Page 317: ...ing caps NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting if equipped and mark inner and outer yoke for correct re positioning during installation 2...

Page 318: ...y seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedu...

Page 319: ...FRAME MOUNT 8 4 TRANSMISSION REAR STABILIZER MOUNTS 8 5 TRANSMISSION CONTROL ARM BRACKET MOUNTS 8 6 SHIFT LINKAGE INSPECTION 8 7 GEAR SELECTOR REMOVAL 8 8 TRANSMISSION REMOVAL 8 8 TRANSMISSION INSTAL...

Page 320: ...2 3 6 Snorkel Torx Screw 8 12 11 17 Bearing Cover 8 12 11 17 Carrier Cover 23 27 33 39 Shift Fort Retainer Screws 8 12 11 17 Park Plate 8 12 11 17 Special Tools PART NUMBER TOOL DESCRIPTION 2871695 Pa...

Page 321: ...ris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc Transmission Frame Mounts 1 Frame Long Bolt 37 10 ft lbs 50 13 Nm 2 Side Fasteners 37 10 ft lbs 50 13 Nm 3 Frame Long Bolt 20 10 f...

Page 322: ...aris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc Transmission Upper Frame Mount 1 Upper Bracket to Frame Fasteners 37 10 ft lbs 50 13 Nm 1 Bracket to Transmission Bolt 37 10 ft l...

Page 323: ...Service Manual Copyright 2013 Polaris Sales Inc Transmission Rear Stabilizer Mounts 1 Stabilizer to Frame Fasteners 20 ft lbs 27 Nm 2 Stabilizer to Transmission Bolt 37 ft lbs 50 Nm 3 Stabilizer to Tr...

Page 324: ...8 6 9924871 R03 2014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc Transmission Control Arm Bracket Mounts Bracket Fasteners 37 ft lbs 50 Nm TRANSMISSION...

Page 325: ...pect shift linkage rod bushing clips and replace if worn or damaged Lubrication of rod ends is not required REF DESCRIPTION NOTES 1 COVER SHIFT 2 SCREW 3 KNOB GEAR SELECTOR 4 BUSHING SNAP LINKAGE 5 WA...

Page 326: ...eners from each side 14 Remove the upper transmission support bracket completely from the ATV 15 With the help of an assistant lift and remove transmission out of rear of frame while pulling the outpu...

Page 327: ...Polaris AGL Plus Gearcase Lubricant to the proper level See Chapter 2 for proper fill procedures and Torque Specifications Polaris AGL Gearcase Lubricant PN 2878068 12 oz PN 2878069 Gallon Troublesho...

Page 328: ...E clip C that retains the gear selector switch D and remove the switch 6 Remove the sector cover bolts E and remove the sector cover F NOTE Removal can be aided by using your thumbs to press down on t...

Page 329: ...mission 12 Note location of chain tensioner cam N If fully extended chain is worn beyond service limit and should be replaced along with the chain tensioner shoe 13 Remove the cam chain tensioner spri...

Page 330: ...Using a T27 Torx driver remove the screws that secure the output gear U 17 Remove the shift drum V from the gearcase by moving the drum up and to the right to clear the shift shaft 18 Remove the outp...

Page 331: ...ller see Figure 8 1 23 Remove the 33T gear and needle bearing from the reverse shaft see Figure 8 1 24 The reverse shaft should slide out of the silent chain to separate the assembly 25 Remove the res...

Page 332: ...when disassembling the shift rail The compressed springs on the shift rail may pop off causing eye or face injury Snorkel Shaft Removal Disassembly 30 Using a T27 Torx driver remove the snorkel tube l...

Page 333: ...e from the snorkel shaft 35 Remove the snap ring and shim retaining the bearing in the snorkel tube 36 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 37 To remove...

Page 334: ...small amount of white lithium grease on the threads of the snorkel tube 3 Install the snorkel shaft into the gearcase Using the Snorkel Tool PA 50231 tighten the snorkel tube about 10 full rotations D...

Page 335: ...ding or excess lash tighten or loosen the snorkel shaft until there is zero lash Do not overtighten the snorkel tube Gears should rotate freely without binding 8 Look down into the gearcase at the sno...

Page 336: ...ew to specification Snorkel Locking Screw 8 12 ft lbs 11 16 Nm 13 With the snorkel shaft assembly properly installed remove the 4 Torx screws and remove the output shaft assembly Transmission Assembly...

Page 337: ...n a flat surface and measure the length of 8 pitches in a minimum of three places on the chain Replace the chain if the measurement is longer than the service limit Silent Chain Service Limit 8 pitch...

Page 338: ...ar Retaining Screws 8 12 ft lbs 11 16 Nm 7 Install the oil deflector shield into the gearcase Apply Loctite 242 to the threads of the screws Torque the screws to specification Oil Deflector Retaining...

Page 339: ...e and place them into the transmission Insert the front pin through the tensioner cam and the rear pin through the tensioner shoe Place the spring over the front pin and hook the spring leg under the...

Page 340: ...stall the seals into the gearcase halves refer to the following illustration to identify the seals needing replacement 12 Thoroughly clean the shift shaft housing Be sure the transmission is in Revers...

Page 341: ...e raised edge facing outward 16 Install the detent pawl onto the shift shaft and carefully install the compression spring 17 Install a new O ring on each shift shaft Apply a small amount of white lith...

Page 342: ...splined on the bellcrank and shift shaft Install the nut and torque to specification Bellcrank Nut 12 18 ft lbs 16 24 Nm 20 Install the shift shaft onto the bellcrank end if removed and secure with th...

Page 344: ...ng Ring 55 1 Retaining Ring 16 1 Shim 56 1 Sector Gear 16 T 17 1 Ball Bearing 57 1 Detent Star 18 1 Center Drive Shaft 58 1 O Ring 19 1 Retaining Ring 59 1 Snorkel Shaft 20 1 Thrust Washer 60 1 Ball B...

Page 345: ...14 REMOVAL 9 14 INSTALLATION 9 14 FRONT BRAKES 9 15 PAD REMOVAL 9 15 ASSEMBLY 9 16 BRAKE BURNISHING PROCEDURE 9 17 FRONT BRAKE DISC 9 18 INSPECTION 9 18 REMOVAL REPLACEMENT 9 19 FRONT CALIPER 9 20 RE...

Page 346: ...OVERVIEW 9 34 REAR MASTER CYLINDER EXPLODED VIEW ALL MODELS 9 34 REAR MASTER CYLINDER REMOVAL INSTALLATION 9 35 PEDAL REMOVAL AND INSTALLATION 9 35 TROUBLESHOOTING 9 36 BRAKES SQUEAL 9 36 POOR BRAKE P...

Page 347: ...er Some special procedures are used when torquing certain bolts and fasteners Component Service Limits FRONT BRAKE CALIPER All Models ITEM STANDARD SERVICE LIMIT Brake Pad Thickness 290 7 6 mm 180 4 6...

Page 348: ...014 Polaris Sportsman 570 EFI Service Manual Copyright 2013 Polaris Sales Inc Special Tools PN 2870975 Mity Vac Bosch Automotive Service Solutions 1 800 328 6657 or online at http polaris service solu...

Page 349: ...oir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the b...

Page 350: ...systems use only Polaris DOT approved brake fluid WARNING Once a bottle is opened use what is necessary and discard the rest in accordance with local laws Do not store or use a partial bottle of brake...

Page 351: ...the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the h...

Page 352: ...d press down on the cap to be sure it fits evenly and snug 14 Torque the screw to specification Master Cylinder Cover Screw 7 in lbs 0 79 Nm 15 Field test machine at low speed before putting into serv...

Page 358: ...on 1 Install master cylinder on handlebars Torque mounting bolts to specification Torque the inner bolt first as indicated in the illustration below Master Cylinder Mount Bolt 25 in lbs 3 Nm Torque In...

Page 359: ...ve the wheel 3 Loosen pad adjuster screw 2 3 turns 4 Remove caliper from mounting bracket 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brak...

Page 360: ...Pad Thickness Service Limit 180 4 6 mm Assembly 1 Lubricate mounting bracket pins with a light film of disc brake caliper lube and install rubber dust boots 2 Compress mounting bracket and make sure d...

Page 361: ...ff 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheels and torque wheel nuts It is required that a burnishing proc...

Page 362: ...rent points around the pad contact surface Replace disc if worn beyond service limit Brake Disc Thickness Service Limit 140 3 556 mm Brake Disc Thickness Variance Service Limit 002 051 mm between meas...

Page 363: ...bolts 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install disc on hub 5 Insta...

Page 364: ...remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 2 Push upper pad retainer pin inward and slip brake pads past edge Loosen pad adjuster 3 Remove mo...

Page 365: ...aged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad replacement in this section See BRAKE PAD INSPECTION earlier in this chapter Reassembly 1 Install new cali...

Page 366: ...r grease Installation 1 Install caliper on hub strut and torque mounting bolts to specification Brake Caliper Mounting Bolt 18 ft lbs 24 Nm 2 Install brake line and torque the banjo bolt to specificat...

Page 367: ...ke 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 the caliper bore slowly using a C clamp or lockin...

Page 368: ...he service limit Rear Brake Pad Thickness Service Limit 180 4 6 mm Touring Pad Installation 1 Lubricate mounting bracket pins with a light film of disc brake caliper lube and install rubber dust boots...

Page 369: ...stall the adjuster screw and turn clockwise until the stationary pad contacts the disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to the MAX line inside reservoir...

Page 370: ...installed 6 Remove the caliper slide pins and remove the brake pads from the caliper 7 Clean the caliper with brake cleaner or alcohol 8 Measure the thickness of the pad material Replace pads if worn...

Page 371: ...ssure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder 6 It is recommended that a burnishing procedure be performed afte...

Page 372: ...brake fluid draining from brake lines 3 Remove the two caliper mounting bolts and the caliper 4 Remove the slide bolt snap rings A the slide pins B the bracket pad C and the brake pads D 5 Remove the...

Page 373: ...nd replace if necessary 11 Inspect surface of caliper piston for nicks scratches or damage and replace if necessary Assembly 1 Install new O rings in the slide bolt bushing holes Be sure O ring and se...

Page 374: ...35 ft lbs 41 48 Nm 4 Install caliper and torque mounting bolts to specification Caliper Mounting Bolt 16 18 ft lbs 22 24 Nm 5 Install brake line and tighten securely with a line wrench Torque the brak...

Page 375: ...fall Severe injury may occur 1 Clean caliper area before removal 2 Place a container below the caliper to catch brake fluid that will drain from the brake line Remove brake line from caliper 3 Remove...

Page 376: ...D Service Limit 1 193 30 30 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined f...

Page 377: ...to remove any dirt oil or grease REAR BRAKE DISC Inspection 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Use a micrometer and measure d...

Page 378: ...cylinder fluid reservoir Make sure the brake lever and pedal returns freely and completely Adjust stop pin on caliper if applicable after pad service Check and adjust master cylinder reservoir fluid...

Page 379: ...install the rear brake master cylinder mount the master cylinder to the mount plate and torque bolts to specification Master Cylinder to Frame Bolt 8 ft lbs 11 Nm 5 Reinstall the brake line and torque...

Page 380: ...c and or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Improper clearance between lever and switch Lever Vibration Disc dam...

Page 381: ...OPERATION OVERVIEW 10 17 DIAGNOSING SYSTEM FAILURES 10 17 SPEED SENSOR 10 19 SPEED SENSOR LOCATION 10 19 SPEED SENSOR TESTING 10 19 TESTING 10 20 REPLACEMENT 10 20 THROTTLE RELEASE SWITCH TRS 10 21 T...

Page 382: ...10 41 CONVENTIONAL BATTERY INSPECTION REMOVAL 10 41 CONVENTIONAL BATTERY INSTALLATION 10 42 CONVENTIONAL BATTERY TESTING 10 42 CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE TEST 10 42 CONVENTIONAL BAT...

Page 383: ...TOOL DESCRIPTION PV 43568 Fluke 77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness Polaris MDX 610P SPX PN PU...

Page 384: ...les Inc Ignition System Basic Electrical Components REF PART DESCRIPTION NOTE 1 ECU 2 Starter Solenoid 3 Battery 12 volt 4 Starter 5 Fuse Box 6 Terminal Block 7 Diagnostic Connector 8 Voltage Regulato...

Page 385: ...PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of th...

Page 386: ...s NOTE Some features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the ATV by hand or with a garden hose using mild soap Certain products in...

Page 387: ...ts 7 Engine Temperature Indicator LED icon illuminates when the ECM determines the engine is overheating The indicators will initially flash to indicate the engine is overheating The indicators will s...

Page 388: ...trol acts as the MODE button when pressed and released quickly The transmission cannot be in reverse when using the override button as a MODE button Odometer The odometer records and displays the tota...

Page 389: ...When the service interval reaches 0 the LCD wrench icon will flash for approximately 10 seconds each time the key is turned ON To change the hour setting or reset the function follow these steps 1 To...

Page 390: ...1 Toggle the MODE button until the odometer is displayed 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance...

Page 391: ...en Standard and Metric units of measurement follow these steps 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes t...

Page 392: ...e and a high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If volt...

Page 393: ...l CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers will appear in the information display area The first num...

Page 394: ...opyright 2013 Polaris Sales Inc Instrument Cluster Pinouts FUNCTION PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 International Mod...

Page 395: ...nality can be indicated by the following items not working on the instrument cluster No engine speed displayed No vehicle speed displayed No gear position displayed Odometer Tripmeters not working Rev...

Page 396: ...can be accessed through the RH wheel well area 2 Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector Do not pull on the wiring 3 Test the transmissio...

Page 397: ...res Verify the AWD switch is functional Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter AWD Hub Coil Resistance 24 5 Verify the wiring harness wiring connectors connecto...

Page 399: ...Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect...

Page 400: ...and replace as required Replacement of sensor is required as it is not serviceable Speed Sensor Test Using Special Tools Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 Rep...

Page 401: ...be closed touching When the throttle lever is moved the contacts will open and allow normal operation If the contacts remain closed or become closed during throttle movement the ECM will limit engine...

Page 402: ...fan should start running 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition for proper operation refer to FAN MOTOR CURRENT DRAW in this section Repair or repla...

Page 403: ...and temperature sensor at room temperature 68 F 20 C disconnect the harness connector 2 With the meter in the ohms mode place the meter leads onto the sensor contacts 3 Use the Temperature Resistance...

Page 404: ...ter the five minutes you will need to cycle the key switch and restart the engine to regain power steering operation The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indica...

Page 406: ...tion will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 Vdc per connection or component To perform the test place the meter on DC volts and p...

Page 407: ...for a maximum of 5 seconds With the solenoid energized resistance should read about 0 0 5 Ohms between terminals A and B If resistance measurement is out of specification replace the starter solenoid...

Page 408: ...ER SYSTEM TESTING FLOW CHART Condition Starter fails to turn motor NOTE Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system A digital multitester must...

Page 409: ...he battery should be fully charged before performing this test WARNING Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will result Do not run test for exte...

Page 410: ...2 Resistance Value of Stator Leg to Ground 2 Measure the resistance value of each of the stator legs to ground Y1 to Ground Y2 to Ground Y3 to Ground NOTE Any measurement other than Infinity open will...

Page 411: ...in the left front wheel well area in front of the left front wheel behind the left front inner fender NOTE If the regulator rectifier overheats the unit will turn itself off to cool down The unit will...

Page 412: ...ual Copyright 2013 Polaris Sales Inc Charging System Testing Flow Chart Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in go...

Page 413: ...Slowly tilt invert the tank so that gravity moves the sender float to the full position the meter should now read 90 ohms 6 If the readings are not between 6 ohms and 90 ohms or if the reading is erra...

Page 414: ...ket counter clockwise and remove 5 Carefully remove headlamp bulb from housing 6 Remove the headlamp and replace with a new headlamp NOTE Do not touch the lamp with bare fingers Hold the plastic part...

Page 415: ...pod 8 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm See illustration 9 Adj...

Page 416: ...m below the mark placed on the wall in Step 2 NOTE Rider weight must be included on the seat On machines with separate low beam lights the drop should be 8 20 3 cm in 25 from the center of the low bea...

Page 417: ...low beam can be adjusted slightly upward or downward 2 Loosen the phillips screw located at the rear of the headlamp 3 Tilt the headlamp upward or downward 4 Tighten the screw Lower Headlight Adjustm...

Page 418: ...e headlight pod cover 2 Set meter to DC Volts and probe the headlamp plug wires Brown and Yellow at back of connector for 12 Volts 3 Turn ignition and headlight on If there is no power continue with c...

Page 419: ...Disconnect battery 2 Remove the front rack 3 Remove the front cover The brake pressure switch is located below the ecu THe vehicle wiring harness will need to be pushed to the side to gain access 4 D...

Page 420: ...of battery your ATV has refer to the illustration below and follow the correct service and charging procedures that follow in the manual Battery Conductance Analyzer Conductance describes the ability...

Page 421: ...y unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service New Battery Battery...

Page 422: ...ble Coat terminals and bolt threads with Nyogel Grease PN 2871329 4 Install clear battery vent tube from vehicle to battery vent if equipped WARNING Vent tube must be free from obstructions and kinks...

Page 423: ...the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenev...

Page 424: ...tucked away in front and behind battery Low Maintenance Battery Battery Check NOTE All Low Maintenance batteries are fully charged and tested at the factory before installation Expected shelf life va...

Page 425: ...V or less the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidel...

Page 426: ...TIONAL BATTERY 100 13 0V 12 70V 75 Charged 12 80V 12 50V 50 12 50V 12 20V 25 12 20V 12 0V 0 Charged less than 12 0V less than 11 9V Measurement at 80 F NOTE Subtract 01 from the specific gravity readi...

Page 427: ...ked with a digital multitester Readings of 12 8 volts or less require further battery testing and charging See charts and Load Test Remove the battery from the machine and wash the case and battery tr...

Page 428: ...SPORTSMAN 570 EFI FOREST ELECTRICAL Head Lamps Tail Lamps Exploded View REF DESCRIPTION QTY REF DESCRIPTION QTY 1 Stop Tail Turn lamp Housing Asm 1 5 1 4 Turn Socket 2 2 Head lamp Housing Asm 1 6 Tur...

Page 429: ...on is off the flasher driver will remain off until a lamp load is connected turn or hazards on to reduce current draw Two or more lamps connected to the flash output will flash at the normal rate in t...

Page 430: ...into the corresponding opening and install the harness 5 Install the upper pod screws and tighten sufficiently Speed Control The speed control system utilizes the ECU Speed Sensor Solenoid Valve and e...

Page 437: ...Assembly 5 22 Side Panel Removal 5 3 Torque Values 5 2 Winch and Front Bumper Mounting 5 23 Brakes Auxiliary Adjustment 2 31 Auxiliary Testing 2 31 Bleeding 9 7 Brake Caliper Removal Rear 9 28 Brake L...

Page 438: ...ession 3 43 Diagnostic Code Table 4 34 Digital Wrench Communication Errors 4 40 Controller Reprogramming 4 44 Diagnostic Connector 4 40 Diagnostic Software 4 39 Updates 4 41 Version and Update ID 4 41...

Page 439: ...51 Piston Removal 3 50 Piston Ring Installation 3 54 Piston Ring Installed Gap 3 52 Piston to Cylinder Clearance 3 51 Removal 3 31 Service 3 30 Special Tools 3 4 Specifications 3 7 Top Dead Center 3 3...

Page 440: ...11 General Information 2 5 Lubrication Components 2 10 Service Products and Lubricants 2 9 Shift Linkage 2 22 Storage Tips 2 8 Throttle 2 12 Throttle Cable 2 12 Throttle Release Switch 2 12 Transmiss...

Page 441: ...Torque 10 20 Transmission Silent Chain Length 8 18 Valve Seat Contact Width 3 47 Valve Spring 3 44 Valve Stem Diameter 3 46 Valve Stem Guide I D 3 46 Speed Sensor 10 20 Speedometer 10 6 Standard Bolt...

Page 442: ...ment 3 58 Exhaust Valve Lash Tappet Selection Matrix 3 62 Inspection 2 18 Intake Valve Lash Tappet Selection Matrix 3 61 Valve Cover Installation 3 67 Removal 3 40 Valve Sealing Test 3 57 Valve Seat R...

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