Polaris RANGER 500 2017 Service Manual Download

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9850043 R01 - 2017-2021

RANGER

500 / 570 Service Manual

3.31

TROUBLESHOOTING

ENGINE

Spark Plug Fouling

• Spark plug cap loose or faulty

• Incorrect spark plug heat range or gap

• PVT system calibrated incorrectly/ components worn

or mis-adjusted

• Fuel quality poor (old) or octane too high

• Low compression

• Restricted exhaust

• Weak ignition (loose coil ground, faulty coil, or stator)

• Restricted air filter (main or pre-cleaner) or breather

system

• Improperly assembled air intake system

• Restricted engine breather system

• Oil contaminated with fuel

Engine Turns Over But Fails To Start

• No fuel

• Dirt in fuel line or filter

• Fuel will not pass through fuel valve

• Fuel pump inoperative/restricted

• Tank vent plugged or pinched

• Engine flooded

• Low compression (high cylinder leakage)

• No spark (Spark plug fouled) ignition component

failure

Engine Does Not Turn Over

• Dead battery

• Starter motor does not turn

• Engine seized, rusted, or mechanical failure

Engine Runs But 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

• Air box removed (reinstall all intake components)

• Incorrect flywheel installation or sheared flywheel key.

• Restricted exhaust system

• Cam worn excessively

Engine Has Low Power

• Spark plug fouled

• Cylinder, piston, ring, or valve wear or damage (check

compression)

• PVT not operating properly

• Restricted exhaust muffler

• Cam worn excessively

Piston Failure - Scoring

• Lack of lubrication

• Dirt entering engine through cracks in air filter or ducts

• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

• Excessive piston-to-cylinder clearance

• Worn rings, piston, or cylinder

• Worn valve guides or seals

• Restricted breather

• Air filter dirty or contaminated

Piston Failure - Scoring

• Lack of lubrication

• Dirt entering engine through cracks in air filter or ducts

• Engine oil dirty or contaminated

Slow Engine Cranking

• Weak battery

• Loose Electrical connections

• Decompression Mechanism not functioning properly.

ENGINE / COOLING SYSTEM

Summary of Contents for RANGER 500 2017

Page 1: ...an authorized 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 manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Service Manual Service Literature Question Consumers please provide your feedback in writing to...

Page 2: ...on which if not avoided WILL result in death or serious injury WARNING SAFETY ALERT WARNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury NOTICE NOTICE provides key information by clarifying instructions IMPORTANT IMPORTANT provid...

Page 3: ...y Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the ne...

Page 4: ...REVISION INDEX REV DATE CHANGES R01 01 13 2021 Initial release ...

Page 5: ...er to provide Polaris with an overall satisfaction rating for this service manual provide comments on your experience or upload pictures video This feedback form is viewable on a mobile device by scanning the QR code or by clicking HERE if viewing this document electronically ...

Page 6: ......

Page 7: ...FORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING SYSTEM CHAPTER 4 ENGINE ELECTRICAL CHAPTER 5 FUEL SYSTEM CHAPTER 6 PVT SYSTEM CHAPTER 7 TRANSMISSION CHAPTER 8 FINAL DRIVE CHAPTER 9 STEERING SUSPENSION CHAPTER 10 BRAKE SYSTEM CHAPTER 11 BODY FRAME CHAPTER 12 ELECTRICAL ...

Page 8: ......

Page 9: ...17 2018 RANGER 570 4X4 TRACTOR INTL 1 26 2017 2018 RANGER 570 CREW 1 28 2019 RANGER 500 1 30 2019 RANGER 570 4X4 1 32 2019 RANGER 570 4X4 INTL 1 34 2019 RANGER 570 4X4 TRACTOR INTL 1 36 2019 RANGER 570 CREW 1 38 2020 RANGER 500 1 40 2020 RANGER 570 4X4 1 42 2020 RANGER 570 CREW 1 44 2021 RANGER 500 1 46 2021 RANGER 570 4X4 1 48 2021 RANGER 570 CREW 1 50 MISC SPECIFICATIONS AND CHARTS 1 52 CONVERSI...

Page 10: ...OSTICS 1 89 FUEL SYSTEM TROUBLESHOOTING 1 89 PVT SYSTEM DIAGNOSTICS 1 91 PVT SYSTEM TROUBLESHOOTING 1 91 PVT SYSTEM OVERHEATING DIAGNOSIS 1 93 TRANSMISSION DIAGNOSTICS 1 94 HARD SHIFTING 1 94 TRANSMISSION ISOLATION 1 94 FINAL DRIVE DIAGNOSTICS 1 95 ALL WHEEL DRIVE AWD CONCERNS 1 95 DRIVESHAFT HALF SHAFT DIAGNOSTICS 1 95 BRAKE SYSTEM DIAGNOSTICS 1 96 BRAKE NOISE TROUBLESHOOTING 1 96 BRAKE VIBRATION...

Page 11: ... Copyright Polaris Inc 1 3 TESTING FOR A SHORT TO GROUND 1 104 TESTING FOR A SHORT TO VOLTAGE 1 105 TESTING FOR INTERMITTENT CONDITIONS 1 106 TESTING CURRENT FLOW AMPERAGE 1 106 CURRENT DRAW KEY OFF 1 107 TESTING VOLTAGE DROP 1 107 GENERAL INFORMATION 1 ...

Page 12: ...N NUMBER VIN DESIGNATION 2015 Example 4XARUE573FG000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE CHASSIS MODIFIER ENGINE SIZE ENGINE MODIFIER CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R U E 5 7 3 F G 0 0 0 0 0 0 Model Year A 2010 B 2011 C 2012 D 2013 E 2014 F 2015 G 2016 H 2017 J 2018 K 2019 L 2020 M 2021 ...

Page 13: ...entify 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 i e In this example the first two digits are 31 which would use key blank PN 4110141 SERIES PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION 1 ...

Page 14: ...1 R17RMT57E1 9927386 2017 RANGER 570 EPS Tractor Intl R17RMS57C1 R17RMS57CK R17RMS57E1 R17RMS57EK 2018 RANGER 500 2x4 R18RM250B1 9928588 2018 RANGER 500 R18RMA50B1 R18RMA50B4 2018 RANGER 570 EPS R18RMA57B1 R18RMA57B9 R18RME57BV 9928587 2018 RANGER 570 HD Intl R18RME57N4 2018 RANGER 570 CREW R18RNA57B1 2018 RANGER 570 CREW EPS R18RNA57B9 R18RNE57BV R18RNE57NV 2018 RANGER 570 Intl R18RMA57F1 R18RMA5...

Page 15: ...HD Intl R20MAE57D7 2020 RANGER 570 CREW R20M4A57B1 R20M4A57B9 R20M4A57L1 2020 RANGER 570 CREW EPS R20M4E57BH 2020 RANGER 570 Intl R20MAA57K1 2021 RANGER 500 R21MAA50B1 R21MAA50B7 R21MAA50J7 9931254 2021 RANGER 570 EPS R21MAA57B1 R21MAA57B9 R21MAE57BX 2021 RANGER 570 HD Intl R21MAE57D7 2021 RANGER 570 CREW R21M4A57B1 R21M4A57B9 2021 RANGER 570 CREW EPS R21M4E57BX 2021 RANGER 570 Intl R21MAA57F1 R21...

Page 16: ...isted or depicted are mandatory while other tools may be 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 the Polaris official tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or https polaris service solutions com GENERAL INFORMATION ...

Page 17: ... 47053 Rolling Engine Stand PU 50624 Engine Stand Adapter Mounts To The Engine PU 50824 A Engine Stand Sleeve Adapter Use With 2 Bore Stand PU 50625 Engine Stand Sleeve Adapter Use With 2 375 Bore Stand PW 47054 Flywheel Puller PA 49316 Stator Cover Removal Handles PA 49317 Valve Spring Compressor PV 1253 Water Pump Seal Installation Tool PU 50869 GENERAL INFORMATION 1 ...

Page 18: ...al Installation Tool Kit PU 50784 Oil Filter Wrench PU 50105 Oil Pressure Gauge PV 43531 Oil Pressure Gauge Adapter 2017 and earlier models PU 50569 Oil Pressure Gauge Adapter 2018 and later models PU 52502 Valve Spring Compressor Adapter PV 43513 A 570 ONLY Cylinder Holding Camshaft Timing Plate PU 50563 GENERAL INFORMATION ...

Page 19: ...PU 47471 Includes PU 47470 PU 47469 PU 47468 Serial Number Registration Card PU 48731 A Digital Wrench PC Interface Cable PU 47470 Digital Wrench Vehicle Interface Cable PU 47469 Digital Wrench SmartLink Module PU 47468 Digital Wrench Wireless Vehicle Link PU 51435 Fuel Pressure Gauge Kit PU 43506 A Fuel Pressure Gauge Adapter PV 48656 GENERAL INFORMATION 1 ...

Page 20: ...pter PS 48762 Fluke 77 Digital Multi Meter Fluke 77 PV 43568 Throttle Position Sensor Tester Kit 2201519 A Includes 547927 PU 47466 Laptop or Desktop Computer USB Serial Adaptor Saelig RS 232 Commercially Available refer to diagnostic software user manual or HELP section for minimum requirements GENERAL INFORMATION ...

Page 21: ...2871226 Drive Clutch Puller Short PA 48595 Drive Clutch Holding Tool 9314177 A Drive Clutch Spider Removal and Install Tool 2870341 Piston Pin Puller 2870386 Roller Pin Tool 2870910 A Universal Clutch Compressor Tool PU 50518 A Standard Clutch Alignment Tool 2870654 Clutch Center Distance Tool PU 50658 A GENERAL INFORMATION 1 ...

Page 22: ...t of 2871702 Kit Rear Driveshaft Seal Guide 2871699 Part of 2871702 Kit Rear Output Seal Driver 2871698 Part of 2871702 Kit Snorkel Tool PA 50231 Transmission Nut Socket PU 50566 FINAL DRIVE 1 3 4 Straight Wrench 2870772 ADC Gearcase Piston Installation Tool PA 48542 CV Boot Clamp Pliers 8700226 or PU 48951 Roller Pin Removal Tool 2872608 GENERAL INFORMATION ...

Page 23: ...is Inc 1 15 STEERING SUSPENSION Ball Joint Removal Installation Tool 2870871 Strut Compression Tools 2871573 2871574 Shock Absorber Spring Compression Tool 2870623 BRAKES Mity Vac Pressure Test Tool 2870975 BODY FRAME Multi Function Pliers 2876389 GENERAL INFORMATION 1 ...

Page 24: ...nc ELECTRICAL Battery Conductance Analyzer PU 50296 Battery Hydrometer PU 50338 Fluke 77 Digital Multimeter PV 43568 Hall Sensor Probe Harness 2460761 Static Timing Light Harness 2871745 Timing Light 2870630 Relay Bypass PU 49466 Connector Test Kit PV 43526 GENERAL INFORMATION ...

Page 25: ...uence for all steps Step 1 21 ft lbs 28 N m Step 2 26 ft lbs 35 N m Step 3 Additional 135 Torque the Outer M6 Head Bolts 89 9 in lbs 10 1 Nm ITEM TORQUE Cylinder Head Bolts Silver Apply light coat of engine oil to bolt threads and under bolt head Torque in sequence for all steps Step 1 18 ft lbs 25 N m Step 2 30 ft lbs 41 N m Step 3 Loosen all fasteners until they are unseated Step 4 15 ft lbs 20 ...

Page 26: ... One Way Clutch Bolts 9 ft lbs 12 Nm Stator Cover Screws 9 ft lbs 12 Nm Stator Mounting Bolts 9 ft lbs 12 Nm Stator Wire Retainer 6 ft lbs 9 Nm ITEM TORQUE Steering Rack Mounting Bolts 16 ft lbs 22 Nm Steering Shaft to EPS Unit 20 ft lbs 27 Nm Steering Shaft to Steering Rack 46 51 ft lbs 62 69 Nm Steering Wheel Nut 65 ft lbs 88 Nm Strut Casting Pinch Bolt 17 ft lbs 23 Nm Strut Mounting Nut top 15 ...

Page 27: ...ck 7043594 1800 3700 6000 12000 25 48 5633217 Black 7043594 RANGER 570 ALTITUDE SHIFT WEIGHT DRIVE SPRING Meters Feet 0 1800 0 6000 25 52G 5632409 Black 7043594 1800 3700 6000 12000 25 48 5633217 Black 7043594 RANGER CREW 570 ALTITUDE SHIFT WEIGHT DRIVE SPRING Meters Feet 0 1800 0 6000 25 52G 5632409 Black 7043594 1800 3700 6000 12000 25 48 5633217 Black 7043594 GENERAL INFORMATION 1 ...

Page 28: ...CITY Length 110 279 4 cm Width 58 147 3 cm Height 73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1080 lbs 490 kg Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue C...

Page 29: ...7 0 85 0 08 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R DRI...

Page 30: ...185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue...

Page 31: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 32: ... Height 73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg H...

Page 33: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 34: ... 147 3 cm Height 73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs ...

Page 35: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 36: ...th 140 355 6 cm Width 60 152 4 cm Height 73 185 cm Wheel Base 105 266 7 cm Ground Clearance 10 25 4 cm Turning Radius 237 602 cm Dry Weight 1323 lbs 600 kg 1352 lbs 613 kg W EPS Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1250 lbs 567 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4 ...

Page 37: ...ontrolled Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 8 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only ELECTRICAL Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp...

Page 38: ... cm Height 73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1080 lbs 490 kg Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Capacity 150 lbs 68 kg GENERAL INFORMATI...

Page 39: ...7 0 85 0 08 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R DRI...

Page 40: ...m Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Capa...

Page 41: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 42: ...3 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Capacity 150 lbs 6...

Page 43: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 44: ...se 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Capacity 150 l...

Page 45: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 46: ...ght 73 185 cm Wheel Base 105 266 7 cm Ground Clearance 10 25 4 cm Turning Radius 237 602 cm Dry Weight 1323 lbs 600 kg 1352 lbs 613 kg W EPS Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1250 lbs 567 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4 kg Hitch Tongue Capacity 150 lbs 68 k...

Page 47: ...ontrolled Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 8 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only ELECTRICAL Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp...

Page 48: ...ght 73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1080 lbs 490 kg Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Capacity 150 lbs 68 kg GENERAL INFORMATION ...

Page 49: ...7 0 85 0 08 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R DRI...

Page 50: ...73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Ton...

Page 51: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 52: ...m Height 73 185 cm Wheel Base 105 266 7 cm Ground Clearance 10 25 4 cm Turning Radius 237 602 cm Dry Weight 1323 lbs 600 kg 1352 lbs 613 kg W EPS Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1250 lbs 567 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4 kg Hitch Tongue Capacity 150 lbs...

Page 53: ...ontrolled Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 8 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only ELECTRICAL Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp...

Page 54: ... 58 147 3 cm Height 73 185 cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1080 lbs 490 kg Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Capacity 150 lbs 68 kg GENERAL ...

Page 55: ...7 0 85 0 08 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift P H L N R DRI...

Page 56: ... cm Wheel Base 73 185 cm Ground Clearance 10 25 4 cm Turning Radius 150 381 cm Dry Weight 1075 lbs 488 kg 570 1100 lbs 499 kg 570 EPS 1140 lbs 517 kg 570 w park Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1000 lbs 454 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4kg Hitch Tongue Ca...

Page 57: ...ed Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 9 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp Lights 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT S...

Page 58: ...ght 73 185 cm Wheel Base 105 266 7 cm Ground Clearance 10 25 4 cm Turning Radius 237 602 cm Dry Weight 1323 lbs 600 kg 1352 lbs 613 kg W EPS Cargo Box Capacity 500 lbs 227 kg Cargo Box Dimensions inside dimensions L 42 x W 32 x H 11 5 107 x 81 x 29 cm Vehicle Payload 1250 lbs 567 kg Includes weight of riders cargo and accessories Towing Capacity 1500 lbs 680 4 kg Hitch Tongue Capacity 150 lbs 68 k...

Page 59: ...ontrolled Spark Plug Gap NGK MR7F 0 0276 0 0315 0 7 0 8 mm Battery Amp Hr Yuasa Conventional 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI Chassis Fan Fuel Pump Headlight EPS EPS model only ELECTRICAL Circuit Breaker Fan Motor 20 Amp Fuses Brake Light 5 Amp EFI 20 Amp Fuel Pump 10 Amp EPS EPS model only 20 Amp Accessory 20 Amp Drive 10 Amp...

Page 60: ... 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 x 0 454 kg kilogram kg x 2 2046 lbs cubic inches cu in x 16 387 cc cubic centimeters cc x 0 061 cubic inches US quarts x 0 946 liters L liters L x 1 057 US quarts US gallons x 3 785 liters L liters L x 0 264 ...

Page 61: ... 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 12 1 11 64 10 32 21 1 1 2 6 1 11 32 12 24 17 1 1 2 12 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2...

Page 62: ...937 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 00 5 16 0 3125 5 16 9 x 1 25 5 16 0 3125 5 16 10 x 1 25 11 32 0 3437 11 32 10 x 1 50 R 0 339 11 32 11 x 1 50 3 8 0 375 3 8 12 x 1 50 13 32 0 406 13 32 12 x 1 75 13 32 0 406 13 32 GENERAL INFORMATION ...

Page 63: ...5 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 3594 3 8 0 375 25 64 0 3906 10 mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 1...

Page 64: ...5 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 22 mm 0 8661 7 8 0 875 57 64 0 8906 23 mm 0 9055 29 32 0 9063 59 64 0 9219 15 16 0 9375 24 mm 0 9449 61 64 0 9531 31 32 0 9688 25 mm 0 9843 63 64 0 9844 1 1 000 GENERAL INFORMATION ...

Page 65: ...icated and compared to a like vehicle No If the concern has not been able to be duplicated gather more information about the concern After the concern has been duplicated please compare to a like vehicle Is the concern present on that vehicle Yes If the same concern is present on the like vehicle it is likely that the concern is a normal operational characteristic Yes No Are there any bulletins re...

Page 66: ...been selected Refer to the Transmission or Final Drive Chapters for further diagnostic information No Is the concern related to a Noise Yes Refer to necessary service information for pin pointing noise location and diagnosis GUIDED SYMPTOM REFERENCES For concerns that have not been able to be duplicated or are repeat concerns Refer to the Customer Questionnaire and gather more information from the...

Page 67: ...nch Guided diagnosis Certain failures may not display a CEL MIL on the instrument cluster In this instance record CEL s from the instrument cluster and refer to the necessary section in the Service Manual Refer to Warning Lights page 1 66 For ENGINE HOT WARNING Check Coolant level If not full fill to correct level Check Oil level If not full fill to correct level Visually inspect for Oil or Coolan...

Page 68: ...oad test battery If battery fails the load test charge replace battery as needed Retest for concern before proceeding Check Ignition Switch and connections Concern may be caused by faulty Ignition Switch Refer to No Crank No Start or Slow Crank page 1 64 for further diagnostic procedures t Does the engine stay running Yes Continue to step y No Check air filter for blockage Check for spark Refer to...

Page 69: ...not moving concern may be within transmission Refer to the necessary section in the applicable service manual u Test drive vehicle for concern If the concern is related to the PVTsystem Transmission or Final Drive refer to the applicable section in the service manual If the concern is electrical systems related refer to Electrical Troubleshooting If the concern is overheating or related to the coo...

Page 70: ...ure that the fuel being used meets the correct octane rating specific to the vehicle If filled with fuel vehicle starts and gauge still is not reading test the fuel sending unit 6 Check fuses or fuel system relays where applicable If any fuel related system fuses are blown replace fuses and recheck Wiring concern or faulty parts may cause fuse to blow It is advisable to try swapping a relay with a...

Page 71: ...cern Check ECU for power and grounds to make sure that computer is turning on 12 If all previous checks pass concern may be caused by internal engine issue Refer to Cylinder Leakdown Test Previous testing may be caused by or lead to replacement of one or more of the following Cylinder head gasket leak No valve clearance cam wear Cylinder or piston worn Piston rings worn leaking broken or sticking ...

Page 72: ...ositive terminals at starter and solenoid for available voltage using DMM Readings should be 12 6 V With battery disconnected check cables for high resistance Reading should be less than 1 Ohm If resistance is higher than specification replace wiring Reconnect battery and perform voltage drop test on wiring to starter and to starter solenoid Concern may still be caused by high resistance in wires ...

Page 73: ... need of changing may cause increase in engine temperature Too high of oil level may cause engine temperatures may cause increase in engine temperature Check level and correct as necessary Check maintenance history to determine if oil need to be changed 7 Check Cooling Fan operation Make sure the cooling fan is engaging Command cooling fans on and off using Digital Wrench to check operation Monito...

Page 74: ...spect hoses and radiator for coolant leaks Repair as necessary Pressurize cooling system and look for pressure losses This indicates a leak in the cooling system Inspect for external leaks if none are found it is possible there is an internal leak Check cooling system using combustion leak tester for any combustion gasses entering the cooling system This could indicate possible Head Headgasket fai...

Page 75: ...njector Fuel pump inoperative restricted Tank vent plugged or pinched Engine flooded Injector control circuit failure Low compression high cylinder leakage No spark Spark plug fouled ignition component failure Intake leak vacuum leak ENGINE DOES NOT TURN OVER Battery Starter and Ground Cable Connections Engine seized rusted or mechanical failure Starter motor does not turn Starting system circuit ...

Page 76: ...der Worn valve guides or seals Restricted breather Air filter dirty or contaminated LOW COMPRESSION Cylinder head gasket leak No valve clearance cam wear Valve not seating properly bent or carbon accumulated on sealing surface Cylinder or piston worn Bent valve or stuck valve Piston rings worn leaking broken or sticking Valve spring broken or weak BACKFIRING Ignition system faulty Spark plug cap c...

Page 77: ...ed in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump Fuel pump output weak Cooling fan inoperative or turning too slowly perform current draw test Faulty hot light circuit Electrical malfunction Water pump failure Loose impeller Thermistor failure Low oil level Thermostat stuck closed or not opening completely LEAK AT WATER PUMP WEEP HOLE Faulty water pump mechani...

Page 78: ...refer to the Digital Wrench System Help To access the Digital Wrench System Help do one of the following Expand the Digital Wrench Help drop down on the left side of the main screen and click System Help Select the Display Diagnostic System Help menu icon question mark on the main screen SPECIAL TOOLS SPECIAL TOOL PART NUMBER Digital Wrench Diagnostic Kit PU 47063 C which includes the following Di...

Page 79: ...op down select Digital Wrench and then click Digital Wrench Updates 3 Select the Digital Wrench X X Updates link 4 Select the update you want to install on your PC IMPORTANT You must have the latest Base Version installed on your PC before you can install the update Updates will not install on older Base Versions of Digital Wrench If you do not have the latest Base Version installed on your PC ski...

Page 80: ... Wrench home page www polaris diagsys com and locate the following information under Knowledge Base Errors and Troubleshooting Frequently Asked Questions FAQs Procedures and Solutions DIGITAL WRENCH DIAGNOSTIC CONNECTOR The diagnostic connector q is located under the hood as shown DIGITAL WRENCH SERIAL NUMBER LOCATION To locate the Digital Wrench serial number do the following 1 Launch the Digital...

Page 81: ...art format This is the most viewed screen Add and or update vehicle and customer information Also view ECU Identification View information from the main ECU sensors Access the Vehicle Home Page Set up data capture and record functions Access the System Configuration screen Perform specialized testing and adjustment functions service reports Access the Digital Wrench System Help Open the ASSERT ASK...

Page 82: ...verview for information on how to access the System Help REPROGRAMMING REFLASH PROCEDURE 1 Verify the most current version of the Digital Wrench software is installed on your PC 2 Connect the SmartLink Module cables to your PC and the vehicle 3 Launch the Digital Wrench software 4 Select the Change Vehicle menu icon 5 Select the Year Product Line and Description 6 Select the Special Tests menu ico...

Page 83: ...VIEW NOTICE The diagnostic mode is accessible only when the check engine MIL has been activated If there is a diagnostic problem with the power steering system the power steering MIL will illuminate and blink in place of the check engine MIL Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Error codes ar...

Page 84: ...idth Or Period P0501 9 Abnormal Update Rate P160A 10 Abnormal Rate Of Change C1068 C1705 12 Bad Intelligent Device Or Component P3503 19 Received Vehicle Speed Has Error P106B C1069 P306B 91 Accelerator Position 1 3 Voltage Too High P0228 4 Voltage Too Low P0227 96 Fuel Level Signal 2 Data Erratic Intermittent Or Incorrect P0461 3 Voltage Above Normal Or Shorted To High Source P0463 4 Voltage Too ...

Page 85: ...ormal Or Shorted To Low Source P2228 10 Abnormal Rate Of Change P2230 110 Engine Temperature Sensor 0 Engine Overheat Shutdown P1217 2 Data Erratic Intermittent Or Incorrect P0116 3 Voltage Too High P0118 4 Voltage Too Low P0117 10 Abnormal Rate Of Change P0119 15 Data Valid But Above Normal Operating Range P1116 16 Temperature Too High P0217 17 Data Valid But Below Normal Operating Range P0128 19...

Page 86: ...mputation P121D 523 Gear Sensor Signal 2 Data Erratic Intermittent Or Incorrect P0914 3 Voltage Above Normal Or Shorted To High Source P0917 4 Voltage Too Low P0916 9 Abnormal Update Rate P1914 11 Root Cause Not Known P0915 525 Transmission Requested Gear 19 Received Network Data In Error U255C 527 Cruise Control Panel Switches 31 Condition Exists P153D 563 ABS active 19 Received Network Data In E...

Page 87: ... Above Normal Or Shorted To High Source P0647 4 Voltage Below Normal Or Shorted To Low Source P0646 5 Current Below Normal Or Open Circuit P0645 905 Wheel Speed Sensor Front Left 2 Data Erratic Intermittent Or Incorrect C1131 3 Voltage Above Normal Or Shorted To High Source C1231 4 Voltage Below Normal Or Shorted To Low Source C1331 5 Current Below Normal Or Open Circuit C1631 6 Current Above Norm...

Page 88: ...ta Erratic Intermittent Or Incorrect P0236 3 Voltage Above Normal P0238 4 Voltage Below Normal P0237 31 Condition Exists P1234 1268 Ignition Coil Primary Driver 1 MAG 3 Voltage Above Normal P1353 4 Voltage Below Normal P1361 5 Current Below Normal Or Open Circuit P1351 1269 Ignition Coil Primary Driver 2 PTO 3 Voltage Above Normal P1354 4 Voltage Below Normal P1362 5 Current Below Normal Or Open C...

Page 89: ...oltage Above Normal Or Shorted To High Source P0132 4 Voltage Below Normal Or Shorted To Low Source P0131 C1049 12 Bad Intelligent Device Or Component P113A 17 Data Valid But Below Normal Operating Range Least Severe Level C2049 3057 Oxygen Sensor Bank 1 Sensor 2 2 Data Erratic Intermittent Or Incorrect P0136 3 Voltage Above Normal Or Shorted To High Source P0138 4 Voltage Below Normal Or Shorted ...

Page 90: ...rottle Release Signal 2 Data Erratic Intermittent Or Incorrect P1553 3 Voltage Above Normal Or Shorted To High Source P1555 4 Voltage Below Normal Or Shorted To Low Source P1554 7 Mechanical System Not Responding Or Out Of Adjustment P1552 520198 Throttle Position Sensor 2 0 Data Valid But Above Normal Operational Range Most Severe Level P1223 1 Data Valid But Below Normal Operational Range Most S...

Page 91: ...l Failure 31 Condition Exists C1053 520225 EPS Inverter Temperature 0 Data Valid But Above Normal Operational Range Most Severe Level C1055 12 Bad Intelligent Device Or Component C102F 16 Data Valid But Above Normal Operating Range Moderately Severe Level C1054 520226 EPS Communications Receive Data Error 2 Data Erratic Intermittent Or Incorrect U0100 31 Condition Exists C1067 520227 EPS CAN Commu...

Page 92: ...rent Below Normal Or Open Circuit P125A 520275 Accelerator Position Brake Position Interaction 31 Condition Exists P150A U1007 520276 Throttle Position Sensor 1 or 2 Indeterminable 2 Data Erratic Intermittent Or Incorrect P150C 12 Bad Intelligent Device Or Component P150B 520277 Throttle Body Control Power Stage 2 Data Erratic Intermittent Or Incorrect P151A 3 Voltage Above Normal Or Shorted To Hi...

Page 93: ...tion Exists C1681 520496 Intercooler Pump Driver Circuit 3 Voltage Above Normal Or Shorted To High Source P107D 4 Voltage Below Normal Or Shorted To Low Source P107C 5 Current Below Normal Or Open Circuit P107E 520498 Stator 4 Voltage Below Normal Or Shorted To Low Source P1510 5 Current Below Normal Or Open Circuit P1511 520513 Motor Controller Encoder 2 Data Erratic Intermittent Or Incorrect P11...

Page 94: ...rating Range Least Severe Level P150F 524076 Engine Oil Pressure Sensor Switch 17 Data Valid But Below Normal Operating Range Least Severe Level P151F 524085 EPS Fault Lamp Driver Circuit 12 Bad Intelligent Device Or Component C106C 524086 EPS SEPIC Voltage Error 3 Voltage Above Normal Or Shorted To High Source C106D 4 Voltage Below Normal Or Shorted To Low Source C106E GENERAL INFORMATION ...

Page 95: ...the throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur The check engine light will remain illuminated until there are 4000 engine revolutions i e 4000 RPM for one minute without a significant misfire being detected Once this condition is met the check engine l...

Page 96: ...low at this time clean and continue to monitor It is possible that the fluid is residual from manufacturing or previous repairs 2 Thoroughly clean the area using an appropriate cleaner Brake cleaner Throttle Body cleaner Soap etc prior to diagnosing the leak 3 Operate the vehicle under the condition that the leak presented and re inspect for leak 4 Pinpoint location of leak Check for any damage to...

Page 97: ...el injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts air box cover Faulty oxygen sensor RICH MIXTURE SYMPTOMS CAUSES Hard start or no start Bog Backfire Popping through Intake Exhaust Hesitation Detonation Low Power Spark plug erosion fouling Engine runs hot Surging High Erratic idle No fuel in tank Restricted tank vent or...

Page 98: ... warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector TMAP damaged check with Digital Wrench Tight valves low compression or high leakdown Ignition timing incorrect Belt dragging Dirty air filter High percentage of cylinder leakdown worn engine Low compression worn engine Spark ...

Page 99: ...d operating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift weights Drive clutch binding Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Driv...

Page 100: ...r s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Find leak and repair as necessary Operator error Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Replace belt Water ingestion Inspect and seal PVTsystem Belt contaminated with oil or grease Inspect and clean PVT noise Belt worn...

Page 101: ...le overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVTsystem Remove the PVT drain plug Shift the transmission to neutral Using the throttle vary the engine r...

Page 102: ...l transmission components TRANSMISSION ISOLATION To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the transmission should be isolated using the following information After the transmission is isolated refer to Additional Shifting Causes or the proper chapter in the service manual for additional information 1 Disconnect the shift cable...

Page 103: ...or coil magnetized Rule out armature plate by putting it close to something metal to see if it tries to stick Drivetrain wedged Often caused by torsion spring coming out of place AWD Does not engage Roller cage is broken Can typically find debris in the oil if drained No power to AWD coil Jump power and ground directly to the coil and verify AWD function If AWD functions this confirms an electrica...

Page 104: ...led Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake Adjust pad stop Set to proper level Clean compensating port Inspect Repair as necessary Clean piston s seal Educate operator Loose wheel hub or bearings Check wheel and hub for abnormal movement Check axle nut torque Inspect replace bearing...

Page 105: ...he throttle and brakes at the same time Excessive use of the brakes POOR BRAKE PERFORMANCE POOR BRAKE PERFORMANCE Air in system Water in system brake fluid contaminated Caliper or disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged brake pad noise insu...

Page 106: ...ocedure s available in Digital Wrench Power Steering Non Functional MIL is ON Cycle the ignition switch Is MIL on No There is no issue MIL on due to 5 minute timeout Verify code using Digital Wrench No Is Battery Voltage 11 and 16VDC No Determine cause of incorrect battery voltage and repair Yes Is EPS Fuse OK No Replace EPS Fuse Yes 12 VDC and GND across 2 Pin EPS Connector with Key On No Check E...

Page 107: ...nal MIL is OFF Is Battery Voltage 11 and 16VDC No Determine cause of incorrect battery voltage and repair Yes Is EPS Fuse OK No Replace EPS Fuse Yes 12 VDC and GND across 2 Pin EPS Connector with Key On No Check EPS Power Relay and Circuit Yes 12 VDC on Pin 3 of the 8 pin EPS Connector No Check wiring from Connector to Ignition Switch Circuit Yes Begin Digital Wrench EPS Trouble shooting Procedure...

Page 108: ...gh EEPROM Failure These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit TABLE 2 EPS Inverter Temperature Test 1 Verify that the Power Steering module heat sink surface top surface is clean and free of mud and dirt Make a note of how much debris was on heat sink before cleaning Record all power steering error codes EPS inverter...

Page 109: ...ates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body i e road conditions and operating temperature It is important to properly identify the difference between normal operation weepage or misting and a shock that has a leak Below are some images to help ...

Page 110: ...ill only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge STATIC AND DYNAMIC TESTING There are many methods for testing a DC circuit These methods fall into one of two categories either static or dynamic STATIC TESTING The two most common forms of static tes...

Page 111: ...upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the terminal or attempting to adjust tighten the tang in the female terminal For a video demonstration scan the QR code below or right click it and select open in new tab BACK PROBING Back probing is typi...

Page 112: ...o ground B so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There are many possible causes of a short to ground here are some The harness rubbing against a component that is grounded such as the frame chassis component or engine A component s internal circuitry contac...

Page 113: ...t Testing Continuity Resistance page 1 104 4 Ensure you have checked for a short to ground Testing For A Short To Ground page 1 104 5 Ensure that neither end of the circuit is connected 6 Set your DMM to DC volts 7 Connect one meter lead securely to the battery negative post 8 Connect the other lead to either end of the disconnected circuit Ensure you are using the correct adapter Connector Probin...

Page 114: ...ulation damage Improper routing especially when it leads to chaffing or heat damage especially near exhaust You may need to use different techniques to duplicate these concerns These include but are not limited to Moving the harness by wiggling it or flexing certain areas Pulling at or near the suspected connector Pushing in different directions to flex the connector body and try to isolate poor c...

Page 115: ...p after switched power is removed 8 Maximum allowable is 10 milliamps If your meter is ranged to the 10 Amp scale this will appear as 0 010 Amps Current Draw Key Off Maximum of 01 DCA 10 mA 9 If over 10 milliamps go to the fuse block and start systematically removing one fuse at a time until the value drops indicating the circuit that requires attention TESTING VOLTAGE DROP NOTICE If you disconnec...

Page 116: ...1 108 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc For a video demonstration scan the QR code below or right click it and select open in new tab GENERAL INFORMATION ...

Page 117: ... 11 POLARIS LUBRICANTS MAINTENANCE AND SERVICE PRODUCTS 2 11 ENGINE 2 12 COMPRESSION AND LEAKDOWN TEST 2 12 ENGINE OIL LEVEL 2 12 OIL AND FILTER CHANGE 2 12 BREATHER HOSE 2 13 BREATHER VALVE INSPECTION 2 13 500 SOHC 2 14 VALVE CLEARANCE SOHC 2 14 570 DOHC 2 14 VALVE CLEARANCE DOHC 2 14 COOLING SYSTEM 2 16 COOLING SYSTEM OVERVIEW 2 16 COOLANT LEVEL INSPECTION 2 16 50 50 EXTENDED LIFE ENGINE ANTIFRE...

Page 118: ... WHEEL TOE ALIGNMENT INSPECTION 2 30 TOE ADJUSTMENT 2 30 CAMBER AND CASTER 2 31 SUSPENSION 2 32 SUSPENSION INSPECTION 2 32 SPRING PRE LOAD ADJUSTMENT 2 32 STABILIZER BAR PIVOT LUBRICATION 2 32 SUSPENSION PIVOT POINT LUBRICATION 2 33 SHOCK ANALYSIS 2 34 BRAKE SYSTEM 2 35 BRAKE FLUID INSPECTION 2 35 BRAKE HOSE AND FITTING INSPECTION 2 35 BRAKE PAD INSPECTION 2 35 BRAKE DISC INSPECTION 2 36 ELECTRICA...

Page 119: ...heck for proper function Wheels check for tightness of wheel nuts and axle nuts check to be sure axle nuts are secured by cotter pins Air cleaner element check for dirt 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 bolts or fasteners Engine coolant check for proper level at the recovery...

Page 120: ...e at sustained idle or sustained high speed 6 Pull only light loads 7 Perform regular checks on fluid levels controls and areas outlined in the Pre Ride Inspection checklist 8 Perform a break in oil and filter change at 25 hours 250 miles whichever comes first change every 100 hours thereafter Change more frequently during cold weather operation 9 Perform a transmission break in fluid level check ...

Page 121: ... monitor level If oil level begins to rise discontinue use and determine cause NOTICE Inspection may reveal the need for replacement parts Always use genuine Polaris parts WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services PERIODIC MAINTENANCE CHART ITEM MAINTENANC...

Page 122: ...M Lubricate D E Throttle Cable Release Switch 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E Throttle body air intake ducts flange 50 H 6 M 500 800 Inspect ducts for proper sealing air leaks Drive belt 50 H 6 M 500 800 Cooling system 50 H 6 M Inspect coolant strength seasonally pressure test system yearly Engine oil and filter change 100 H 6 M 1000 1600 Change oil and filter perf...

Page 123: ... 24 M Change every two years Spark arrestor 60 M Clean out D E Valve clearance 200 H 2000 3200 Inspect adjust Idle speed Adjust as needed D Toe adjustment Inspect periodically adjust when parts are replaced D Auxiliary brake if equipped Inspect daily adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Se...

Page 124: ...s of storage and after pressure washing or submerging the vehicle Front A Arm Polaris All Season Grease Locate fitting and grease Semi annually Rear A Arm Polaris All Season Grease Locate fitting and grease Semi annually Rear Stabilizer Bar Bushings If equipped with grease fittings Polaris All Season Grease Locate fitting and grease Semi annually Semi annually or 50 hours of operation Refer to Mai...

Page 125: ...ereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Engine Coolant Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Check level daily change coolant every 2 years 3 Brake Fluid Polaris DOT 4 Brake Fluid Maintain fluid level between MAX and MIN lines on the master cylinder reservoir Check level at pre ride inspection change fl...

Page 126: ...fuel lines and injectors should be completely drained of gasoline NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the maintenance interval charts FLUID LEVELS Inspect the fl...

Page 127: ...nt 2880514 50 50 Extended Life 1 US Quart 0 9 L 12 per case 2880513 50 50 Extended Life 1 US Gallon 3 8 L 4 per case 2880512 50 50 Extended Life 55 US Gallon Drum 208 L Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Premium Starter Grease 2871515 U Joint Grease 3 oz 24...

Page 128: ...level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Set machine on a level surface 2 Clean the area around the dip stick 3 Remove dipstick and wipe dry with a clean cloth 4 Reinstall dipstick completely NOTICE The dipstick must be screwed completely in to ...

Page 129: ...ter and turn it by hand until the filter gasket contacts the sealing surface then turn an additional 3 4 of a turn 15 Remove dipstick 16 Add oil as necessary to bring the oil level to the upper mark on the dipstick Do not over fill the engine the maximum oil capacity is 2 qts 1 9 l NOTICE The dipstick must be screwed completely in to ensure accurate measurement 17 Reinstall the upper fill cap if r...

Page 130: ...nce is out of specification MEASUREMENT Intake Valve Clearance 0 006 0 002 0 152 0 051 mm Exhaust Valve Clearance 0 010 0 002 0 254 0 051 mm 6 Record the results of each measurement for future reference 7 Reinstall all components that were removed 570 DOHC VALVE CLEARANCE DOHC Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center TDC on compressio...

Page 131: ...wn IMPORTANT Intake cam sprocket should have I marks aligned with the gasket surface and the exhaust cam sprocket should have E marks aligned with the gasket surface 6 Measure the valve clearance of each valve using a feeler gauge Record the measurement if clearance is out of specification MEASUREMENT Intake Valve Clearance 0 006 0 002 0 15 0 05 mm Exhaust Valve Clearance 0 008 0 002 0 20 0 05 mm ...

Page 132: ...f Polaris 50 50 Extended Life Antifreeze or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTICE Polaris 50 50 Extended Life Antifreeze is already premixed and ready to use Do not dilute with water COOLANT LEVEL INSPECTION The recovery bottle q and radiator pressure cap w are located under the hood With the engine at operating temperature the coolant l...

Page 133: ...ll not allow the recovery system to function properly 6 Remove the recovery bottle cap 7 Fill the recovery bottle to the MAX mark with Polaris Premium 50 50 Anti Freeze Coolant or a 50 50 mixture of antifreeze coolant and distilled water as required for freeze protection in your area 8 Reinstall the recovery bottle cap 9 If coolant was required start engine and check for leaks Make sure radiator f...

Page 134: ...xing the two will affect the service interval To receive the full 5 year service interval benefit the cooling system must be fully drained and replenished with the Extended Life antifreeze To determine if a vehicle is using 60 40 or 50 50 Extended Life antifreeze note the color 60 40 antifreeze is green while 50 50 Extended Life antifreeze is yellow 50 50 EXTENDED LIFE ANTIFREEZE PART NUMBERS PART...

Page 135: ...impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat FLUID CAPACITY Recommended Anti Freeze Coolant Polaris 50 50 Anti Freeze Coolant 2871534 Quart COOLING SYSTEM HOSES REF DESCRIPTION q Clamp w Hose to Thermostat e Radiator r Recovery Bottle t Hose to Water Pump y Retainer u Bolt 1 Inspect all hoses for cracks deterioration abrasi...

Page 136: ...not recommended COOLANT DRAIN RADIATOR REMOVAL 1 Allow the vehicle to cool down if recently operated 2 Place a suitable drain pan underneath the right hand side of the radiator 3 Open the hood and slowly open the radiator pressure cap to relieve system pressure WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before ...

Page 137: ...age the cooling fins 10 Remove the four bolts that retain the fan motor and shroud to the radiator Installation 11 Reverse previous procedures for installation 12 Upon installation be sure the lower radiator mounts are placed properly in the frame support 13 After the radiator is installed verify the rubber mounts e have remained in place 14 After installation and reassembly remove the pressure ca...

Page 138: ...es CAUTION Make sure lines are not kinked or pinched 3 Replace all fuel lines every two years FUEL PUMP FILTER The fuel pump components on the RANGER are not serviceable If a component requires replacement the fuel pump assembly must be replaced NOTICE See the Online Electronic Parts Catalog for correct parts information For all other information related to the Fuel System refer to Chapter 4 VENT ...

Page 139: ...ox of any oil or water deposits and apply a small amount of grease to the sealing surfaces of the filter 5 Reinstall the air filter into the airbox container Be sure the filter fits tightly in the air box and engage the 2 clips ENGINE AIR INTAKE INSPECTION 1 Remove the cover from the outer side of the seat base q and remove the pre filter element 2 If the pre filter element is dirty clean it with ...

Page 140: ...l it is tight against the bracket 5 Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable TRANSMISSION LUBRICATION NOTICE It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The transmission lubricant level should be checked and changed in accordance with t...

Page 141: ...arcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule Be sure vehicle is positioned on a level surface when checking or changing the fluid Check vent hose to be sure it is routed properly and unobstructed Front Gearc...

Page 142: ...O ring and torque to specification 11 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole FLUID CAPACITY Recommended Front Gearcase Fluid Polaris Demand Drive PN 2877922 Quart Capacity 6 7 7 6 oz 200 225 ml 12 Reinstall fill plug with a new O ring and torque to specification TORQUE Front Gearcase Drain Fill Plug 10 f...

Page 143: ... front and rear for damage tears wear or leaking grease If the rubber boot exhibits any of these symptoms replace the boot Refer to Final Drive for CV boot replacement WHEEL REMOVAL RE F DESCRIP TION NOTES q Wheel Nuts Torque Steel Wheels 36 ft lbs 49 Nm Aluminum Wheels 30 ft lbs 90º 41 Nm 90º w Washers 1 Stop the engine place the transmission in gear and chock wheels 2 Loosen the wheel nuts sligh...

Page 144: ...h tapered wheel nuts make sure the tapered end of the nut goes into the taper on wheel TIRE INSPECTION Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect vehicle handling MEASUREMENT Tread Depth Service Limit Replace if 1 8 3 mm or less WARNING Operating with worn tires w...

Page 145: ...is chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician when replacing worn or damaged steering parts Use only genuine Polaris replacement parts TIE ROD END STEERING INSPECTION To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement Replace any worn steering components ...

Page 146: ...nd record Call this measurement B w Subtract measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B MEASUREMENT Wheel Toe Out A B 1 8 1 4 3 to 6 cm TOE ADJUSTME...

Page 147: ...fied in Wheel Toe Alignment IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly 4 After alignment is complete torque jam nuts to specification TORQUE Tie Rod Jam Nut 14 ft lbs 19 Nm CAMBER AND CASTER The camber and caster are non adjustable MAINTENANCE ...

Page 148: ...e rear shock absorber springs are adjustable Rotate the adjuster cam q either direction to increase or decrease spring tension Always adjust both left and right sides equally Vehicle loads effect suspension spring pre load requirements Use Spanner Wrench to adjust pre load as necessary to avoid bottoming of the shocks Shock Spanner Wrench 2871095 STABILIZER BAR PIVOT LUBRICATION 1 Grease stabilize...

Page 149: ...SION PIVOT POINT LUBRICATION Grease all four front A Arm pivot points q and all eight rear A Arm pivot points w See the maintenance chart for service intervals or grease as needed NOTICE Wheels removed for clarification only Procedure can be done with wheels installed on unit MAINTENANCE ...

Page 150: ...ubricates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body i e road conditions and operating temperature It is important to properly identify the difference between normal operation weepage or misting and a shock that has a leak Below are some images to ...

Page 151: ...transmission in Park P and chock wheels 3 View the brake fluid level in the reservoir The level should be between the MAX and MIN level lines 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and t...

Page 152: ...brake discs 3 The disc s should be replaced if thickness is less than the specified service limit REF PART SERVICE LIMIT q Front Disc See the specifications at the beginning of the Brake System chapter w Rear Disc WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper MAINTENANCE ...

Page 153: ...th water for 15 minutes and get prompt medical 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 OF REACH OF CHILDREN NOTICE Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at...

Page 154: ...intained by using a Polaris battery tender charger or by charging about once a month to make up for normal self discharge Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point BATTERY CHARGING 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during chargi...

Page 155: ... spark plugs and torque to specification Recommended Spark Plug Autolite 5924 TORQUE Spark Plug 15ft lbs 20 Nm Do Not Apply Anti Seize 8 Install spark plug wire into spark plug engine 570 DOHC SPARK PLUG SERVICE 570 1 Remove spark plug high tension lead q Clean plug area so no dirt and debris can fall into engine when plug is removed 2 Remove spark plug w 3 Inspect electrodes for wear and carbon b...

Page 156: ... 0 7 0 8 mm 6 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 7 Install spark plug and torque to specification Recommended Spark Plug NGK MR7F TORQUE Spark Plug 9 ft lbs 12 Nm w o anti seize MAIN FRAME ENGINE GROUND Inspect engine ground cable connections q Be sure ground wires are tight and not corroded The main chassis g...

Page 157: ...NT FLOW DIAGRAM 3 20 COOLING SYSTEM SPECIFICATIONS 3 21 COOLING SYSTEM PRESSURE TEST 3 21 PRESSURE CAP TEST 3 21 RADIATOR 3 22 COOLANT DRAIN RADIATOR REMOVAL 3 22 THERMOSTAT REPLACEMENT 3 23 COOLING SYSTEM BLEEDING PROCEDURE 3 24 WATER PUMP COVER AND IMPELLER SERVICE STATOR COVER REMAINS ON ENGINE 3 25 WATER PUMP MECHANICAL SEAL OIL SEAL REPLACEMENT 3 25 TROUBLESHOOTING 3 31 ENGINE 3 31 COOLING SY...

Page 158: ...TION 3 59 PISTON CONNECTING ROD ASSEMBLY 3 60 CYLINDER INSTALLATION 3 60 CYLINDER HEAD INSTALLATION 3 61 VALVE SEALING TEST 3 62 VALVE CLEARANCE CHECK ADJUSTMENT 3 62 VALVE LASH TAPPET SELECTION MATRIX 3 64 CAMSHAFT INSTALLATION TIMING 3 65 CAMSHAFT TIMING QUICK REFERENCE 3 67 VALVE COVER INSTALLATION 3 68 ENGINE DISASSEMBLY INSPECTION LOWER END 3 69 CRANKCASE DISASSEMBLY 3 69 STATOR COVER REMOVAL...

Page 159: ...BLY 3 97 CYLINDER HEAD INSPECTION 3 98 CYLINDER HEAD WARP INSPECTION 3 98 VALVE INSPECTION 3 98 COMBUSTION CHAMBER CLEANING 3 99 VALVE SEAT RECONDITIONING 3 100 CYLINDER REMOVAL 3 102 CYLINDER INSPECTION 3 102 PISTON REMOVAL 3 103 PISTON TO CYLINDER CLEARANCE 3 103 PISTON ROD INSPECTION 3 104 PISTON RING INSTALLED GAP 3 105 ENGINE ASSEMBLY TOP END 3 106 PISTON RING INSTALLATION 3 106 PISTON CONNEC...

Page 160: ...AL 3 129 CRANKSHAFT INSPECTION 3 129 PTO SIDE CRANKCASE BEARING SERVICE 3 130 MAG SIDE CRANKCASE BEARING SERVICE 3 131 OIL PICKUP ASSEMBLY INSPECTION 3 132 OIL PRESSURE REGULATOR BYPASS VALVE INSPECTION 3 132 CRANKCASE INSPECTION 3 132 ENGINE ASSEMBLY LOWER END 3 133 CRANKCASE ASSEMBLY PTO SIDE 3 133 BALANCE SHAFT INSTALLATION TIMING 3 135 FINAL CRANKCASE ASSEMBLY 3 135 STARTER ONE WAY CLUTCH INST...

Page 161: ...Flywheel Puller PU 50105 Oil Filter Wrench PV 43531 Oil Pressure Gauge PU 50569 Oil Pressure Gauge Adapter 2017 and earlier models PU 52502 Oil Pressure Gauge Adapter 2018 and later models PA 49317 Stator Cover Removal Handles PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PU 50689 Water Pump Mechanical Oil Seal Installation Kit Bosch Automotive Service Solutions 1 800 ...

Page 162: ...ean the area around the main oil gallery plug q located on the oil filter adapter housing 4 Remove the plug and insert the oil pressure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTICE Test results are based on the use of the recommended engine oil Polaris PS 4 at operating temperature and may vary considerably if any other oil is used or if eng...

Page 163: ...3 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 7 ENGINE OIL FLOW CHART ENGINE COOLING SYSTEM ...

Page 164: ...ing Width Intake Service Limit 0 0551 1 4 mm Valve Seat Contacting Width Exhaust Standard 0 0590 0 0039 1 5 0 10 mm Valve Seat Contacting Width Exhaust Service Limit 0 0748 1 9 mm Valve Seat Angles 30 0 1 5 45 0 0 5 60 0 1 5 Valve Guide Valve Guide Inner Diameter 0 2165 0 2171 5 500 5 515 mm Valve Valve Lash Cold Intake 0 006 0 002 0 152 0 050 mm Valve Lash Cold Exhaust 0 008 0 002 0 203 0 050 mm ...

Page 165: ...Service Limit 0 0220 0 56 mm Oil Control Rails Standard 0 0098 0 0401 0 25 1 02 mm Oil Control Rails Service Limit 0 0480 1 22 mm Ring to Groove Clearance Top Ring Standard 0 0011 0 0037 0 030 0 095 mm Top Ring Service Limit 0 0042 0 108 mm Second Ring Standard 0 0007 0 0029 0 020 0 076 mm Second Ring Service Limit 0 0035 0 089 mm Connecting Rod Connecting Rod Small End I D Standard 0 8665 0 8670 ...

Page 166: ...d engine components can be serviced while the engine is mounted in the chassis ENGINE REMOVAL NOTICE Some engine repair procedures can be performed without removing the engine assembly from the vehicle Refer to Accessible Engine Components for further information The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine Have an assistant ...

Page 167: ... the correct Drive Clutch Puller PA 48595 to prevent damage to crankshaft 9 Disconnect the stator wire connector and cut the tie strap securing the wiring to the front engine mount bracket Replace tie strap for engine installation 10 Remove the CPS sensor from the stator cover on the right hand side of the engine Plug CPS hole with clean shop towel Inspect CPS O ring and replace if needed 11 Disco...

Page 168: ...ecuring the engine to the front motor mount bracket 23 Remove the 8 bolts Item 7 securing the coupler brackets to the engine and transmission 24 Loosen the 2 bolts and nuts Item 6 so the engine mount bracket can be slightly tilted away from engine 25 With the help of an assistant and the engine hoist raise the engine vertically out of the vehicle frame NOTICE Have an assistant help guide the engin...

Page 169: ...Item 1 Do not tighten at this time 5 Install the four engine to transmission coupler plates Item 2 and instal the 8 bolts and washers Item 3 Do not tighten fasteners at this time NOTICE DO NOT torque fasteners at this time 6 Install the Clutch Center Distance Tool PU 50658 or PU 50658 A onto the crankshaft and transmission input shaft The pictures below show a properly installed tool PU 50658 NOTI...

Page 170: ...nt center isolator bolts Item 4 to specification TORQUE Isolator Center Bolt 40 ft lbs 54 Nm 10 Remove the lifting straps and overhead or portable engine hoist and remove the support previously installed under the transmission case during the engine removal process 11 Reposition the head pipe assembly in the chassis and install new muffler and head pipe seals Item 5 Install the 3 head pipe bolts I...

Page 171: ...ure all hose and wire routing is correct Torque all fasteners to specification as outlined in the PVT System chapter 26 Install the intake baffle assembly Secure the 3 clamps that attach the assembly to the crankcase vent air box lid and inner clutch cover 27 Install the rear bumper and cargo box assembly See Body Frame chapter 28 Install the left hand rear wheel and torque wheel nuts to specifica...

Page 172: ...nd 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 Check oil level indicated on the dipstick Add oil if necessary 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular check...

Page 173: ...ce Manual Copyright Polaris Inc 3 17 ENGINE MOUNTING AND TORQUE VALUES REF DESCRIPTION NOTES q Bolt Torque to 55 ft lbs 75 Nm w Bolt Torque to 40 ft lbs 54 Nm e Nut Torque to 25 ft lbs 34 Nm r Bolt Torque to 18 ft lbs 25 Nm ENGINE COOLING SYSTEM ...

Page 174: ...aft sprockets to ensure the engine is at TDC of the compression stroke 2 With the valve cover and thermostat housing removed rotate the engine so the cam lobes are facing outward and the Cylinder Holding and Camshaft Timing Plate can be installed into the slots of the camshafts as shown below This will set TDC of the compression stroke Camshaft Timing Plate PU 50563 NOTICE Intake cam sprocket shou...

Page 175: ...rt a 1 4 drive socket extension through the crankcase and into the crankshaft locating hole q This will set TDC but not necessarily TDC of the compression stroke View the timing marks on the cam shaft sprockets to ensure the engine is at TDC of the compression stroke ENGINE COOLING SYSTEM ...

Page 176: ...is Inc COOLING SYSTEM COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM REF DESCRIPTION NOTES q Radiator w Fan Shroud e Cooling Fan r Recovery Bottle t Radiator Drain Plug y Upper Radiator Hose u Lower Radiator Hose i Bypass Hose o Water Pump Hose ENGINE COOLING SYSTEM ...

Page 177: ...may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Polaris Premium 50 50 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use COOLING SYSTEM PRESSURE TEST 1 Remove the hood from the front cab WARNING Never remove pressure cap when engine is warm or hot The cooling system is under pressure and serious burns may resu...

Page 178: ...hen the engine and radiator are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 2 Slowly remove the pressure cap to relieve any cooling system pressure 3 Place a suitable drain pan underneath the drain valve on the front left side of the vehicle 4 Drain the coolant from the radiator by opening the drain valve q in the lower left corner of the radiator Properly disp...

Page 179: ...nder pressure and serious burns may result 2 Remove the pressure cap to relieve any system pressure see Pressure Cap Test 3 Drain coolant to a level below the thermostat housing 4 Tilt the cargo box 5 Remove the two bolts q retaining the thermostat cover 6 Lift the cover from the engine and remove the thermostat 7 Reverse this procedure for installation Replace thermostat seal if worn or damaged T...

Page 180: ... pressure cap Item 2 and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck 5 Remove the cargo box access cover to gain access to the coolant bleed screw that is on top of the thermostat housing 6 Open the bleed screw Item 3 to allow any trapped air to escape 7 Fill the radiator until a steady stream of coolant begins to drain out of the bleed screw 8 Tighten the bl...

Page 181: ...ove the water pump impeller r NOTICE The water pump impeller r uses reverse left threads 11 Inspect the water pump cover and impeller for damage Replace as necessary 12 Follow this procedure in reverse to assemble the water pump impeller and cover Always use a new water pump cover gasket Torque all fasteners in sequence to specification TORQUE Water Pump Cover Fastener 9 ft lbs 12 Nm Apply Loctite...

Page 182: ...asket e Discard the water pump gasket 12 Remove the water pump impeller r NOTICE The water pump impeller uses reverse left threads 13 Remove the oil dipstick t 14 Remove the 13 bolts y securing the stator cover to the engine 15 If needed install the stator cover removal handle tool PA 49317 to the water pump cover bolt holes to aid in stator cover removal CAUTION The flywheel contains powerful mag...

Page 183: ...e oil seal o from the stator cover 20 Press out the water pump drive shaft bearing a from the stator cover Discard bearing and replace with new Water Pump Assembly 21 Thoroughly clean the stator cover 22 Press in a new water pump drive shaft bearing a until it is fully seated in the cover CAUTION Be sure bearing is fully seated in cover or severe engine damage may result 23 Clean and de grease the...

Page 184: ...h clean engine oil 27 Use the water pump oil seal installation tool in kit PU 50869 to fully install the new water pump oil seal s CAUTION Be sure the oil seal is fully seated in cover or severe engine damage may result 28 Use the water pump mechanical seal installation tool in kit PU 50869 to fully install the new water pump mechanical seal d until it is fully seated in the cover 29 Install a new...

Page 185: ...r to verify the crankshaft slot and the water pump drive shaft blade are properly engaged Verify the stator cover is laying flat on the engine case CAUTION The flywheel contains powerful magnets Use caution when installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal and installation process or injury could result CAUTION If the water pump drive ...

Page 186: ...lant hose to the water pump cover and tighten hose clamp 42 Connect the stator wire connector and install a new tie strap securing the wiring to the front engine mount bracket 43 Install the CPS sensor into the stator cover Inspect CPS O ring and replace if needed 44 Install the right hand rear wheel and torque the wheel nuts to specification Safely lower vehicle TORQUE Steel Wheel Nuts 36 ft lbs ...

Page 187: ...ilure Engine Runs But 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 Air box removed reinstall all intake components Incorrect flywheel installation or sheared flywheel key Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plu...

Page 188: ...lty Poor connections 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 leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or...

Page 189: ...it 0 0024 0 060 mm Cylinder Head Standard Height 4 745 0 0020 120 53 0 05 mm Valve Seat Contacting Width Intake Standard 0591 0 0039 1 5 0 10 mm Contacting Width Intake Service Limit 0 0748 1 9 mm Contacting Width Exhaust Standard 0 0787 0 0039 2 0 0 10 mm Contacting Width Exhaust Service Limit 0 0945 2 4 mm Valve Seat Angles 30 0 1 5 45 0 0 5 60 0 1 5 Valve Guide Valve Guide Inner Diameter 0 2741...

Page 190: ... Second Ring Standard 0 0094 0 0196 0 24 0 50 mm Second Ring Service Limit 0 0220 0 56 mm Oil Control Rails Standard 0 0098 0 0401 0 25 1 02 mm Oil Control Rails Service Limit 0 0480 1 22 mm Ring to Groove Clearance Top Ring Standard 0 0011 0 0037 0 030 0 095 mm Top Ring Service Limit 0 0042 0 108 mm Second Ring Standard 0 0007 0 0029 0 020 0 076 mm Second Ring Service Limit 0 0035 0 089 mm Connec...

Page 191: ...3 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 35 ENGINE TORQUE SEQUENCES CYLINDER HEAD CAM CARRIER VALVE COVER WATER PUMP COVER ENGINE COOLING SYSTEM ...

Page 192: ...3 36 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc STATOR COVER CRANKCASE ENGINE COOLING SYSTEM ...

Page 193: ...LANT PATH Apply sealant as shown Crankcase Sealant 2871557 NOTICE Clean the case halves with ISOPROPYL ALCOHOL to remove all sealant before applying new sealant Alignment Pins MUST be installed prior to assembly IMPORTANT Clean the case deck q of all sealant after assembly ENGINE COOLING SYSTEM ...

Page 194: ...DES OIL PICKUP REGULATOR VALVE REF DESCRIPTION NOTES q Oil Pickup Install until fully seated in bore hole Engine oil may be used to aid installation w Oil Pressure Regulator Assembly Torque 20 ft lbs 12 Nm e Piston Oil Jet Torque 35 in lbs 4 Nm r Oil Pump Cover Torque 106 in lbs 12 Nm ENGINE COOLING SYSTEM ...

Page 195: ...3 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 39 CYLINDER OIL FILTER OIL PUMP BREATHER ENGINE COOLING SYSTEM ...

Page 196: ...8 Nm u Oil Filter Lubricate seal with engine oil prior to filter installation i Gear Sprocket to be installed so that OUT is visible o Screw Torque 12 Nm Replace if loosened or removed a Gear Sprocket to be installed so that OUT is visible s Screw Torque 106 in lbs 12 Nm d Oil Pump Cover Apply ENGINE OIL to bore of oil pump cover prior to assembly f Drain Plug Torque 11 ft lbs 16 Nm g Gerotor Inne...

Page 197: ...3 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 41 CAMSHAFTS CYLINDER HEAD FLYWHEEL IDLER GEARS STATOR COVER ENGINE COOLING SYSTEM ...

Page 198: ...mbly i Gear o Screw 44 ft lb 60 Nm Replace camshaft sprocket bolt if loosened or removed a Head Bolt See Cylinder Head Installation page 3 61 s Screw d Timing Chain Tensioner Torque 37 ft lbs 50 Nm Ensure the sealing washer is in place prior to torquing Replace sealing washer if loosened or removed f Screw Torque 106 in lbs 12 Nm g Nut Replace if loosened or removed Torque to spec back off 180 deg...

Page 199: ...3 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 43 SPARK PLUGS STARTER THROTTLE BODY VALVE COVER ENGINE COOLING SYSTEM ...

Page 200: ...que 89 in lbs 10 Nm r Fuel Injector Apply P80 rubber lubricant prior to assembly t Screw Torque 26 in lbs 2 8 Nm y T MAP Sensor Apply P80 rubber lubricant prior to assembly u Intake Boot Apply P80 rubber lubricant prior to assembly i Screw Torque 22 5 Nm o Screw Torque 22 5 Nm a Screw Torque 89 in lbs 10 Nm s Screw Torque 89 in lbs 10 Nm d Starter Motor Apply grease to starter o ring f Dipstick Ap...

Page 201: ...3 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 45 PISTON CRANKSHAFT BALANCE SHAFT ENGINE COOLING SYSTEM ...

Page 202: ... Nm Apply Loctite 272 Replace if loosened or removed t Rod Apply ENGINE OIL or WHITE LITHIUM grease to bearing surfaces and or bore y Crankshaft Crankshaft to be drawn through bearings in PTO case without side loading the bearing balls Bearing inner race to be supported during installation Minimum axial load to be applied to seat the crank in bearings is 13 3 kN Apply ENGINE OIL or WHITE LITHIUM g...

Page 203: ...3 47 IMPORTANT Orient cir clip as shown below The gap should be located at the 6 o clock or 12 o clock locations IMPORTANT Orient Piston as shown Arrow should be pointing to the exhaust valve side IMPORTANT Time balance shaft and crankshaft gears as shown ENGINE COOLING SYSTEM ...

Page 204: ...e right hand rear wheel well area 5 Replace valve cover seal w if oil leaks are evident CAMSHAFT CARRIER REMOVAL NOTICE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the piston is at Top Dead Center TDC on the compression stroke NOTICE To verify TDC see Setting TDC Top Dead Center 2 Remove the hydraulic cam chain tensioner e from the cylinder Replace ...

Page 205: ...ing down into the engine 6 Carefully remove the camshafto from the engine CAMSHAFT SPROCKET INSPECTION Inspect cam sprocket teeth q for wear or damage Replace timing chain and sprockets as a set if worn or damaged TORQUE Camshaft Sprocket Bolt 44 ft lb 60 Nm CAMSHAFT CAMSHAFT BORE INSPECTION Inspect all main journals and cam lobes as described below and compare to specifications Replace camshaft o...

Page 206: ...under spring pressure to the resting position against gravity NOTICE If the ball or bushing are damaged the whole camshaft needs to be replaced If there is damage to the weight spring or shaft the service kit 2207556 can be ordered to replace the assembly Decompression Kit Part Number 2207556 CAM CHAIN AND GUIDE SERVICE NOTICE The crankcase has a removable lower cam chain drive guide that prevents...

Page 207: ...d bolts e evenly 1 8 turn 45 degrees at a time until all are loose 3 Remove and discard the cylinder head bolts e Replace with new upon assembly 4 Tap cylinder head lightly with a soft faced hammer until loose Tap only in reinforced areas or on thick parts of the cylinder head casting 5 Remove the cylinder head w and head gasket r CYLINDER HEAD DISASSEMBLY CAUTION Wear eye protection during cylind...

Page 208: ...alve 8 Clean the combustion chamber and head gasket surface CYLINDER HEAD INSPECTION Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon IMPORTANT Use care not to damage gasket sealing surface All gasket surfaces must be clean dry and free of any oil or grease upon assembly Clean sealing surfaces with rubbing alcohol or electrical contact cleaner Do not touch ...

Page 209: ...rn burnt bent or damaged 6 Measure diameter of valve stem with a micrometer in three places then rotate 90 and measure again take six measurements total Compare to specifications MEASUREMENT Valve Stem Diameter Intake 0 2731 0 2737 6 938 6 953mm Exhaust 0 2724 0 2730 6 918 6 933 mm 7 Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micromete...

Page 210: ...lve seat must be reconditioned IMPORTANT If the valve seat is cracked the cylinder head must be replaced Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper width all the way around If the seat is uneven compression leakage will result If the seat...

Page 211: ...wer the valve seat If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut MEASUREMENT Intake Seat Cutter Diameter 1 979 in 50 26 ...

Page 212: ... feeler gauge Cylinder Warpage 00098 025 mm 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 Measure in two different directions front to back and side to side on three different levels 1 2 down from top in the middle and 1 2 up from bottom 5 Record measurements taken in Step 4 If cylinder is tapered or out ...

Page 213: ... ring expander PISTON TO CYLINDER CLEARANCE 1 Measure the outside diameter of the piston 12 mm from the skirt and at a right angle to the direction of the piston pin q 2 Subtract this measurement from the maximum cylinder size measurement from cylinder inspection Piston to Cylinder Clearance 00138 00256 035 065 mm Piston O D 3 6592 3 6598 92 943 92 957 mm PISTON ROD INSPECTION 1 Measure piston pin...

Page 214: ...o Groove Clearance Top Ring Std 0 0011 0 0037 0 030 0 095 mm Service Limit 0 0042 0 108 mm Second Ring Std 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 cylinder head gasket surface 2 Measure installed gap with a feeler gauge at location q Piston Ri...

Page 215: ...n groove until butt ends are on PTO side of piston see illustration 1 NOTICE Ends must butt squarely together and must not overlap 2 Install lower ring with end gap positioned as shown in step 3 3 Install upper ring with end gap positioned as shown REF DESCRIPTION y Upper Ring Gap Position u Lower Ring Gap Position i Spring Expander Gap Position PTO Side 4 Install second ring with marking facing t...

Page 216: ...en installing the piston ensure the piston marking arrow is positioned towards the exhaust side of the engine 4 Place piston q on connecting rod w Push piston pin e through rod and piston until it seats against the installed circlip NOTICE Do not tap on pin or cause any sideways force to connecting rod Warm piston crown with a heat gun if pin cannot be installed by hand or use a piston pin install...

Page 217: ...piston at TDC NOTICE If cam chain and flywheel are installed top end work only is being performed hold cam chain tight while rotating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade CYLINDER HEAD INSTALLATION NOTICE Head gasket and surfaces must be DRY and oil free Use care during assembly to keep oil and finger prints off of gasket 1 Prepare cylinder head gasket se...

Page 218: ... into intake port w and check for leakage around the valves The valve seats should hold fluid with no seepage 3 Repeat for exhaust valve by pouring fluid into exhaust porte VALVE CLEARANCE CHECK ADJUSTMENT NOTICE Always inspect valve clearance prior to camshaft installation or final engine assembly NOTICE Valve clearance should only be checked on a cold engine 1 Install the cam chain guides and ca...

Page 219: ...ll valve clearance measurements are within specification remove the camshaft carriers and proceed to Camshaft Installation Timing 9 Remove the valve tappet q from a valve that was out of specification NOTICE Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes Mark each component or place them in an organized rack as you remove them 10 Re...

Page 220: ...rms and Links Click or go to https www polarisdealers com files ServWarr English Engine 20Valve 20Adjustment 20Calculator pdf The proper valve tappet may also be obtained by completing these steps IMPORTANT The Valve Lash Specification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 ...

Page 221: ...Place the camshaft into the cylinder head and align the timing marks as shown below 4 Wrap the cam chain around the camshaft in its current position 5 Verify that the timing marks qare in alignment as shown below 6 Carefully install the camshaft carrier onto the camshafts 7 Install the four bolts that retain the camshaft carrier Tighten the bolts evenly until snug Do not torque at this time 8 Veri...

Page 222: ...e exhaust decompression mechanism still moves freely and returns by spring force after sprocket has been installed 13 Insure the new sealing washer q is in place 14 Install the hydraulic cam chain tensioner w into the cylinder and torque to specification TORQUE Cam Chain Tensioner 37 ft lbs 50 Nm 15 Rotate crankshaft through two revolutions and verify camshaft timing is correct NOTICE Verify the v...

Page 223: ...cket should have notch marks q aligned with gasket surface Stator Cover Flywheel Removed Flywheel Key faces down and insert a 1 4 drive socket extension through the crankcase and into the crankshaft locating hole q Stator Cover Flywheel Installed V marked on the flywheel is aligned with the CPS mounting hole ENGINE COOLING SYSTEM ...

Page 224: ...E COVER INSTALLATION 1 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 2 Install a new valve cover seal w 3 Install the four valve cover bolts q 4 Torque valve cover bolts to specification TORQUE Valve Cover Bolts 9 ft lbs 12 Nm ENGINE COOLING SYSTEM ...

Page 225: ...move starter drive gear w and shaft q Inspect gear teeth for damage Inspect fit of shaft inside gear and replace gear assembly if clearance is excessive Inspect shaft and shaft bearing surfaces in case and stator housing for wear 6 Hold flywheel special service tool and remove flywheel nut and washer e Discard the flywheel nut and replace for assembly Flywheel special service tool PU 51220 NOTICE ...

Page 226: ...om the flywheel assembly 7 Remove the three one way clutch retaining bolts 8 Remove clutch and inspect both sides of drive rollers w and roller contact surface e inside hub for wear damage or uneven surface 9 Inspect drive surface of starter gear r and bearing surface t for wear damage or uneven surface If any starter clutch component is worn or damaged replace clutch clutch hub and starter gear E...

Page 227: ...er DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result 2 Remove and discard the stator cover gasket CAUTION Be sure engine coolant does not contaminate the engine oil during stator cover service 3 Remove the three bolts e that secure the stator q to the stator cover w 4 Remove the two bolts that secure the stator wire routing bracket r to ...

Page 228: ...50043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc OIL PUMP REMOVAL REF DESCRPITION NOTES q Screw w Cover Oil Pump e Washer r Pin Solid t Shaft Oil Pump y ASM Gerotor ENGINE COOLING SYSTEM ...

Page 229: ... sprocket d mounts to the oil pump shaft 4 Remove the upper oil pump sprocket spacer 5 Remove the three bolts securing the oil pump cover to the crankcase 6 Grasp the oil pump shaft and pull it outward to remove the shaft oil pump cover and inner oil pump geroter This will prevent the oil pump drive pin from falling out and into the crankcase NOTICE The gerotor set has two orientation dots that mu...

Page 230: ...Slide the gerotor w onto the drive shaft and lock them into position on the drive pin 5 Install the washer e onto the drive shaft 6 Install the oil pump cover r onto the shaft assembly 7 Grasp the complete oil pump assembly by the drive shaft and install the assembly into the crankcase 8 Install the three oil pump cover bolts and torque to specification 9 Torque cover bolts to specification TORQUE...

Page 231: ...s Install a new gasket and torque the two fasteners to specification TORQUE Crankcase Breather Cover Bolts 9 ft lbs 12 Nm CRANKCASE SEPARATION NOTICE Before the crankcase can be separated be sure the entire top end and oil pump assembly are removed from the engine as outlined in this chapter 1 Rotate the engine on the engine stand so the magneto side is facing upward 2 Remove the oil filter and th...

Page 232: ...Inspect bearing surfaces for scoring or signs of wear 5 Inspect replace the balance shaft bearings in both crankcase halves See Crankcase Bearing Inspection Removal procedure in this chapter NOTICE Due to extremely close tolerances and minimal wear counterbalance shaft ball bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the inner race of eac...

Page 233: ...tant holding the crankshaft slowly tighten the screw e until the crankcase is completely separated from the crankshaft 4 Remove all special tools from the crankcase CRANKSHAFT INSPECTION NOTICE The connecting rod uses plain bearings The connecting rod bearings are not serviceable If ANY excessive wear or movement is present or if the rod does not rotate on the crankshaft freely the crankshaft asse...

Page 234: ...he outer race of each bearing should fit tightly in the crankcase The inner 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 1 Remove and discard the PTO side crankshaft seal Replace with new for assembly 2 If not already performed remove the screws that secure the bearing retainer...

Page 235: ...ing Retainer Fastener 8 ft lbs 11 Nm Apply Loctite 272 MAG SIDE CRANKCASE BEARING SERVICE Bearing Removal 1 Support the crankcase and drive press or extract the balance shaft bearing q with a blind bearing remover NOTICE The MAG side crankshaft plain bearing w is not serviceable Crankcase replacement is required if the bearing is damaged or has excessive wear The crankshaft is reusable if it meets...

Page 236: ...S VALVE INSPECTION The oil pressure regulator bypass valve is located in the Mag side crankcase w 1 Use a brass drift to press out the oil pressure valve from the crankcase 2 Replace the oil pressure valve if the inner plunger binds sticks or does not operate smoothly 3 Remove and discard the o ring 4 Thoroughly clean the valve 5 Replace the o ring and lubricate with clean engine oil 6 Press the o...

Page 237: ... crankcase Crankshaft Removal Installation Tool PU 50784 Install plate q over adapter w Evenly attach the assembly q onto the PTO side crankcase flange using the four bolts provided with tool Place the nut and large washer onto the crankshaft installation screwe Insert the crankshaft installation screw through the threaded portion of the adaptor w Fully thread the crankshaft installation screw int...

Page 238: ... crankshaft flange 10 Use the crankshaft removal installation tool to properly drive the crankshaft seal into the crankcase Crankshaft Removal Installation Tool PU 50784 Center plate q over the crankshaft so it is resting on the crankshaft seal Center adaptor w over the crankshaft end Place the nut and large washer onto the crankshaft installation screw Insert the crankshaft installation screw thr...

Page 239: ...ng 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 crankcase mating surface as indicated below q Be sure alignment pins w are in place Crankcase Sealant PN 2871557 3 Carefully assemble MAG crankcase to PTO crankcase immediately Do not allow sealant to dry 4 Tap crankcase evenly unti...

Page 240: ...stand adapter onto the engine ears as shown below Engine Stand Adapter PU 50824 A 9 Select the proper engine stand sleeve adapter and install it onto the engine stand adapter Sleeve adapter for a 2 bore engine stand PU 50625 Sleeve adapter for a 2 375 bore engine stand PW 47054 10 Place engine onto the engine stand for top end engine assembly as outlined in this chapter Engine Stand PU 50624 A ENG...

Page 241: ...e one way clutch retaining bolts threads w Place hub on flywheel and install bolts 4 Torque screws to specification TORQUE One Way Clutch Retaining Bolts 1st 6 ft lbs 8 Nm 2nd 9 ft lbs 12 Nm Apply Loctite 272 FLYWHEEL INSTALLATION 1 Clean the threads q taper w and flat e of crankshaft to remove all oil or grease 2 Clean flywheel taper r with alcohol to remove all oil or grease 3 Apply a small amou...

Page 242: ...nward while rotating the starter gear counter clock wise Fully install the flywheel until seated on the crankshaft taper 9 Install the flywheel washer 10 Hold flywheel with commercially available strap wrench 11 Torque new flywheel nut u to specification TORQUE Flywheel Retaining Nut 1st 133 ft lbs 180 Nm 2nd Back off 180 3rd Re torque to 133 ft lbs 180 Nm NOTICE The flywheel nut has standard rota...

Page 243: ...ctite 242 to end 8 10 threads of the stator screws e and the wire routing bracket screws r 6 Install a new stator cover gasket 7 Install the stator cover TORQUE Stator Wire Retainer 6 ft lbs 8 Nm Apply Loctite 242 CAUTION The flywheel contains powerful magnets Use caution when installing the stator cover DO NOT place fingers between cover and crankcase at any time during the installation process o...

Page 244: ...olts 22 ft lbs 30 N m Torque in Sequence Shown Crankshaft Position Sensor CPS Fastener 9 ft lbs 12 N m Cylinder Head Bolts Black Torque in sequence for all steps Step 1 21 ft lbs 28 N m Step 2 26 ft lbs 35 N m Step 3 Additional 135 Torque the Outer M6 Head Bolts 89 9 in lbs 10 1 Nm Cylinder Head Bolts Silver Apply light coat of engine oil to bolt threads and under bolt head Torque in sequence for ...

Page 245: ... Pressure Regulator 20 ft lbs 27 N m Oil Pressure Regulator Valve Cover 7 ft lbs 10 N m Oil Pump Sprocket Bolt 9 ft lbs 12 N m Oil Pump Cover Bolt 8 ft lbs 11 Nm Spark Plug 9 ft lbs 12 N m Do Not Apply Anti Seize Starter Mounting Bolts 3 ft lbs 4 Nm Starter One Way Clutch Screws 9 ft lbs 12 Nm Apply Loctite 272 Stator Cover Screws 9 ft lb 12 Nm Stator Wire Routing Bolts 6 ft lbs 9 Nm Apply Loctite...

Page 246: ...ved Apply light coat of engine oil to bolt threads and under bolt head Torque in sequence for all steps Step 1 18 ft lbs 25 N m Step 2 30 ft lbs 41 N m Step 3 Loosen all fasteners until they are unseated Step 4 15 ft lbs 20 N m Step 5 26 ft lbs 35 N m Step 6 Additional 180 Step 7 Additional 180 Torque the Outer M6 Head Bolts 89 9 in lbs 10 1 Nm M6 Bolts 7 ft lbs 10 Nm ENGINE COOLING SYSTEM ...

Page 247: ...t Polaris Inc 3 91 STATOR COVER WATER COVER Stator Cover Bolts 9 ft lbs 12 Nm Water Cover Bolts 9 ft lbs 12 Nm Apply Loctite 204 to bolt threads CAM CARRIER VALVE COVER Camshaft Carrier Bolts 7 ft lbs 10 N m Valve Cover Bolts 7 ft lbs 10 N m ENGINE COOLING SYSTEM ...

Page 248: ...3 92 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc CRANKCASE TIMING SEALING PATH TIMING MARKS CRANKCASE SEALING PATH ENGINE COOLING SYSTEM ...

Page 249: ...gine and remove it out of the right hand rear wheel well area 5 Replace isolators after each usew 6 Replace Valve cover seal eif oil leaks are evident 7 Remove the spark plug r Stuff spark plug hole with a shop towel to prevent anything from falling into the combustion chamber if further engine disassembly is required CAMSHAFT CARRIER REMOVAL NOTICE The camshafts can be removed with the engine ins...

Page 250: ... into the engine 6 Mark the intake o and exhaust a camshafts to ensure proper assembly 7 Lift upward on the intake camshaft while rotating it counter clockwise Walk the timing chain off of the sprocket Carefully remove the intake camshaft from the engine 8 Remove the cam chain from the exhaust camshaft sprocket a and remove the exhaust camshaft from the engine CAMSHAFT SPROCKET INSPECTION NOTICE C...

Page 251: ...cification NOTICE Replace camshafts if damaged or if any part is worn past the service limit MEASUREMENT Camshaft Lobe Height Intake 1 5704 0 0038 39 89 0 097 mm Exhaust 1 5405 0 0038 39 13 0 097 mm EXHAUST CAMSHAFT DECOMPRESSION MECHANISM NOTICE Removal of the decompression mechanism is not necessary unless replacement is required 1 Thoroughly clean and inspect the decompression mechanism q locat...

Page 252: ...if excessive wear is evident 5 Upon installation torque all fasteners to specification and reassemble engine and vehicle as outlined in this chapter TORQUE Lower Cam Chain Guide Fasteners 9 ft lbs 12 Nm Upper Cam Chain Guide Fasteners 7 ft lbs 10 Nm CYLINDER HEAD REMOVAL NOTICE The cylinder head can be serviced with the engine installed in the chassis Do not rotate head assembly up side down until...

Page 253: ...ead 2 Compress the valve spring by hand using valve spring compressor adapter Valve Spring Compressor Adapter PV 43513 A 3 Push down on the spring and remove the split keepers q 4 Slowly release valve spring pressure and remove the compressor adapter 5 Remove the valve retainer w valve spring e valve stem seal r and valve spring seat t Discard the valve seal NOTICE Replace valve seals whenever cyl...

Page 254: ...everal different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head MEASUREMENT Cylinder Head Warp Limit 0024 0 06 mm VALVE INSPECTION 1 Remove all carbon from valves with a soft wire wheel or brush 2 Check valve face for excessive runout pitting and burnt spots 3 To check for bent ...

Page 255: ...ve Guide I D 0 2165 0 2171 5 500 5 515 mm 8 Be sure to measure each guide and valve combination individually NOTICE The valve guides cannot be replaced COMBUSTION CHAMBER CLEANING WARNING Wear eye protection during combustion chamber cleaning 1 Clean all accumulated carbon deposits from combustion chambers and valve seat area q NOTICE Polaris Premium Carbon Clean can be used to help remove carbon ...

Page 256: ...e seat pressure is reduced causing carbon accumulation and possible compression loss If the seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of the seat I...

Page 257: ...h on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut Intake Seat ...

Page 258: ... the reinforced areas only until loose 4 Rock cylinder forward and backward and lift it from the crankcase supporting piston and connecting rod 5 Remove the cylinder from the engine 6 Remove and discard cylinder base gasket CYLINDER INSPECTION 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder for warpage using a straight edge and feeler gauge Cylinde...

Page 259: ... may lose radial tension 3 Remove top ring IMPORTANT Using a piston ring pliers carefully expand ring and lift it off the piston Do not expand the ring more than the amount necessary to remove it from the piston By hand use both of your thumbs to spread the ring open and push up on the opposite side 4 Repeat steps for the second ring 5 Remove oil control ring top rail first then remove the bottom ...

Page 260: ...d small end ID Inspect bearing surface for damage Piston Pin Degree of Fit Pin should be a push fit by hand with piston at room temperature or warmed slightly Connecting Rod Small End ID Std 0 8665 0 8670 22 010 22 023 mm 4 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove clearance exceeds s...

Page 261: ...ylinder head gasket surface 2 Measure installed gap with a feeler gauge at location q Piston Ring Installed Gap Top Ring Std 0 0059 0 0122 0 15 0 31 mm Limit 0 0137 0 35 mm Second Ring Std 0 0094 0 0196 0 24 0 50 mm Limit 0 022 0 56 mm Oil Ring Rails Std 0 0098 0 0401 0 25 1 02 mm Limit 0 0480 1 22 mm NOTICE Always check piston ring installed gap after re boring a cylinder or when installing new r...

Page 262: ...n groove until butt ends are on PTO side of piston see illustration 1 NOTICE Ends must butt squarely together and must not overlap 2 Install lower ring with end gap positioned as shown in step 3 3 Install upper ring with end gap positioned as shown REF DESCRIPTION y Upper Ring Gap Position u Lower Ring Gap Position i Spring Expander Gap Position PTO Side 4 Install second ring with marking facing t...

Page 263: ...ition NOTICE Never re use a piston pin circlip 3 When installing the piston be sure the piston marking EX is positioned towards the exhaust side of the engine 4 Place piston q on connecting rod w Push piston pin e through rod and piston until it seats against the installed circlip NOTICE Do not tap on pin or cause any sideways force to connecting rod Warm piston crown with a heat gun if pin cannot...

Page 264: ...ignment with chain room 6 Carefully compress rings with fingers or commercially available spring compression tool and install cylinder with a slight front to back rocking motion until all rings are captive in cylinder and past the taper of the sleeve 7 Remove support block and ring compressor 8 Push cylinder downward until fully seated on base gasket 9 Hold the cylinder in place and rotate the eng...

Page 265: ...70 Service Manual Copyright Polaris Inc 3 109 CRANKCASE IDENTIFICATION The first image displays 1 crankcase dowel q for 2015 and earlier models The second image displays 2 crankcase dowels w for 2016 and later models ENGINE COOLING SYSTEM ...

Page 266: ...der head gasket sealing surfaces by cleaning thoroughly to remove all residue The new head gasket must be installed clean and dry free from oil or grease NOTICE Do not touch sealing surfaces of the new head gasket 3 Guide cam chain r through a new head gasket t and install the gasket on the cylinder locating it on the alignment pins 4 Carefully set the cylinder head y in place on alignment pins NO...

Page 267: ...all residue The new head gasket must be installed clean and dry free from oil or grease NOTICE Do not touch sealing surfaces of the new head gasket 3 Guide cam chain r through a new head gasket t and install the gasket on the cylinder locating it on the alignment pins 4 Carefully set the cylinder head y in place on alignment pins 5 Install and finger tighten the four NEW cylinder head bolts u even...

Page 268: ... to camshaft installation or final engine assembly 1 Install the cam chain guides and cam chain before camshaft installation if removed as outlined in this chapter 2 Reference the camshaft intake q and exhaust w markings made 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 bea...

Page 269: ...timing plate PU 50563 Cylinder Holding Camshaft Timing Plate PU 50563 9 Measure the valve clearance of each valve using a thickness feeler gauge Record the measurement if clearance is out of specification MEASUREMENT Intake Valve Clearance cold 006 002 0 150 050 mm MEASUREMENT Exhaust Valve Clearance cold 008 002 0 200 050 mm 10 If any of the valve clearance measurements are out of specification r...

Page 270: ...appropriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 15 Install the new tappet NOTICE Lubricate the outer portion of the valve bucket upon installation 16 Repeat steps until all necessary valves have been adjusted 17 Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 ft lbs...

Page 271: ...ecification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the valve lash specification from the actual valve lash on the engine i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3 digit tappet number by 100 i e 450 100 4 5 mm 3 Add the results of step 1 and step 2 i e 0 09 mm 4 5 mm 4 59 mm 4 Multiply that answer by 100 to obtain the correct new tappet i e 4 59 mm x 100 459 5 Refe...

Page 272: ...S 4 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 the exhaust cam in its current position 6 Carefully install the intake cam at an angle to allow for cam chain installation Roll the cam shaft into its bearing pockets and verify that the timing marks are in align...

Page 273: ...rect and the piston is a TDC NOTICE For correct sprocket orientation insure the I for intake on cam and the E for exhaust on cam are positioned as shown View from mag side 11 If timing marks are not aligned Remove the Camshaft Timing Plate from the end of the camshafts Remove the cam carrier bolt and cam carrier Correct the camshaft timing as needed Reinstall the cam carrier Re check cam timing 12...

Page 274: ...new sealing washer u is in place 16 Install the hydraulic cam chain tensioner i into the cylinder and torque to specification TORQUE Cam Chain Tensioner 30 ft lb 40 Nm 17 Rotate crankshaft through two revolutions and verify camshaft timing is correct 18 Check the valve lash after tensioner installation and two engine revolutions NOTICE Verify the valve lash after rotating the engine ENGINE COOLING...

Page 275: ...ts of the camshafts as shown Intake cam sprocket should have I marks aligned with gasket surface and the exhaust cam sprocket should have E marks aligned with gasket surface Stator Cover Flywheel Removed Flywheel Key faces down and insert a 1 4 drive socket extension through the crankcase and into the crankshaft locating hole q Stator Cover Flywheel Installed V marked on the flywheel is aligned wi...

Page 276: ...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 t as shown Crankcase Sealant 2871557 4 Install a new valve cover seal w 5 Install the three valve cover shoulder bolts e and new isolators r Around each T40 fastener 6 Torque valve cover bolts to specification TORQUE Valve Cover Bolts 7 ft lbs...

Page 277: ...emove starter drive gear w and shaft q Inspect gear teeth for damage Inspect fit of shaft inside gear and replace gear assembly if clearance is excessive Inspect shaft and shaft bearing surfaces in case and stator housing for wear 6 Hold flywheel special service tool and remove flywheel nut and washer e Discard the flywheel nut and replace for assembly Flywheel special service tool PU 51220 NOTICE...

Page 278: ...rom the flywheel assembly 7 Remove the three one way clutch retaining bolts 8 Remove clutch and inspect both sides of drive rollers w and roller contact surface e inside hub for wear damage or uneven surface 9 Inspect drive surface of starter gear r and bearing surface t for wear damage or uneven surface If any starter clutch component is worn or damaged replace clutch clutch hub and starter gear ...

Page 279: ...er DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result 2 Remove and discard the stator cover gasket CAUTION Be sure engine coolant does not contaminate the engine oil during stator cover service 3 Remove the three bolts e that secure the stator q to the stator cover w 4 Remove the two bolts that secure the stator wire routing bracket r to ...

Page 280: ...50043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc OIL PUMP REMOVAL REF DESCRPITION NOTES q Screw w Cover Oil Pump e Washer r Pin Solid t Shaft Oil Pump y ASM Gerotor ENGINE COOLING SYSTEM ...

Page 281: ...p sprocket d mounts to the oil pump shaft 4 Remove the upper oil pump sprocket spacer 5 Remove the three bolts securing the oil pump cover to the crankcase 6 Grasp the oil pump shaft and pull it outward to remove the shaft oil pump cover and inner oil pump geroter This will prevent the oil pump drive pin from falling out and into the crankcase NOTICE The gerotor set has two orientation dots that m...

Page 282: ... Slide the gerotor w onto the drive shaft and lock them into position on the drive pin 5 Install the washer e onto the drive shaft 6 Install the oil pump cover r onto the shaft assembly 7 Grasp the complete oil pump assembly by the drive shaft and install the assembly into the crankcase 8 Install the three oil pump cover bolts and torque to specification 9 Torque cover bolts to specification TORQU...

Page 283: ...es Install a new gasket and torque the two fasteners to specification TORQUE Crankcase Breather Cover Bolts 9 ft lbs 12 Nm CRANKCASE SEPARATION NOTICE Before the crankcase can be separated be sure the entire top end and oil pump assembly are removed from the engine as outlined in this chapter 1 Rotate the engine on the engine stand so the magneto side is facing upward 2 Remove the oil filter and t...

Page 284: ...Inspect bearing surfaces for scoring or signs of wear 5 Inspect replace the balance shaft bearings in both crankcase halves See Crankcase Bearing Inspection Removal procedure in this chapter NOTICE Due to extremely close tolerances and minimal wear counterbalance shaft ball bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the inner race of eac...

Page 285: ...stant holding the crankshaft slowly tighten the screw e until the crankcase is completely separated from the crankshaft 4 Remove all special tools from the crankcase CRANKSHAFT INSPECTION NOTICE The connecting rod uses plain bearings The connecting rod bearings are not serviceable If ANY excessive wear or movement is present or if the rod does not rotate on the crankshaft freely the crankshaft ass...

Page 286: ...The outer race of each bearing should fit tightly in the crankcase The inner 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 1 Remove and discard the PTO side crankshaft seal Replace with new for assembly 2 If not already performed remove the screws that secure the bearing retaine...

Page 287: ...ring Retainer Fastener 8 ft lbs 11 Nm Apply Loctite 272 MAG SIDE CRANKCASE BEARING SERVICE Bearing Removal 1 Support the crankcase and drive press or extract the balance shaft bearing q with a blind bearing remover NOTICE The MAG side crankshaft plain bearing w is not serviceable Crankcase replacement is required if the bearing is damaged or has excessive wear The crankshaft is reusable if it meet...

Page 288: ...SS VALVE INSPECTION The oil pressure regulator bypass valve is located in the Mag side crankcase w 1 Use a brass drift to press out the oil pressure valve from the crankcase 2 Replace the oil pressure valve if the inner plunger binds sticks or does not operate smoothly 3 Remove and discard the o ring 4 Thoroughly clean the valve 5 Replace the o ring and lubricate with clean engine oil 6 Press the ...

Page 289: ... crankcase Crankshaft Removal Installation Tool PU 50784 Install plate q over adapter w Evenly attach the assembly q onto the PTO side crankcase flange using the four bolts provided with tool Place the nut and large washer onto the crankshaft installation screwe Insert the crankshaft installation screw through the threaded portion of the adaptor w Fully thread the crankshaft installation screw int...

Page 290: ...e crankshaft flange 10 Use the crankshaft removal installation tool to properly drive the crankshaft seal into the crankcase Crankshaft Removal Installation Tool PU 50784 Center plate q over the crankshaft so it is resting on the crankshaft seal Center adaptor w over the crankshaft end Place the nut and large washer onto the crankshaft installation screw Insert the crankshaft installation screw th...

Page 291: ...ng 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 crankcase mating surface as indicated below q Be sure alignment pins w are in place Crankcase Sealant PN 2871557 3 Carefully assemble MAG crankcase to PTO crankcase immediately Do not allow sealant to dry 4 Tap crankcase evenly unti...

Page 292: ...ne stand PW 47054 10 Place engine onto the engine stand for top end engine assembly as outlined in this chapter Engine Stand PU 50624 A STARTER ONE WAY CLUTCH INSTALLATION 1 Install one way clutch in clutch hub with flange of clutch q facing the flywheel NOTICE The one way clutch can be installed into the hub incorrectly This will cause engine cranking issues 2 Clean screw threads in flywheel to r...

Page 293: ... NOT apply engine oil to the crankshaft taper 4 Rotate crankshaft so the flywheel key y is facing upward 5 Fully install starter gear onto the crankshaft as shown 6 Align the flywheel keyway with flywheel key on the crankshaft 7 Thoroughly clean the crank taper with alcohol 8 By hand lightly press the flywheel inward while rotating the starter gear counter clock wise Fully install the flywheel unt...

Page 294: ...ng 2 Clean mounting surfaces of stator q and housing w 3 Apply crankcase sealant to edges of rubber stator grommet 4 Set the stator in housing and press wire grommet into slot on housing 5 Apply Loctite 242 to end 8 10 threads of the stator screws e and the wire routing bracket screws r 6 Install a new stator cover gasket 7 Install the stator cover TORQUE Stator Wire Retainer 6 ft lbs 8 Nm Apply L...

Page 295: ...2021 RANGER 500 570 Service Manual Copyright Polaris Inc 3 139 8 Install the stator cover screws and torque in sequence to specification TORQUE Stator Mounting Bolts 9 ft lbs 12 Nm Apply Loctite 242 ENGINE COOLING SYSTEM ...

Page 296: ...3 140 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc NOTES ENGINE COOLING SYSTEM ...

Page 297: ...RVIEW 4 4 ETC TEST 4 4 ETC REPLACEMENT 4 4 ETC LEARN PROCEDURE 4 4 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE T MAP 4 5 T MAP OVERVIEW 4 5 T MAP SENSOR TEST 4 5 T MAP SENSOR REPLACEMENT 4 5 PEDAL POSITION SENSOR PPS 4 6 OPERATION OVERVIEW 4 6 PPS TEST 4 6 PPS REPLACEMENT 4 6 CRANKSHAFT POSITION SENSOR 4 7 CPS OVERVIEW 4 7 CPS TEST 4 7 CPS REPLACEMENT 4 9 ENGINE COOLANT TEMPERATURE SENSOR ETC 4 10 ECT ...

Page 298: ...le Code Table or by using Digital Wrench The ECU requires a minimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected RPM LIMIT To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit is exceeded the ECU suppresses the injection signals cutting off the fuel flow and retards ...

Page 299: ...ns provided in Digital Wrench 1 Carefully follow the ECU replacement instructions provided in Digital Wrench to ensure that all essential data contained within the original ECU is transferred to the replacement ECU 2 Remove seat and ECU cover q 3 Remove the 4 screws w retaining the ECU 4 With the ignition turned off disconnect the wire harness from the ECU Lift the connector locking lever and rota...

Page 300: ...uthorization Use Digital Wrench to perform all troubleshooting of this component Use a Volt Ohm meter to test the vehicle harness continuity between the ETC connector and ECU connector Refer to the wire diagram for pin out details If the ETC is faulty the entire ETC assembly must be replaced ETC REPLACEMENT 1 Lift the rear cargo box 2 Remove the airbox and breather box if equipped 3 Disconnect the...

Page 301: ...e temperature and pressure are in your environment when the key is turned on engine not running When the vehicle is started manifold absolute pressure will be around 9 PSI cold engine and drop to around 6 PSI warm engine If unsure about the readings compare to a known good unit Wiring harness issues are more likely to be the cause of a poor running condition than a faulty T MAP The T MAP sensor is...

Page 302: ... varies as the pedal is pressed Reference the Data Display section and be sure the Pedal Position is displayed With the ignition key on for at least 15 seconds and engine not running the Pedal Position will read approximately 9 6 when the pedal is released With the pedal fully depressed the Throttle Position will vary depending on what gear you have selected High Neutral Park Invalid 100 Low 100 R...

Page 303: ...unning CPS TEST NOTICE The CPS is a sealed non serviceable assembly If fault code diagnosis indicates a problem with this sensor circuit test as follows RESISTANCE TEST 1 Access the CPS connector 2 Disconnect CPS from the main harness connector 3 Measure the resistance between the CPS terminals shown below q using an ohmmeter Verify the resistance at room temperature is within specification CPS Re...

Page 304: ...omponents Measuring the air gap between the CPS sensor q and flywheel encoder w must be done using multiple measurements as the stator cover design does not allow direct air gap measurement 1 Disconnect the CPS q from the main harness 2 Remove the CPS 3 Measure the distance between the sensor mounting flange and the bottom face of the sensor 4 Rotate the engine until a tooth of the encoder flywhee...

Page 305: ...sist thoroughly inspect the relevant wiring connections as a electrical component or connection may persist 7 Install the stator if removed see Engine Cooling System chapter 8 Install the stator cover if removed see Engine Cooling System chapter 9 Install a NEW or known good CPS see the CPS Replacement procedure 10 Fill and bleed the coolant system see Engine Cooling System chapter CPS REPLACEMENT...

Page 306: ...TURE TEST CAUTION Contact with boiling water or steam may cause burns 1 Disconnect the main wiring harness from the ECT sensor on the engine 2 Remove the ECTsensor 3 Fill a pot of water half way 4 Place the pot of water on a hot plate 5 Place the sensor tip of a thermometer in the water ensure the display is legible as you will reference the thermometer throughout the test 6 Safely position the EC...

Page 307: ... level below sensor 3 Disconnect harness from the sensor q 4 Using a wrench remove and replace the sensor applying a light coating of thread sealant to aid installation 5 Torque the sensor to specification TORQUE ETC Fasteners 7 ft lbs 10 N m 6 Add the required amount of coolant and properly bleed the cooling system see Engine chapter ENGINE ELECTRICAL ...

Page 308: ...4 12 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc NOTES ENGINE ELECTRICAL ...

Page 309: ...T LOCATIONS RIGHT VIEW 5 9 LINE HOSE ROUTING 5 10 FUEL LINE ROUTING 5 10 VENT LINE TERMINATION FITTING 5 11 AIR BOX INTAKE SYSTEM 5 12 AIR BOX AIR FILTER ASSEMBLY VIEW 5 12 AIR BOX REMOVAL INSTALLATION 5 14 FUEL TANK PUMP SENDING UNIT 5 15 FUEL TANK ASSEMBLY VIEW 5 15 FUEL TANK REMOVAL 5 15 FUEL TANK INSTALLATION 5 16 FUEL SENDER TEST 5 16 FUEL PUMP TEST 5 17 FUEL PUMP REPLACEMENT 5 18 IGNITION CO...

Page 310: ...5 2 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc POOR IDLE 5 34 FUEL SYSTEM ...

Page 311: ...his determines how long the injector is open and releasing fuel which meters the amount of fuel delivered This range can vary depending on fuel requirements The 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 When the intake valve opens the fuel air m...

Page 312: ...mbly Check Engine Light INITIAL PRIMING STARTING PROCEDURE NOTICE The injection system must be purged of all air prior to the initial start up and or any time the system has been disassembled If the EFI system is completely empty of fuel or has been disassembled and repaired 1 Cycle the key switch from OFF to ON 6 times waiting for approximately 3 seconds at each ON cycle to allow the fuel pump to...

Page 313: ...ols listed or depicted are mandatory while other tools may be 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 the Polaris official tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or https polaris service solutions com FUEL SYSTEM ...

Page 314: ... is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately Do not induce vomiting If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result lo...

Page 315: ...ssary It is recommended to use the DSA USB to serial port adaptor which can be purchased through DSA at www diagsys com DIGITAL WRENCH SMARTLINK MODULE 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 following separately SmartLink Module PU 47468 Vehicle Inte...

Page 316: ...NT LOCATIONS EFI COMPONENT LOCATIONS LEFT VIEW EFI COMPONENT LOCATIONS LEFT VIEW REF COMPONENT 1 Instrument Cluster 2 Ignition Switch 3 Battery 4 Starter Motor Solenoid 5 Regulator Rectifier 6 Fuse Relay Box 7 Starter Motor 8 ECU 9 Ignition Coil 10 Engine Temperature Sensor ECT FUEL SYSTEM ...

Page 317: ... Service Manual Copyright Polaris Inc 5 9 EFI COMPONENT LOCATIONS RIGHT VIEW REF COMPONENT 11 Fuel Pump Sender 12 High Tension Wire Spark Plug 13 Throttle Body ETC 14 Speed Sensor Mounted to Transmission 15 CPS 16 Stator Magneto FUEL SYSTEM ...

Page 318: ...is Inc LINE HOSE ROUTING FUEL LINE ROUTING The fuel supply line q is routed as shown below and retained by a clip w at the front engine mount The fuel vent line e is routed as shown below and terminates at the fuel vent connector r that is inserted in the frame FUEL SYSTEM ...

Page 319: ...cted and tested using a Mity Vac to ensure proper venting Connect the Mity Vac to the fitting and give it 5 pumps The gauge should return to 0 immediately or there is an obstruction NOTICE If the vent line fitting is removed from the frame it must be replaced The ears on the clip arrows will not hold properly once it is removed FUEL SYSTEM ...

Page 320: ...5 12 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc AIR BOX INTAKE SYSTEM AIR BOX AIR FILTER ASSEMBLY VIEW FUEL SYSTEM ...

Page 321: ... NOTES q Cover Airbox w Seal Cover e Airbox r Plug Drain t Air Filter y Intake Boot u Clamp Gear i Clamps Gear Torque to 24 in lbs 2 5 Nm o Pre Filter a Box Intake s Plug Drain d Screw Torque to 8 ft lbs 11 Nm f Seal Engine Inlet g Screw h Nut Torque to 18 ft lbs 27 Nm j Hose Breather FUEL SYSTEM ...

Page 322: ... bottom of the air box assembly to the transmission bracket 5 Remove the air box assembly Air Box Installation Procedure 1 Install the air box bottom assembly back into the engine compartment 2 Reinstall the screw and nut securing the air box to the transmission mount Torque nut to specification TORQUE Air Box Fastener 18 ft lbs 24 Nm 3 Reinstall the air box cover Verify the cover tabs engage the ...

Page 323: ...icle 3 Disconnect the negative and then positive battery cables from the battery 4 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump q Move the fuel line out of the way for tank removal NOTICE A small amount of fuel may come out of the fuel line or tank Properly drain fuel into a suitable container 5 Disconnect the fuel pump electrica...

Page 324: ...QUE Fuel Tank Screw Torque 17 Ft Lbs 23 Nm 3 Reinstall the RH fender panel the fuel cap and all previously removed fasteners 4 Connect the fuel pump electrical harness the fuel line and the vent line Verify the fuel line is locked in to place by lightly tugging on the connector at the fuel pump 5 Reconnect the negative battery cable Test the fuel pump by turning the ignition key on and listening f...

Page 325: ...ions 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 performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately Do not induce vomiting If you spill gasoline on your ski...

Page 326: ...d range and there was continuity across the pump terminals reconnect the plug to the fuel pump making sure you have a clean connection Turn on the key switch and listen for the pump to activate NOTICE If the pump starts repeat steps 3 4 and 5 to verify correct pressure 9 If the pump still does not operate check for correct ECU operation by plugging in a known good ECU of the same model NOTICE If t...

Page 327: ...l line q from the fuel pump NOTICE A small amount of fuel may come out of the fuel line or tank Properly drain fuel into a suitable container 5 Disconnect the fuel pump electrical harness w 6 Be sure the top of the fuel tank is clean If it requires cleaning hand wash the top of the tank e to ensure no debris will enter the fuel system when the fuel pump is removed WARNING Failure to clean area aro...

Page 328: ... provided to clean fuel tank surface and threads Remove all debris grease and oil Allow surfaces to dry completely 13 Install new PFA gasket onto fuel pump assembly using care not to damage gasket or bend float arm 14 Install fuel pump into fuel tank hold float arm to the pump body and tilt assembly to ensure float arm does not get caught or bent during installation 15 Gently push down on fuel pum...

Page 329: ...ngage the retainer on fuel line until it snaps into place Pull on fuel line lightly to confirm connection 21 Connect the fuel pump electrical harness 22 Connect battery 23 Install the seat 24 Test the fuel pump by turning on the key and listening for the pump to activate Cycle the key several times to prime the system and check for leaks FUEL SYSTEM ...

Page 330: ...of the ignition coil windings Spark is induced by the ECU opening the ground leg of the coil circuit This causes the magnetic field in the primary to collapse causing self induction and a great voltage increase in both the primary and secondary This causes voltage to become high enough in the secondary circuit that it can jump the spark plug gap IGNITION COIL WIRE TEST The ignition coil can be tes...

Page 331: ...lectromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector contains a series of calibrated openings which directs the fuel into the intake port in a cone shaped spray pattern The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injec...

Page 332: ... for a period of one hour after shutting off the engine before servicing the fuel pump This allows the exhaust to cool and fuel pressure to drop 1 Tilt the cargo box 2 Be sure the engine has cooled enough to work on 3 Remove the seat and disconnect the negative battery cable 4 Thoroughly clean the fuel injector area if all dirt and debris 5 Hold a shop towel over the fuel line fittings and remove ...

Page 333: ...Excessive voltage will burn out the injector Do not ground the injector with the ignition on The fuel injector will open turn on if relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external ...

Page 334: ...d you should have no continuity 5 If the resistance is high or open a wiring harness inspection is required including a thorough inspection of the ECU connector for contamination or damage 6 If the sensor and wiring passes inspection and reconnecting the ECU does not resolve the issue use a known good ECU from the exact model and year to test for problem resolution Never attempt to service any fue...

Page 335: ... 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 numbers will appear in the information area The first number located far left can range from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes present The se...

Page 336: ...w Normal 4 P1506 Abnormal Frequency or Pulse Width 8 P0501 Abnormal Update Rate 9 P160A Abnormal Rate of Change 10 C1068 C1705 Bad Intelligent Device 12 P3503 Received Vehicle Speed Has Error 19 P106B C1069 Accelerator Position 1 Not Plausible 91 2 P0225 Voltage Too High 3 P0228 Voltage Too Low 4 P0227 Fuel Level Signal Voltage Above Normal 96 3 Voltage Below Normal 4 Manifold Absolute Pressure Se...

Page 337: ...1059 Valid But Below Normal 1 C1060 Data Erratic or Intermittent 2 C1061 Mechanical System Not Responding 7 P1219 Received Engine Speed Has Error 19 C1066 Error in Engine Speed Computation 31 P121C Engine Speed Error in Engine Speed Computation 400 31 P121D Gear Sensor Signal Date Erratic or Intermittent 523 2 P0914 Voltage Above Normal 3 P0917 Voltage Too Low 4 P0916 Abnormal Rate of Change 9 P19...

Page 338: ...Sensor 1 Data Erratic Intermittent or Incorrect 3056 2 P0130 Voltage Above Normal or Shorted to High Source 3 P0132 Voltage Below Normal or Shorted to Low Source 4 P0131 Bad Intelligent Device 12 P113A ECU Output Supply Voltage 1 Valid But Above Normal 3597 0 P16A3 Valid But Below Normal 1 P16A6 Voltage Too High 3 P16A2 Voltage Too Low 4 P16A1 Valid But Above Normal least severe 16 P16A5 Valid But...

Page 339: ... Low Source 4 P0031 Current below Normal or Open Circuit 5 P0030 Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050 Steering Excessive Current Error Current Above Normal or Grounded 520222 6 C1051 Steering Torque Partial Failure Condition Exists 520223 31 C1052 Steering Torque Full Failure Condition Exists 520224 31 C1053 EPS Inverter Temperature Greater than 120 C 248...

Page 340: ...d 5 P1505 Mechanical System Not Responding 7 P1549 Out Of Calibration 13 P1301 Accelerator Position Brake Position Interaction Condition Exists 520275 31 P150A Throttle Position Sensor 1 or 2 Indeterminable Position Sensor Correlation Fault 520276 2 P150C Neither Position Sensor Passed Test 12 P150B Throttle Body Control Power Stage Not Plausible 520277 2 P151A Voltage Above Normal 3 P150D Voltage...

Page 341: ... Off Level 2 Condition Exists 520289 31 P1543 Controller Option Setting Not Programmed Out of Calibration 520290 13 P1544 Throttle Body Control Requested Throttle Angle Not Plausible Condition Exists 520305 31 P1530 ECU Analog to Digital Converter Fault No Load Condition Exists 520306 31 P1531 ECU Analog to Digital Converter Fault Voltage Condition Exists 520307 31 P1532 Accelerator Sensor Synchro...

Page 342: ...ooty 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 dirty plugged Poor fuel quality old fuel Fouled spark plug Injector failure Failed sensor or disconnected wiring Throttle stop screw tampering POOR IDLE Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle...

Page 343: ...BLY 6 8 DRIVE BELT 6 9 BELT REMOVAL 6 9 BELT INSPECTION 6 9 BELT INSTALLATION 6 10 PVT BREAK IN DRIVE BELT CLUTCHES 6 10 CLUTCH ALIGNMENT OFFSET CENTER DISTANCE 6 11 INSPECTION 6 11 ADJUSTMENT 6 12 DRIVE CLUTCH SERVICE 6 13 DRIVE CLUTCH ASSEMBLY VIEW 6 13 CLUTCH DISASSEMBLY 6 14 SHIFT WEIGHT INSPECTION 6 15 SPIDER REMOVAL 6 16 ROLLER PIN AND THRUST WASHER INSPECTION 6 16 BUTTON TO TOWER CLEARANCE ...

Page 344: ...ler PU 50518 Universal Clutch Compressor Tool 2871025 Clutch Bushing Replacement Tool Kit 2870654 Standard Clutch Alignment Tool PART NUM BER SPECIAL SUPPLIES N A Loctite 680 8560054 RTV Silicone Sealer Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com PVT SYSTEM FASTENER TORQUES ITEM TORQUE VALUE Drive Clutch Retaining Bolt 45 ft lbs 61 Nm Drive Clutch Spider...

Page 345: ...e proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures The Polaris Variable Transmission PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clu...

Page 346: ...rfectly matched PVTsystem should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVTsystem changes engine load requirements by either upshifting or backshifting PVT BREAK IN DRIVE BELT CLUTCHES A proper...

Page 347: ...ow only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss o...

Page 348: ... SERVICE PVT SEALING GUARD AND DUCT COMPONENTS REF DESCRIPTION NOTES q Outer Clutch Cover w Clutch Cover Seal e Inner Clutch Cover r PVT Intake Duct t PVT Exhaust Duct y Drain Plug u Clamp Torque to 10 ft lbs 14 Nm i Screw Torque to 60 in lbs 7 Nm o Bolt Torque to 24 in lbs 3 Nm PVT SYSTEM ...

Page 349: ... of rotation and remove drive belt see DRIVE BELT Belt Removal 8 Remove the driven clutch retaining bolt and driven clutch assembly 9 Install the Drive Clutch Holder 10 Remove the drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller Drive Clutch Puller PA 48595 Drive Clutch Holder 9314177 NOTICE Be sure to use the correct Drive Clutch Puller to prevent damage to cranks...

Page 350: ...nes on the shaft 9 Install the inner clutch sheave thrust washers 3 and noting clutch sheave orientation outer clutch sheave Torque retaining bolt to specification TORQUE Driven Clutch Retaining Bolt 38 ft lbs 51 Nm 10 Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch 11 Install drive clutch onto the engine and torque retaining bolt to specification TORQUE D...

Page 351: ...utch mounting bolt 5 Remove the outer sheave 6 Remove the belt from the vehicle BELT INSPECTION 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 2 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Compare belt m...

Page 352: ...7 times to properly seat the belt in the driven clutch 5 Install the outer clutch cover and 8 screws Torque screws to specification TORQUE Outer Clutch Cover Retaining Screws 50 in lbs 5 Nm PVT BREAK IN DRIVE BELT CLUTCHES A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 1...

Page 353: ...or PU 50658 A NOTICE Images for Reference only The tool shown should only be used to check center to center distance The location the tool rests on the shafts may vary PU 50658 A HOLE YEAR VEHICLE DESCRIPTION 1 2012 RZR 570 2 2011 14 RZR 900 2014 15 RZR XP 1000 2013 RANGER 900 3 2014 16 ACE 2015 19 ACE 570 2015 16 RGR ETX 2013 19 RZR 570 2014 19 RANGER 500 570 2015 19 RANGER 570 Full Size 4 2014 1...

Page 354: ...ransmission mounting fasteners loose install the Clutch Center Distance Tool as shown in the inspection process Clutch Center Distance Tool PU 50658 6 With the tool now properly installed in sequence torque the eight engine to transmission coupler bolts to specification TORQUE Engine To Trans Coupler Bolts In Sequence 55 ft lb 75 Nm 7 Torque the two rear transmission isolator fasteners e to specif...

Page 355: ...TION REF DESCRIPTION q Clutch Bolt Replace if removed 47 ft lbs 63 5 Nm s Washers w Lock Washer d One Way Bearing EBS e Flat Washer f Bolt r Cover Screws 100 in lbs 12 Nm g Shift Weight t Spring h Nut 25 in lbs 2 8 Nm y Limiter Spacer j Button u Spider 210 ft lbs 284 Nm k Washer i Sheave Bushing l Roller o Bushing 1 Pin a Spacer PVT SYSTEM ...

Page 356: ...g q 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 brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 5 Remove and inspect the clutch spring See Drive Clutch Spring Specifications for spring inspection 6 Remove the limit...

Page 357: ...r 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 SPECIFICATIONS COLOR FREE LENGTH Red Orange 2 54 64 52 mm Black 2 8 71 12 mm SHIFT WEIGHT INSPECTION 1 Remove shift weight bolts and weights Inspect the contact surface of the weight q The surface should be smooth and free of de...

Page 358: ... moveable sheave bushing Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter ROLLER PIN AND THRUST WASHER INSPECTION 1 Inspect all rollers bushings and roller pins by pulling a flat metal rod across the roller Turn roller with your finger If you notice resistance galling or flat spots replace ...

Page 359: ... See Spider Removal procedure Button to Tower Clearance 000 010 2 Inspect sheave surfaces Replace the entire clutch if worn damaged or cracked BEARING INSPECTION 1 Rotate the clutch bearing in both clockwise and counter clockwise directions The non braking bearing should rotate both directions on the shaft with only a slight amount of drag 2 Verify there is no binding or rough spots If problems ar...

Page 360: ...ace 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 MEASUREMENT Shaft Diameter Standard 1 3745 1 375 34 91 34 93 mm Service Limit 1 3730 34 87 mm 5 Visually inspect PTFE thrust washers for damage Measure the thickness and compare to specification Replace if worn or damaged MEASUREMENT PT...

Page 361: ...1 Adapter Reducer 5010 279 10 1 Number Two Puller Adapter 5020 633 NOTICE Bushings are installed at the factory using Loctite 609 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing CAUTION Clutch components will be hot In order to avoid serious burns wear insulated gloves...

Page 362: ...hing in place on sheave 16 Insert installation puller tool Item A B with A side down into center of bushing 17 With towers pointing upward slide sheave bushing and tool onto puller rod 18 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 19 Turn sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 20 Rem...

Page 363: ...ter of clutch cover 33 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 34 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 35 Turn clutch cover counterclockwise on puller rod until bushing is seated 36 Remove nut from puller rod Take installation tool and clutch cover off rod PVT SYSTEM ...

Page 364: ...tch balance and belt to sheave clearance be sure to reinstall the original quantity and thickness of washers spacers beneath the spider during assembly 3 Compress spider buttons for each tower and install spider q making sure that X or the marks that were made earlier on spider aligns with X or the marks that were made earlier in moveable sheave 4 Torque spider to specification using the holding f...

Page 365: ...VICE ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION q Subassembly Stationary Boss u Cup Spring Boss w Roller Clutch i Plate Retainer e Washer Thrust o Screw 9 ft lbs 12 Nm r Ring Retaining E Ring External a Label Clutch Boss t Subassembly Moveable Boss s Washer Thrust y Spring Compression PVT SYSTEM ...

Page 366: ...l it touches the spring cup 6 Using a T30 Torx driver remove the five screws that secure the spring retainer to the inner clutch sheave 7 Turn the compression tool handle counter clockwise to relieve spring pressure and allow the spring cup and retaining ring to move out from the moveable sheave 8 Remove the compressor tool from the clutch assembly 9 Remove the spring retainer A spring cup B sprin...

Page 367: ... to be shimmed for the following concerns Creeping Hard Shifting Belt tracking too close to one sheave To correct any of these concerns proceed with the following 1 Check that the clutches are fully seated on the shafts 2 Disassemble the secondary clutch If belt is riding close to the primary clutch inside fixed sheave Add 1 shim washer 7556483 0 059 thickness in between the secondary clutch sheav...

Page 368: ...Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slippage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassem...

Page 369: ...and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVTsystem Inspect and clean PVT noise Belt worn or separat...

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Page 371: ...ALLATION 7 8 SHIFT CABLE 7 9 INSPECTION 7 9 SHIFT CABLE REMOVAL INSTALL AND ROUTING 7 9 ADJUSTMENT 7 10 TRANSMISSION SERVICE 7 11 TRANSMISSION REMOVAL 7 11 TRANSMISSION INSTALLATION 7 13 TRANSMISSION INTERNALS SERVICE 7 16 DIFFERENTIAL OPERATION 7 16 TRANSMISSION DISASSEMBLY 7 17 PLANETARY DIFFERENTIAL DISASSEMBLY 7 22 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT 7 23 PLANETARY DIFFERENTIAL ASSEMBLY...

Page 372: ...ESCRIPTION PA 50231 Snorkel Tool 2871698 Part of 2871702 Kit Rear Output Seal Driver 2871699 Part of 2871702 Kit Rear Driveshaft Seal Guide 2871282 Bearing Seal Driver 50 mm PU 50566 Transmission Nut Socket PU 50658 Clutch Center Distance Tool Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com TRANSMISSION ...

Page 373: ...ls listed or depicted are mandatory while other tools may be 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 the Polaris official tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or https polaris service solutions com TRANSMISSION ...

Page 374: ...efer to the Polaris Electronic Parts Catalog for gear tooth counts and part numbers To access the Polaris Electronic Parts Catalog visit http parts polarisind com browse browse asp LUBRICATION FLUID CAPACITY Recommended Transmission Lubricant AGL PN 2878068 Quart Capacity 41 oz 1200 ml TRANSMISSION ...

Page 375: ...NGER 500 570 Service Manual Copyright Polaris Inc 7 5 TRANSMISSION MOUNTING AND TORQUE VALUES REF DESCRIPTION NOTES q Bolt Torque to 55 ft lbs 75 Nm w Bolt Torque to 40 ft lbs 54 Nm e Bolt Torque to 25 ft lbs 34 Nm TRANSMISSION ...

Page 376: ...7 6 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc ASSEMBLY VIEW TRANSMISSION ASSEMBLY VIEW TRANSMISSION ...

Page 377: ... Subassembly LH Case 83 Diff Solenoid 15 Washer 48 Subassembly RH Case 84 Switch Rotary 2 pin 16 Pin Dowel 6 x 20 49 Drum Shift 85 O ring 17 Pin Spring Slotted 6 x 12 50 Gear Sector 16T 86 O ring 18 Ring Retaining 51 Gear Sector 31T 87 O ring 19 Ring Retaining 56 Shaft Reverse 25T 88 Seal Triple Lip 25 x 80 x 10 20 Ring Retaining 57 Shaft Front Output 89 Seal Dual Lip 25 x 47 21 Ring Retaining 58 ...

Page 378: ...er Remove the console from the vehicle 3 Remove the clip t and washer y retaining the shift cable u to the shift lever and disconnect the cable end from the lever 4 Remove the retaining ring i and slide the shift lever off the mounting bracket and out from the frame 5 Remove both bushings o from the shift lever and service as needed INSTALLATION 1 Perform the removal steps in reverse order to inst...

Page 379: ...t cable from the retainers 6 Tilt the box to access the cable where attached to the transmission linkage Remove the clip and washer attaching the cable to the linkage e 7 Loosen the jam nut holding the cable to the Shift Cable Bracket r 8 Gently pull the cable towards the rear of the vehicle to remove the cable from the vehicle IMPORTANT Pay close attention to the shift cable routing while removin...

Page 380: ... move the upper jam nut w 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTICE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount...

Page 381: ...repair is required drain the transmission lubricant see Chapter 2 7 Remove the air box mounting bolt Item 1 8 Remove the breather hose Item 2 loosen the air intake duct clamps Item 3 remove the duct mounting bolt Item 4 and remove the intake duct Item 5 9 Disconnect the main harness from the IAC and TPS at the throttle body 10 Loosen the air box to throttle body clamp Item 6 and move the air box a...

Page 382: ...em 11 shift cable clevis pin and washer Item 12 from the transmission 16 Remove the wire ties retaining the main harness harness to transmission and mounts 17 Using a 15mm socket remove the four bolts Item 13 from the coupler securing the transmission to the engine 18 Remove the two bolts Item 14 attaching the rear transmission mount bracket assembly to the frame Remove the bolt Item 15 that attac...

Page 383: ... 25 ft lbs 34 Nm TORQUE Rear Transmission Mount Bracket Bolts 17 ft lbs 23 Nm 3 By hand install the coupler brackets and the eight engine to transmission coupler bolts Do not torque fasteners at this time 4 Install the Clutch Center Distance Tool PU 50658 onto the crankshaft and transmission input shaft to properly position the clutch center distance The pictures below show the tool PU 50658 prope...

Page 384: ...ission output shaft see Chapter 7 13 Install inner clutch cover outlet duct drive clutch driven clutch belt and outer clutch cover see Chapter 6 14 Install new spring ring Item 13 on rear drive shafts Apply an anti seize compound to the splines Item 14 15 Reinstall the driveshafts into the bearing carriers and fasten the bearing carriers to the control arms Torque fasteners to specification TORQUE...

Page 385: ...Polaris Inc 7 15 24 If transmission lubricant was drained fill the transmission with the specified amount of Polaris AGL see Chapter 2 Transmission Lubrication FLUID CAPACITY Recommended Transmission Lubricant AGL PN 2878068 Quart Capacity 41 oz 1200 ml TRANSMISSION ...

Page 386: ... solenoid mounted in the rear portion of the gearcase actuates the shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly This unlocks the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When Differential Lock is selected power is ...

Page 387: ...move the switch 5 Remove the sector cover bolts F and remove the sector cover G NOTICE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J 9 Remove the...

Page 388: ...n the transmission 12 Lift up on the shift shaft rail Q and move the rail assembly rearward to allow the shift fork pins to be removed from the shift drum R Remove the shift drum R from the transmission housing 13 Remove the shift shaft rail Q and shift forks from the transmission housing as an assembly 14 Remove the rear output shaft assembly S by lifting underneath the gear or by tapping the sha...

Page 389: ...then lift shift fork Y and torsion spring out of transmission housing 19 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembly V Lift the pinion shaft assembly straight up to remove it from the housing Note the longer screw W that locks the snorkel tube 20 Remove all seals from the gearcase halves and clean the cases in preparation for assembly Gear Cluster Disassembly ...

Page 390: ...reverse shaft see Figure 8 2 26 To disassemble the shift shaft rail remove the snap ring X from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compressed springs on the shift rail may pop off causing eye or face injury Snorkel Shaft Removal Disassembly CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure t...

Page 391: ...d shim Z from the snorkel shaft 31 Use an arbor press to remove the snorkel tube from the snorkel shaft 32 Remove the snap ring A and shim B retaining the bearing in the snorkel tube 33 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 34 Remove the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft TRANSMISSION ...

Page 392: ...ear prior to disassembly 2 Remove the 6 screws retaining the differential cover and remove the cover 3 Remove the 6 planet gears and each side gear assembly from the ring gear 4 Inspect the female side gear A male side gear B planet gears C and ring gear D Replace components or bushings as needed Bushing replacement can be performed on all necessary differential components If bushing replacement i...

Page 393: ...s 3 Press the new bushing into the ring gear housing 4 Install the bushing to the specified depth as shown Planet Gear Bushing Replacement 5 Press the old bushing out of the planet gear 6 Thoroughly clean the bore of the planet gear and check for any unwanted burs 7 Press the new bushing into the planet gear until it is flush on each end Repeat this procedure for the remaining planet gears Differe...

Page 394: ...th as shown Female Side Gear Bushing Replacement 12 Locate the bushing split Using a small chisel or flat blade screwdriver peel back and remove the old bushing from the side gear being careful not to damage the side gear 13 Thoroughly clean the bore of the side gear and check for any unwanted burs 14 Press the new bushing into the side gear until it bottoms out TRANSMISSION ...

Page 395: ...s 2 Assemble the side gears and place them onto the ring gear along with the 6 planet gears 3 Align and install the differential cover using the previously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification TORQUE Differential Cover Screws 22 ft lbs 30 Nm TRANSMISSION ...

Page 396: ...7 26 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc GEAR SHAFT BEARING INSPECTION TRANSMISSION ...

Page 397: ...etaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly NOTICE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 I...

Page 398: ...tall the longer screw A Installing the longer screw will lock the snorkel tube and not allow for backlash setting adjustment 10 Torque the bearing cover retaining screws to specification TORQUE Snorkel Bearing Cover Retaining Screws 8 ft lbs 11 Nm 11 Rotate the snorkel tube counterclockwise using the snorkel tool PA 50231 until the snorkel gear and pinion gear have zero backlash NOTICE DO NOTovert...

Page 399: ...ise to the next notch 4th notch 15 Once the backlash is set apply Loctite 242 to the threads and install the locking screw to secure the snorkel tube 16 Torque the locking screw to specification TORQUE Snorkel Locking Screw 8 ft lbs 11 Nm Transmission Assembly NOTICE The snorkel shaft and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after asse...

Page 400: ...o screws T and install with retaining plates over shift fork Torque to specification TORQUE Shift Fork Screws 10 ft lbs 14 Nm 20 Slide engagement dog U onto retaining pins of shift fork 21 Assemble the reverse shaft assembly and input shaft assembly if previously disassembled see illustrations TRANSMISSION ...

Page 401: ... engagement dog Ensure bearing is fully seated upon assembly 24 Assemble shift shaft rail if previously disassembled NOTICE Both shift forks need to be orientated the same way so that the shift fork pins are both offset to the same side of the rail 25 Install the shift shaft rail D and shift forks into the transmission housing as an assembly Be sure the shift forks are engaged into the engagement ...

Page 402: ...57 to the left hand transmission mating surface 29 Install the transmission case cover and retaining bolts Torque bolts to specification TORQUE Transmission Case Bolts 18 ft lbs 24 Nm 30 Install new seals into the transmission case halves The snorkel shaft seal F should be pressed in until it seats against the housing counter bore The input shaft seal G should be pressed in until it seats flush wi...

Page 403: ...tent star with the raised edge facing outward and skip tooth aligned 35 Install the detent pawl onto the shift shaft and carefully install the compression spring 36 Install a new O ring on each shift shaft Apply a small amount of white lithium grease on the O rings shift shafts and component contact surfaces prior to installing the sector cover 37 Clean the transmission and gear sector cover matin...

Page 404: ...ue to specification TORQUE Transmission Fill Drain Plug 14 ft lbs 19 Nm 41 Install the bellcrank onto the shift shaft Note the key splined on the bellcrank and shift shaft Install the nut and torque to specification TORQUE Bell Crank Nut 15 ft lbs 20 Nm 42 Refer to Transmission Installation to complete the repair TRANSMISSION ...

Page 405: ...Shift selector rail travel Worn broken or damaged internal transmission components NOTICE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is...

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Page 407: ...8 13 AWD DIAGNOSIS 8 14 FRONT GEARCASE DISASSEMBLY INSPECTION 8 15 FRONT GEARCASE ASSEMBLY 8 18 FRONT GEARCASE ADC 8 21 EXPLODED VIEW FRONT GEARCASE 4WDC 8 21 OPERATION FRONT GEARCASE 4WDC 8 23 DISASSEMBLY INSPECTION FRONT GEARCASE ADC 8 24 REASSEMBLY FRONT GEARCASE ADC 8 28 TROUBLESHOOTING FRONT GEARCASE ADC 8 31 REAR BEARING CARRIER 8 35 INSPECTION 8 35 REMOVAL 8 35 DISASSEMBLY 8 36 ASSEMBLY 8 3...

Page 408: ...3 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc FRONT PROP SHAFT COMPONENTS 8 45 REMOVAL INSTALLATION CREW 8 45 SUPPORT BEARING REPLACEMENT CREW 8 46 DISASSEMBLY 8 47 ASSEMBLY 8 48 FINAL DRIVE ...

Page 409: ...opyright Polaris Inc 8 3 GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roll Pin Removal Tool PU 48951 or 8700226 CV Boot Clamp Tool Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com FINAL DRIVE ...

Page 410: ...e The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts washers and wheel 4 Remove the two brake caliper mounting bolts CAUTION Do not hang the caliper q by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 5 Remove hub cap cotter pin e front spindle nut w and washer 6 Rotate each bearing r by hand and check for smooth rotation Vi...

Page 411: ...bearing Be sure that all oil residue has been removed from each surface 6 Apply Loctite RC 680 to the outer circumference of the new bearing race w and carefully install the new bearing into the strut housing NOTICE Use care to not allow any of the Loctite compound to get in the bearing 7 Wipe the housing clean of any excess compound and install the retaining ring HUB INSTALLATION 1 Inspect the hu...

Page 412: ... new bolts q Tighten bolts to specified torque TORQUE Brake Caliper Bolt Torque 46 ft lbs 62 Nm CAUTION New brake disc bolts have a pre applied locking agent which is destroyed upon removal Always use new brake disc mounting bolts upon assembly if removed 11 Install wheel washers wheel nuts and tighten evenly in a cross pattern to specified torque Refer to Torque Specifications FINAL DRIVE ...

Page 413: ...Inc 8 7 FRONT HUB WHEEL EXPLODED VIEW REF DESCRIPTION NOTES q Cotter Pin w Castle Nut 90 ft lbs 122 Nm e Washer r Wheel Nut Steel Wheel Nuts 36 ft lbs 49 Nm Aluminum Wheel Nuts 30 ft lbs 90º 41 Nm 90º t Washer y Tire u Rim i Front Hub o Stud a Brake Disc s Bolt FINAL DRIVE ...

Page 414: ...ings for side play by grasping tire wheel firmly and checking for movement It should rotate smoothly without binding or rough spots 3 Remove the four wheel nuts and remove the front wheel 4 Remove the brake caliper mounting bolts q CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 5 Remove and discard the cotter pin then rem...

Page 415: ...nes Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer 2 Install drive shaft into strut housing 3 Install the lower A arm onto the lower ball joint torque nut q to specification and install new cotter pin w 4 Install hub and tighten spindle nut to specification Install a new cotter pin 5 Install the brake caliper Torque fasteners...

Page 416: ... harness Item 3 from the retaining dart 5 Remove the vent line Item 4 from the front gearcase 6 Remove the 4 bolts Item 2 securing the front gearcase to frame 7 Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A arm GEARCASE INSTALLATION 1 Install the gearcase back into the vehicle through the left hand wheel well area between the upper and lower A arm...

Page 417: ...arcase Mounting Bolts 33 ft lbs 56 Nm 5 Connect the AWD wire harness Item 4 6 Refer to FRONT DRIVE SHAFT Drive Shaft Installation and install both front drive shafts into the gearcase 7 Add the proper lubricant to the front gearcase Refer to Chapter 2 for fluid fill and change information Polaris Demand Drive PN 2877922 Front Housing Capacity 6 7 7 6 fl oz 200 225 ml FINAL DRIVE ...

Page 418: ...Y VIEW q Seal s Ring Gear w Cover Plate d Spring e AWD Coil f Output Hub r Backlash Spacer g Bearing t Nylon Spacer h Gearcase Housing y Armature Plate j Drain Plug 10 ft lbs 14 N m u Roller Cage k Fill Check Plug 10 ft lbs 14 N m i Roller l Pinion Gear o Spring Retainer 1 Snap Ring a O ring 2 Cover Plate Screws FINAL DRIVE ...

Page 419: ...gement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts an armature plate q that is keyed to the roll cage w When the ring gear e and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement posit...

Page 420: ... wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the coil t is seated in the U shaped y insert that is pressed into the gearcase cover u The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If t...

Page 421: ...particles from the drain plug magnet 2 Remove the seven cover screws q and remove the cover plate w assembly 3 Remove the LH output hub assembly e from the clutch housing or outer cover plate assembly NOTICE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate r Refer to AWD Diagnosis page 8 14 for detailed inspection process FINAL DRIVE ...

Page 422: ...rom the gearcase housing 7 Remove the RH output hub assembly i from the gearcase housing 8 Remove pinion seal o internal retaining ring a and pinion gear assembly s from the gearcase housing Inspect and clean the gearcase housing and replace all oil seals and O rings 9 Inspect the pinion gear s for chipped broken or missing teeth Inspect the pinion bearing for signs of wear and the pinion shaft se...

Page 423: ...llers must slide up and down and in and out freely within the roll cage j sliding surfaces and H springs NOTICE Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assembly or as a complete kit 13 Inspect clutch housing ring gear k for a consistent wear pattern Inspect the ring gear for chipped broken or missing teeth 14 Inspect the roll cage ...

Page 424: ...pinion shaft seal q into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub w into the gearcase housing 5 Carefully install the rollers e into the roll cage assembly while installing the assembly into the clutch housing NOTICE Install roll cage so that the ring gear grooves line u...

Page 425: ...mature plate u Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTICE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer 10 Carefully install the ring gear and roll cage assembly i into the gearcase housing 11 Install a new O ring on the cover pla...

Page 426: ...output hub assembly o into the cover plate Take care not to damage the new cover plate seal while installing the output hub 13 Install the output cover assembly a onto the gearcase housing Install the seven cover plate screws s and torque to specification TORQUE Cover Plate Screws 9 ft lbs 12 N m FINAL DRIVE ...

Page 427: ...8 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 8 21 FRONT GEARCASE ADC EXPLODED VIEW FRONT GEARCASE 4WDC FINAL DRIVE ...

Page 428: ...ASM OUTPUT HUB r KIT FASTENERS 8 ft lbs 11 Nm t KIT SEAL REPAIR y PLATE ARMATURE u PLATE ARMATURE BD i BEARING o KIT ROLLER SET OF 20 a ASM ROLL CAGE INCL CAGE 20 CLIPS s ASM GEARCASE d ASM PLUG DRAIN 11 ft lbs 15 Nm f PLUG OIL FILL 8 10 ft lbs 11 14 Nm g RING RETAINING INTERNAL h KIT SPRING j RING RETAINING EXTERNAL k ASM GEAR HOUSING AND PINION GEAR FINAL DRIVE ...

Page 429: ... is being driven ADC will not slow the vehicle When the vehicle is in 4x4 ADC the AWD coil is turned on and the ADC coil remains off until necessary When descending a hill the EBS slows the driveline and rear wheels The ADC coil detects the speed difference and locks the front wheels to the driveline The front wheels can now assist in controlling the descent Turning on the ADC Coil applies drag to...

Page 430: ... q 2 Remove bolts w retaining the outer cover plate assembly 3 Remove the outer cover plate assembly NOTICE Press on the output hub assembly e while lifting up on the outer cover plate 4 to prevent removing more than the cover plate 4 Remove the output hub assembly e 5 Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or da...

Page 431: ...on process 7 Remove the torsion spring retainer y 8 Remove the torsion spring u from the top of the ring gear i 9 Remove the roll cage assembly o rollers a and ring gear i Inspect for wear 10 Remove the LH output hub s 11 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 FINAL DRIVE ...

Page 432: ...t wear patterns or damage The surfaces should be free of nicks or burrs 14 Inspect roll cage B sliding surface This surface must be clean and free of nicks burrs or scratches Inspect the H springs but do not remove them from the roll cage 15 Inspect the armature plate for a consistent wear pattern Uneven wear of the armature plate indicates a warped plate which may cause intermittent operation NOT...

Page 433: ...ly 18 Remove the input shaft assembly Inspect the pinion gear g for chipped broken or missing teeth Inspect the input shaft bearing h for signs of wear Replace the input shaft cover O ring prior to reassembly 19 Inspect the input shaft bushing j for wear 20 Thoroughly clean the gearcase components before beginning reassembly FINAL DRIVE ...

Page 434: ...scoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install input shaft bearing and snap ring 5 Press the pinion shaft seal into the gearcase until the seal is flush 6 Install the LH output hub s into the gearcase housing The output hub should spin freely 7 Install the torsion spring by wrapping each leg...

Page 435: ...ngaged into the roll cage assembly NOTICE Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves 13 Install the RH output hub e into the gearcase housing The output hub should spin freely 14 Install the cover plate assembly with a new o ring onto the gearcase NOTICE Verify the square O ring is placed flat on the cover surface If the O ring is twisted ...

Page 436: ...30 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 17 Install the drain plug Torque to specification TORQUE Fill Plug 8 10 ft lbs 11 14 Nm Drain Plug 11 ft lbs 15 Nm FINAL DRIVE ...

Page 437: ...been fixed If not continue onto additional problems listed Check to see if front differential is plugged into wire harness Unplugged Plug wire harness into front drive connector Drive vehicle with ADC mode on to determine if problem has been fixed If not continue onto additional problems listed No power from vehicle to front differential blown fuse Unhook wire connector to front differential Using...

Page 438: ...ng Always replace both do not take springs off old cage and put onto new cage Drive vehicle with ADC mode on to determine if problem has been fixed If not continue onto additional problems listed Torsion Spring Make sure Spring is installed properly Make sure Spring is able to index properly in both directions Plastic retainer should index with some force from spring Retainer should also index far...

Page 439: ...se Coil Resistance B C 4X4 23 Ω 4Ω A D 4X4 ADC 12 49 Ω 4Ω 2 Check the minimum battery voltage at the Grey Brown White wires that feed the hub coil wires AWD Coil Applied Battery Voltage 11 80 12 0 Vdc 3 Inspect the armature plate e for a consistent wear pattern There should be two distinct wear bands r one band inside the other If only one band of wear is present or if there is wear between the tw...

Page 440: ...e gap If the top of the coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the AWD system If this is found replace the cover plate assembly 5 Inspect the rollers for nicks scratches and flat spots Also inspect the roll cage o for cracks and ensure the rollers a are able to ...

Page 441: ... rotate smoothly without binding or rough spots Correct as necessary REMOVAL 1 Elevate the rear end of the vehicle and safely support the vehicle under the main frame area 2 Remove wheel nuts washers and wheel 3 Remove the cotter pin q castle nut w and washers e 4 Remove the two brake caliper mounting bolts r and remove the caliper from the bearing carrier CAUTION Do not hang the caliper by the br...

Page 442: ...ngs 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 detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged 5 Replace the bearing carrier bushings if worn ...

Page 443: ...bearing carrier with the upper A arm If previously removed install new upper A arm bushings Install the upper bearing carrier fastener NOTICE The lower shock bolt may need to be removed to allow the upper A arm to move freely 4 Torque the upper and lower bearing carrier fasteners to specification TORQUE Bearing Carrier Fasteners 40 ft lbs 54 Nm 5 Install the wheel hub assembly onto the rear drive ...

Page 444: ...ove the shaft 5 Remove the rear drive shaft using short sharp jerks to free the circlip from the transmission 6 Refer to the DRIVE SHAFT SERVICE section if repairing the drive shaft REAR DRIVE SHAFT INSTALLATION 1 Install a new circlip q on the end of the drive shaft and apply an anti seize compound to the splines 2 Align the splines of the drive shaft with the transmission and reinstall the drive...

Page 445: ...ts to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension 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 are replaced and when joints are cleaned Refer...

Page 446: ...OTICE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 10 Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly 11 Slide the small boot clamp and boot small end first onto the drive shaft and posit...

Page 447: ... housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and tighten the large clamp using the Axle Boot Clamp Tool PU 48951 or 8700226 Axle Boot Clamp Tool PU 48951 or 8700226 20 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pre...

Page 448: ...nging 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 inner race of the joint to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding NOTICE Tap on inner race only 6 Make sure the circlip q is still on the shaft and not left...

Page 449: ...nt with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability DO NOT use substitutes or mix with other l...

Page 450: ...ull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot 22 Position the boot lip in its groove Install and tighten the large clamp using the Axle Boot Clamp Tool Axle Boot Clamp Tool PU 48951 or 8700226 DRIVE SHAFT ASSEMBLY ...

Page 451: ... rear side of the vehicle 7 Reverse this procedure to reinstall the front prop shaft 8 Use a NEW roll pin upon installation FRONT PROP SHAFT COMPONENTS REF DESCRIPTION q Grease Zerk w Rear Yoke e U Joint r Front Yoke REMOVAL INSTALLATION CREW 1 Elevate and safely support vehicle under the frame The use of a vehicle hoist is recommended for this procedure CAUTION Serious injury may result if machin...

Page 452: ...erse this procedure to reinstall and assemble the front prop shaft 11 Torque bearing support fasteners to specification TORQUE Prop Shaft Bearing Support Fasteners 36 ft lbs 49 Nm 12 If front prop shaft was removed use a NEW roll pin upon installation SUPPORT BEARING REPLACEMENT CREW 1 Follow steps 4 6 of the Removal Installation CREW procedure 2 Remove the bearing support upper and lower half and...

Page 453: ... fasteners Torque the support bearing fasteners to specification TORQUE Prop Shaft Support Bearing Fasteners 36 ft lbs 49 Nm 9 Grease the prop shaft yoke s 10 Reinstall the large storage container and front seat base DISASSEMBLY CAUTION Always wear eye protection 1 Remove internal snap ring q from all four bearing caps NOTICE If yoke or bearing is removed cross bearing must be replaced Note orient...

Page 454: ...lly seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 4 Install outer yoke aligning marks made before disassembly 5 Repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings 7 When installation is complete yo...

Page 455: ... SHAFT STEERING RACK REMOVAL NON EPS MODELS 9 9 STEERING WHEEL UPPER STEERING SHAFT REMOVAL EPS 9 10 POWER STEERING UNIT REMOVAL 9 11 POWER STEERING UNIT INSTALLATION 9 11 STEERING RACK REMOVAL INSTALLATION EPS 9 13 FRONT STRUT 9 15 ASSEMBLY VIEW 9 15 FRONT STRUT CARTRIDGE REPLACEMENT 9 16 BALL JOINT REPLACEMENT 9 16 REAR A ARMS 9 18 REMOVAL REPLACEMENT 9 18 INSTALLATION 9 19 ASSEMBLY VIEW 9 20 RE...

Page 456: ...ressor Tool 2876389 Multi Function Pliers 2870871 Strut and Ball Joint Tool Set 2871573 Strut Spring Compressor LH 2871574 Strut Spring Compressor RH Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Included in this machine s tool kit the multi function pliers is designed to remove the plastic push rivets used to fasten body components STEERING SUSPENSION ...

Page 457: ...cates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body i e road conditions and operating temperature It is important to properly identify the difference between normal operation weepage or misting and a shock that has a leak Below are some images to help...

Page 458: ...9 4 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc STEERING ASSEMBLY STEERING ASSEMBLY VIEW NON EPS STEERING SUSPENSION ...

Page 459: ...RING w WHEEL STEERING e SHAFT STEERING UPPER LOWER r ASM GEAR BOX STEERING t CAP STEERING WHEEL y ASM SHOCK OIL LOCKING u BOLT i BOLT 40 ft lbs 54 Nm o SCREW a BOLT s NUT d NUT 16 ft lbs 22 Nm f NUT 40 ft lbs 54 Nm g NUT 36 ft lbs 49 Nm h NUT 65 ft lbs 88 Nm j BUSHING STEERING k PIN COTTER l LOCTITE 271 STEERING SUSPENSION ...

Page 460: ...9 6 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc STEERING ASSEMBLY VIEW EPS STEERING SUSPENSION ...

Page 461: ... r SHAFT STEERING UPPER t ASM GEAR BOX STEERING y ASM TILT STEERING u ASM POWER STEERING i CAP STEERING WHEEL o ASM SHOCK OIL LOCKING a BOLT s BOLT d BOLT 30 ft lbs 41 Nm f SCREW g BOLT h SCREW j BOLT k NUT l NUT 15 ft lbs 21 Nm 1 NUT 40 ft lbs 54 Nm 2 NUT 49 ft lbs 66 Nm 2 NUT 65 ft lbs 88 Nm 2 BUSHING STEERING 2 PIN COTTER 2 LOCTITE 271 STEERING SUSPENSION ...

Page 462: ...mbly comes with new upper and lower bearings installed Use this procedure if replacing just the bearings only 1 Perform the Steering Shaft Removal procedure 2 Remove the steering wheel cap and retaining nut 3 Press steering shaft out of the steering wheel and pivot tube 4 Note the order and location of the spacers between the pivot tube and steering shaft 5 Drive the bearings out of the pivot tube...

Page 463: ...el and align as needed Torque the steering wheel nut to specification TORQUE Steering Wheel Nut 65 lb ft 88 Nm 13 Wipe the pivot tube clean of any excess Loctite 14 Install steering wheel cap and field test steering operation STEERING SHAFT STEERING RACK REMOVAL NON EPS MODELS 1 Remove the pinch bolt w retaining the lower portion of the steering shaft e to the steering rack assembly q 2 Remove upp...

Page 464: ... while installed in the vehicle can permanently damage the EPS unit and cause a Power Steering Fault 2 Remove the pinch bolt retaining the upper steering shaft to the power steering unit 3 Remove the steering tilt assembly fasteners 4 Remove the fastener retaining the upper steering shaft to the power steering unit 5 Remove the steering wheel upper steering shaft and pivot out as an assembly 6 Rem...

Page 465: ...to specification TORQUE EPS Unit Mount Bolts 30 lb ft 41 Nm 2 Align the skip tooth spline on the power steering output shaft with the opening in the lower power steering shaft 3 Install power steering to mount assembly and torque fasteners to specification TORQUE EPS Unit Frame Bolts 14 lb ft 19 Nm 4 Install the pinch bolt retaining the lower power steering shaft to the power steering unit Torque ...

Page 466: ... Unit Pinch Bolts 15 lb ft 20 Nm 9 Install the fastener retaining the steering wheel tilt assembly to the frame Torque fastener to specification TORQUE Steering Wheel Tilt Assembly Fasteners 40 lb ft 54 Nm 10 Reconnect both electrical harnesses onto the power steering unit Be sure the connectors snap into place and the wires are routed correctly 11 Reinstall the upper and lower dash panels making ...

Page 467: ...Remove the fasteners r washers t and nuts y retaining the both tie rod ends to the steering knuckle IMPORTANT Pay close attention to the location of the washers to ensure they are installed in the correct location during assembly 5 Remove the fasteners u washers and nuts attaching the steering rack to the chassis 6 Gently pry between the steering shaft and steering rack while lowering the steering...

Page 468: ... Fasteners 16 ft lbs 22 N m 4 Install the pinch bolt r retaining the steering shaft q to the steering rack assembly w Torque to specification TORQUE Steering Shaft Pinch Bolt 46 ft lbs 62 N m 5 Install the fasteners t washers y and nuts u retaining the both tie rod ends to the steering knuckle Torque to specification TORQUE Tie Rod End Fastener 40 ft lbs 54 N m 6 Install cotter pins in both tie ro...

Page 469: ...Nut 13 17 ft lbs 18 23 Nm d Washers w Washer f Ball Joint e Rubber Spacer g Screws r Upper Pivot Ball h Ball Joint Bracket t Spacer 15 ft lbs 20 Nm j Retaining Ring y Lower Pivot Ball k Wheel Bearing u Spring Retainer l Hubstrut i Spring 1 Cam Adjuster o Bumper 2 Washer a Spacer 2 Front Strut s Bolts 2 Nut 20 ft lbs 27 Nm STEERING SUSPENSION ...

Page 470: ...cation Do not over torque nut TORQUE Strut Mounting Nut top 15 ft lbs 21 Nm BALL JOINT REPLACEMENT 1 Loosen front wheel nuts slightly 2 Elevate and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin q from ball joint castle nu...

Page 471: ... heat to ease installation Drive new joint into strut housing until fully seated 9 Apply Loctite 242 PN 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent Torque screws to specification TORQUE Ball Joint Retaining Plate Screws 8 ft lbs 11 Nm 10 Install A arm on ball joint and torque castle nut to specification TORQUE Ball Joint Nut 30 ft lbs 41 Nm 11 ...

Page 472: ...ilizer linkage to the upper A arm 3 Remove the fastener w attaching the upper A arm to the bearing carrier 4 Remove the fasteners attaching the upper A arm to the frame and remove the upper A arm from the vehicle 5 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View Replace if worn Discard hardware WARNING The locking agent on the existing bolts was destroyed during remova...

Page 473: ...Fasteners 40 ft lbs 54 Nm 2 Attach lower A arm to bearing carrier Torque NEW fastener to specification TORQUE Bearing Carrier Fasteners 40 ft lbs 54 Nm 3 Route the brake line over the top of the lower A arm and secure it in the retainer q 4 Install upper A arm assembly onto vehicle frame Torque new fasteners to specification TORQUE Control Arm Fasteners 40 ft lbs 54 Nm 5 Attach upper A arm to bear...

Page 474: ...00 570 Service Manual Copyright Polaris Inc ASSEMBLY VIEW REF DESCRIPTION REF DESCRIPTION q Lower A Arm y Bushing w Upper A Arm u Pin e Bearing Carrier i Grease Zerk r Wheel Bearing o Nuts 40 ft lbs 54 Nm t Snap Ring STEERING SUSPENSION ...

Page 475: ...spect the stabilizer bar for straightness 5 Inspect the stabilizer bar bushings and replace if needed 6 Inspect the rubber bushings on the stabilizer linkage rod and replace if needed If replacing the stabilizer linkage remove the lower shock bolt from the upper A arm 7 Reverse this procedure for installation 8 Torque the stabilizer retaining bolts and upper rubber bushing nuts to specification 9 ...

Page 476: ...e shock from the vehicle 3 Reverse the procedure to reinstall the shock Torque NEW fasteners to specification TORQUE Shock Fasteners 40 ft lbs 54 Nm SHOCK REPLACEMENT 1 Using a spring compressor compress the shock spring far enough to remove the spring retainer 2 Remove the spring and adjusting cam from the existing shock and install components onto the new shock 3 Compress the shock spring and in...

Page 477: ...10 9 PEDAL INSTALLATION 10 9 BRAKE SERVICE PROCEDURES 10 10 BRAKE BLEEDING FLUID CHANGE 10 10 BRAKE BURNISHING PROCEDURE 10 11 FRONT BRAKE PADS 10 12 2 SEAT 10 12 PAD REMOVAL DISASSEMBLY 10 12 BRAKE PAD INSPECTION 10 12 PAD ASSEMBLY INSTALLATION RANGER 10 13 PAD ADJUSTMENT RANGER 10 13 CREW 10 14 PAD REMOVAL CREW 10 14 PAD INSPECTION 10 15 PAD ASSEMBLY INSTALLATION CREW 10 15 FRONT CALIPER 10 16 2...

Page 478: ...LLATION 10 28 REAR CALIPERS 10 29 CALIPER ASSEMBLY VIEW 10 29 CALIPER REMOVAL 10 30 REAR CALIPER DISASSEMBLY 10 30 REAR CALIPER INSPECTION 10 31 REAR CALIPER ASSEMBLY 10 31 REAR CALIPER INSTALLATION 10 32 REAR BRAKE DISC 10 33 DISC RUNOUT 10 33 BRAKE DISC INSPECTION 10 33 DISC REMOVAL REPLACEMENT 10 34 TROUBLESHOOTING 10 35 BRAKES SQUEAL POOR BRAKE PERFORMANCE 10 35 PEDAL VIBRATION 10 35 CALIPER O...

Page 479: ...Disc Thickness 0 158 4 01 mm 0 140 3 56mm Front Brake Disc Runout 0 010 254mm REAR BRAKE ITEM STANDARD SERVICE LIMIT Rear Brake Pad Thickness 0 298 007 7 56 178 mm 0 030 76 mm Rear Brake Disc Thickness 0 188 4 78 mm 0 170 4 32 mm Rear Brake Disc Runout 0 010 254 mm SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vac Pressure Test Tool Bosch Automotive Service Solutions 1 800 345 2233 or ht...

Page 480: ...TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet is commercially available and can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeak...

Page 481: ... self adjusting Fluid from the reservoir 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 brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port which is opened a...

Page 482: ...LY VIEWS RANGER REF DESCRIPTION NOTES q Master Cylinder w Banjo Bolt Torque to 15 ft lbs 20 Nm e Caliper Mounting Bolts Torque to 46 ft lbs 62 Nm r Pad Adjuster Screw Torque to 48 ft lbs 5 5 Nm t Brake Line Fastener Bolt Torque to 15 ft lbs 20 Nm y Screw Torque to 12 15 ft lbs 16 20 Nm BRAKE SYSTEM ...

Page 483: ... CREW REF DESCRIPTION NOTES q Master Cylinder w Banjo Bolt Torque to 15 ft lbs 20 Nm e Caliper Mounting Bolts Torque to 46 ft lbs 62 Nm r Pad Adjuster Screw Torque to 48 ft lbs 5 5 Nm t Brake Line Fastener Bolt Torque to 15 ft lbs 20 Nm y Screw Torque to 12 15 ft lbs 16 20 Nm BRAKE SYSTEM ...

Page 484: ...anjo Bolts Torque to 15 ft lbs 20 Nm CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 5 Loosen the brake line banjo bolts r and allow the fluid to drain NOTICE Make note of front and rear brake line orientation on the master cylinder 6 Dispose of brake fluid properly and do not re use INSTALLATION Reverse Steps 1 5 for master cyli...

Page 485: ...ng clip q and clevis pin w from the master cylinder e to free it from the brake pedal r 2 Remove the brake pedal pivot fastener and bushings t off the mount bracket PEDAL INSTALLATION 1 Reverse steps for foot brake installation 2 Tighten pivot bolt sufficiently Refer to the general torque specifications in Chapter 1 BRAKE SYSTEM ...

Page 486: ... bleeder fitting 8 Place a small amount of fresh brake fluid into a small clear container and place the other end of bleeder hose into the container 9 Have an assistant slowly pump the brake pedal until pressure builds and then hold 10 Quickly open and close the bleed screw while holding pressure on the brake pedal NOTICE Do not release brake pedal before bleeder screw is tight or air may be drawn...

Page 487: ...ake system for fluid leaks BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Test drive machine and slowly increase speed to above 20 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping ...

Page 488: ...h caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTICE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 5 Push upper pad retainer pin e inward and slip outer brake pad past edge Remove the pad BRAKE PAD INSPECTION 1 Check th...

Page 489: ...up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system PAD ADJUSTMENT RANGER 1 Install the adjuster screw Item 1 and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 2 Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line insi...

Page 490: ... lower caliper mounting bolts and remove the caliper from the front hub NOTICE When removing caliper use care not to damage brake line Support caliper so to avoid kinking or bending brake line 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTICE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when pist...

Page 491: ...If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper onto front hub and torque mounting bolts TORQUE Front Caliper Mount Bolt 46 ft lbs 62 Nm 4 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 5 Install the ...

Page 492: ...PER ASSEMBLY VIEW REF DESCRIPTION NOTES q Adjuster Screw Finger Tighten w Bleeder Screw 30 60 in lbs 3 4 6 8 Nm e Caliper Body r Square O Rings Apply Polaris Dot 4 Brake Fluid t Piston Apply Polaris Dot 4 Brake Fluid y Dust Boots u Caliper Bracket i Caliper Pins Apply Brake Disc Caliper Lube o Pads BRAKE SYSTEM ...

Page 493: ...under caliper to catch fluid draining from brake line 4 Remove brake caliper mounting bolts and caliper FRONT CALIPER DISASSEMBLY RANGER 1 Remove brake pad adjuster screw Item 1 2 Push upper pad retainer pin inward and slip brake pads past edge if pads are still installed 3 Remove mounting bracket Item 2 and dust boot Item 3 4 Remove piston Item 4 and square O rings Item 5 from the caliper body It...

Page 494: ...ds as outlined for brake pad replacement in this chapter FRONT CALIPER ASSEMBLY 1 Install new square O rings q in the caliper body Be sure that the grooves are clean and free of residue or brakes may drag 2 Coat the piston with clean Polaris DOT 4 Brake Fluid P N 2872189 Install piston w with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistan...

Page 495: ...6 ft lbs 62 Nm 2 Install brake line and tighten securely with a flare nut wrench 3 Install the adjuster screw w and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined earlier in this chapter 5 Install wheels and torque wheel nuts to specification TORQUE Steel Wheel Lug Nuts 36 ft lbs 49 Nm 6 Burnish brake pads as outlined in this chapter BRAKE...

Page 496: ...REW FRONT CALIPER ASSEMBLY VIEW REF DESCRIPTION NOTES q Bleeder Screw 47 in lbs 5 3 Nm w Socket Set Screw e Caliper Assembly r Dust Boots t Square O Rings Apply Polaris DOT 4 Brake Fluid y Piston u Caliper Mount i Caliper Pins Apply Disc Brake Caliper Lube o Brake Pads BRAKE SYSTEM ...

Page 497: ...lean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removing the line Remove brake line Item 1 from caliper 5 Loosen brake pad adjustment set screw Item 2 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper assembly from the front strut FRONT CALIPER DISASSEMBLY CREW 1 Push bra...

Page 498: ... air NOTICE Do not remove the caliper pistons with a pliers The piston sealing surfaces will become damaged if a pliers is used 6 Once the pistons are removed use a pick to carefully remove the square O rings from the caliper O rings should be replaced during caliper service 7 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTICE Be sure to clean seal grooves in ...

Page 499: ...ue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with disc brake caliper lube and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seal boots are fully ...

Page 500: ...3 Install the pad adjustment screw Item 2 and turn until stationary pad contacts disc then back off 1 2 turn 4 Perform brake bleeding procedure as outlined earlier in this chapter 5 Install wheel and torque wheel nuts to specification see Chapter 2 NOTICE If new brake pads are installed brake burnishing is required SeeBrake Burnishing Procedure page 10 11 BRAKE SYSTEM ...

Page 501: ...micrometer Replace disc if worn beyond service limit MEASUREMENT Brake Disc Thickness New 150 165 3 81 4 19 mm Service Limit 140 3 56 mm MEASUREMENT Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifi...

Page 502: ...olts 18 ft lbs 25 Nm REAR BRAKE PADS PAD REMOVAL 1 Elevate and support rear of machine WARNING Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the rear wheel Loosen pad adjuster screw q 2 3 turns 3 Clean caliper area before removal 4 Remove caliper mounting bolts w and lift caliper off of disc CAUTION When removing caliper ...

Page 503: ...rt into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Remove the brake pads BRAKE PAD INSPECTION 1 Check the brake pads for wear damage or looseness 2 Inspect the brake pad wear surface for excessive wear MEASUREMENT Brake Pad 030 0 762 mm 3 If any one pad is less than the service limit then all pads should be replaced BRAK...

Page 504: ...rake Caliper Mounting Bolts 46 ft lbs 62 Nm 3 Turn adjuster screw back in finger tight using a hex wrench Then back off 1 2 turn 4 Slowly pump the brake pedal until pressure 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 5 Fill master cylinder to Max level 6 Burnish brakes as outlined in this chapter BRAKE SYSTEM ...

Page 505: ...IPER ASSEMBLY VIEW REF DESCRIPTION NOTES q Socket Set Screw w Bleeder Screw 47 in lbs 5 3 Nm e Caliper Assembly r Dust Boots t Square O Rings Apply Polaris DOT 4 Brake Fluid y Piston Apply Polaris DOT 4 Brake Fluid u Caliper Pins Apply Disc Brake Caliper Lube i Caliper Mount o Brake Pads BRAKE SYSTEM ...

Page 506: ... 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 REAR CALIPER DISASSEMBLY 1 Remove brake pad adjuster screw q 2 Push upper pad retainer pin inward and slip brake pads u past edge if pads are still installed 3 Remove mounting bracket w and dust boot e 4 Remove piston r and square O ring...

Page 507: ...mm 3 Inspect the brake disc and pads as outlined for brake pad replacement in this chapter REAR CALIPER ASSEMBLY 1 Install new square O rings q in the caliper body Be sure that the grooves are clean and free of residue or brakes may drag 2 Coat the piston with clean DOT 4 Brake Fluid PN 2872189 Install piston w with a twisting motion while pushing inward Piston should slide in and out of bore smoo...

Page 508: ... banjo bolt to specification TORQUE Banjo Bolt 15 ft lbs 20 Nm 3 Install the rear wheel and wheel nuts Carefully lower the vehicle 4 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation NOTICE If new brake pads are installed brake...

Page 509: ...0 254 mm BRAKE DISC INSPECTION 1 Check the surface condition of the brake discs 2 Measure the thickness of the front and rear brake discs 3 The disc s should be replaced if thickness is less than the specified service limit REF PART SERVICE LIMIT q Front Disc See the specifications at the beginning of the Brake System chapter w Rear Disc WARNING Do not apply WD 40 or any petroleum product to brake...

Page 510: ...nd torque to specification 6 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Rear Brake Disc Mount Bolts 27 ft lbs 36 Nm Rear Hub Castle Nut 110 ft lbs 150 Nm Front Hub Castle Nut 90 ft lbs 122 Nm 7 Install rear brake caliper see BRAKE CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter 8 Field test...

Page 511: ... SYSTEM INTL MODELS This vehicle uses a brake monitoring system with full plausibility check This system uses a brake pedal switch mounted to the pedal and either one or two brake pressure switches mounted on the master cylinder For this system to operate correctly The Brake Pressure Switch and Brake pedal switch need to close within an acceptable amount of time When the pressure switch or pedal s...

Page 512: ...ke Pedal Switch testing 8 If one both sensors fail the testing check the electrical circuit for the sensor that has failed It is possible that there could be a concern with the circuit If a circuit concern is found repair or replace as necessary 9 If the concern is still present after previous testing has passed suspect there is a fault within the ECU BRAKE PEDAL SWITCH INSPECTION The Brake Pedal ...

Page 513: ...EXPLODED VIEW 11 5 2017 CREW CAB FRAME ASSEMBLY VIEW 11 6 DASH INSTRUMENTS CONTROLS 11 7 HOOD DASH FRONT FASCIA 11 8 FLOOR REAR FENDERS 11 9 SEAT MOUNTING SEAT BELTS 11 10 CREW FLOOR REAR FENDERS 11 11 CREW SEAT MOUNTING SEAT BELTS 11 12 REAR CARGO BOX 11 13 CARGO BOX TAILGATE BOX SUPPORT 11 13 BOX REMOVAL 11 15 BOX INSTALLATION 11 15 BODY COMPONENT REMOVAL 11 16 LOWER SEAT BASE 11 16 FRONT BUMPER...

Page 514: ... Nm Strut Casting Pinch Bolt 26 ft lbs 35 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Tie Rod End Jamb Nut 14 ft lbs 19 Nm Tie Rod End Mounting Nut 40 ft lbs 54 Nm Wheel Lug Nuts 36 ft lbs 49 Nm NOTICE Refer to exploded views throughout this chapter for more torque specifications component identification and location of components SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870872 Shock Spanner...

Page 515: ... CHASSIS BODY ASSEMBLY VIEWS FRAME ASSEMBLY VIEW REF DESCRIPTION NOTES q Main Frame w Front Bumper e Seat Base Frame r Dash Support t Left Floor Support y Right Floor Support u Skid Plate i Bumper Screen o Screws Torque to 22 ft lbs 30 Nm a Screws Torque to 8 ft lbs 11 Nm BODY FRAME ...

Page 516: ...EW REF DESCRIPTION NOTES q Rear Main Frame w Front Main Frame e Front Bumper r Dash Support t Left Floor Support y Right Floor Support u Front Skid Plate i Rear Skid Plate o Seat Base Frame a Bumper Screen s Screws Torque to 22 ft lbs d Screws Torque to 8 ft lbs f Screws Torque to 40 ft lbs BODY FRAME ...

Page 517: ... i Screw M10 x 1 5 x 20 QTY 6 36 ft lb 49 Nm o Bolt M8 x 1 25 x 20 QTY 2 10 ft lbs 14 Nm a Screw M10 x 1 25 x 30 QTY 4 36 ft lb 49 Nm s Screw M6 x 1 0 x 25 QTY 2 8 ft lb 11 Nm d Screw M8 x 1 25 x 30 QTY 4 14 ft lbs 19 Nm f Screw M10 x 1 5 x 75 QTY 4 36 ft lb 49 Nm g Screw M10 x 1 5 x 30 QTY 4 36 ft lb 49 Nm h Nut M10 1 5 QTY 10 j Nut M8 x 1 25 QTY 8 k Nut M10 x 1 25 QTY 4 Nut Used with part f on 2...

Page 518: ...for an image of the 2017 cab frame REF DESCRIPTION NOTES q Front Cab Frame w Middle Cab Frame e Rear Cab Frame r Cab Frame Brace t Screws Torque to 36 ft lbs 48 Nm y Screws Torque to 36 ft lbs 48 Nm u Screws Torque to 36 ft lbs 48 Nm Nut Used with part u on 2017 cab frames i Nets Door Net Rod Mounts Not Shown Screw Used to fasten Net Rod Mounts Torque to 8 ft lbs 11 Nm BODY FRAME ...

Page 519: ... 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 11 7 DASH INSTRUMENTS CONTROLS REF DESCRIPTION NOTES q Instrument Cluster w Bezel e Key Switch r 12V Accessory Plug t Turf Switch y Dash Panel BODY FRAME ...

Page 520: ...7 2021 RANGER 500 570 Service Manual Copyright Polaris Inc HOOD DASH FRONT FASCIA REF DESCRIPTION NOTES q Hood w Front Fascia e Dash Panel r Glove Box Lid t Hood Strap y Hood Hinge Pins u Push Rivet i Hood Latch BODY FRAME ...

Page 521: ...017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 11 9 FLOOR REAR FENDERS REF DESCRIPTION NOTES q Front Floor w Main Floor e Floor Cover r Cup Holder t Push Rivet y Screws Torque to 5 ft lbs 7 Nm BODY FRAME ...

Page 522: ...ER 500 570 Service Manual Copyright Polaris Inc SEAT MOUNTING SEAT BELTS REF DESCRIPTION NOTES q Seat Back w Seat Base e LH Seat Belt Assm r RH Seat Belt Assm t Seat Base Frame y Screw 24 in lbs 3 Nm u Bolt 40 ft lbs 54 Nm BODY FRAME ...

Page 523: ...0 Service Manual Copyright Polaris Inc 11 11 CREW FLOOR REAR FENDERS REF DESCRIPTION NOTES q Front Floor w Main Floor e Front Seat Panel r Rear Main Floor t Storage Box y Front Inner Fender u Cup Holder i Floor Cover o Push Rivet BODY FRAME ...

Page 524: ...ANGER 500 570 Service Manual Copyright Polaris Inc CREW SEAT MOUNTING SEAT BELTS REF DESCRIPTION NOTES q Front Seat Base Frame w Rear Seat Base Frame e Seat Base r Seat Back t Screw 24 in lbs 3 Nm y Bolt 40 ft lbs 54 Nm BODY FRAME ...

Page 525: ...11 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 11 13 REAR CARGO BOX CARGO BOX TAILGATE BOX SUPPORT BODY FRAME ...

Page 526: ...EF DESCRIPTION NOTES q Cargo Box w Box Frame e Tailgate Inner Panel r Tailgate Outer Panel t Box Tilt Shock y Box Tilt Latch u Heat Shield i Tailgate Tube o Tailgate Mount Bracket a Bushing s Tailgate Latch d Screw Torque to 8 ft lbs 11 Nm f Screw Torque to 5 ft lbs 7 Nm BODY FRAME ...

Page 527: ...ides 6 With both hinge pins removed remove the box from the frame Two people may be needed to remove the box from the frame CAUTION Use caution when removing the box It is recommended to have two people carefully remove the box from the frame BOX INSTALLATION 1 If the shock was replaced install the lower portion of the shock to the frame and secure it with the pin and clip 2 Place the cargo box on...

Page 528: ...the bumper 2 Remove the three bolts from the lower portion of the bumper 3 Remove the two fasteners from each side of the upper portion of the bumper 4 Carefully remove the bumper from the vehicle FENDERS FOOT PADS 1 FRONT Remove the lower T27 Torx head screws retaining the foot pads 2 Remove the two push rivets retaining the front fender and remove the fender from the vehicle 3 Repeat this proced...

Page 529: ...e front of the dash to the frame 3 Open the glove box and remove the Torx head screw from the dash 4 Remove the Torx head screw retaining the left portion of the dash 5 Remove the eight fasteners from each side of the dash where it attaches to the front and rear fenders 6 Remove the rubber boot from around shift lever 7 Remove the five push rivets from under the dash panel Unhook all electrical co...

Page 530: ...even Torx head screws retaining the center floor 4 Remove the Torx head screws retaining the front floor cover 5 Remove the Torx head screws retaining the main floor and remove the main floor from the vehicle 6 Continue with Hood Dash Removal procedure 7 Remove the accelerator and brake pedals for adequate clearance to remove the front floor section BODY FRAME ...

Page 531: ...ame treated prior to installing a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appe...

Page 532: ...11 20 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc NOTES BODY FRAME ...

Page 533: ... LOCATION 12 8 SPEED SENSOR TESTING 12 8 INSTRUMENT CLUSTER 12 9 OVERVIEW 12 9 RIDER INFORMATION DISPLAY 12 10 INFORMATION DISPLAY AREA 12 11 DIAGNOSTIC MODE 12 13 INSTRUMENT CLUSTER PINOUTS 12 14 INSTRUMENT CLUSTER REMOVAL 12 14 INSTRUMENT CLUSTER INSTALLATION 12 14 HEADLIGHTS 12 15 HEADLIGHT ADJUSTMENT 12 15 HEADLIGHT BULB REPLACEMENT 12 16 HEADLIGHT HOUSING REMOVAL 12 16 HEADLIGHT HOUSING INSTA...

Page 534: ...ICE 12 29 BATTERY TERMINALS BOLTS 12 29 BATTERY TERMINAL BLOCK 12 29 BATTERY ACTIVATION 12 29 BATTERY INSPECTION 12 30 BATTERY REMOVAL INSTALLATION 12 31 CONVENTIONAL BATTERY TESTING 12 31 OCV OPEN CIRCUIT VOLTAGE TEST 12 31 VOLTAGE DROP TEST 12 31 SPECIFIC GRAVITY TEST 12 31 LOAD TEST 12 32 CHARGING PROCEDURE 12 32 OFF SEASON STORAGE 12 32 STARTER SYSTEM 12 33 TROUBLESHOOTING 12 33 STARTER DRIVE ...

Page 535: ...miliar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter This meter is used when diagnosing electrical problems Readings obtained wi...

Page 536: ...NENTS UNDER HOOD The following components can be accessed under the hood Voltage Regulator Terminal Block Digital Wrench Diagnostic Connector AWD 2WD TURF Switch 12 VDC Accessory Power Point Ignition Switch Instrument Cluster Cooling Fan TRS Connector Brake Switch Headlights ELECTRICAL ...

Page 537: ...should be continuity between switch pins C and D E and F Turn the ignition key to START There should be continuity between switch pins A and B C and D E and F AWD 2WD TURF SWITCH 1 Remove the dash panel from the dash see Chapter 5 2 Disconnect the switch harness Gray Orange White Brown White Green by depressing the connector lock and pulling on the connector Do not pull on the wiring 3 Inspect the...

Page 538: ...wires or bad connections Check for power from the relay connector to ensure the solenoid has power to be activated Check for power at the ECU and Rear Differential Solenoid Relay Check the switch wires for loose connections Remove solenoid from rear differential and ensure the solenoid plunger is actuating CAUTION Do not power the solenoid with 12 Volts for more than 1 second or damage may occur t...

Page 539: ...WD system must be grounded to operate DIAGNOSING SYSTEM FAILURES Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil on the Gray wire Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below AWD Hub Coil Resistance 24 Ohms 5 Verify the wiring harness wiring connectors connector pins and grounds are undamaged c...

Page 540: ...ed 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 the wires from the Static Timing Light Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness PN 2460761 3 Pass a screwdriver back and forth in front of the sensor tip 4 Be sure connections are ...

Page 541: ...Some features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any...

Page 542: ...flash to indicate the engine is overheating The indicators will stay lit and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory and adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it...

Page 543: ... displays the total distance traveled by the vehicle The odometer can not be reset Trip Meter The trip meter records the miles traveled by the vehicle on each trip To reset the trip meter 1 Toggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Tachometer RPM Engine RPM can be displayed digitally Engine Temperature Engine temperature ...

Page 544: ... hour or 24 hour format Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour To set the clock follow these steps 7 Toggle the MODE button until the odometer is displayed 8 Press and hold the MODE button until the hour segment flashes Release the button 9 With the segment flashing tap the MODE button to advance to the desired setting 10 Press and hold the MODE button u...

Page 545: ... diagnostic mode is accessible only when the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off 1 If the trouble code s are not displayed use the MODE button to tog...

Page 546: ...gain access to back of instrument cluster 2 Disconnect the wire connectors from the back side of the instrument cluster 3 Push the instrument cluster out from the back side of the dash panel while securely holding the panel and rubber mount NOTICE Do not remove the rubber mount from the dash panel Only remove the rubber mount if necessary INSTRUMENT CLUSTER INSTALLATION 1 Spray a soap and water mi...

Page 547: ...d be aimed 8 in 20 cm item 2 below the mark placed on the wall in Step 2 NOTICE Rider weight must be included in the seat while performing this procedure 5 Locate the T25 Torx head adjustment screw through the wheel well see illustration Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height 6 Once the beam is set to the position tig...

Page 548: ... in the housing HEADLIGHT HOUSING REMOVAL 1 Open the hood 2 Remove the bulb from the headlight housing see Headlight Bulb Replacement 3 Remove the O rings q from each side of the headlight housing Remove the adjustment screw w and pull the headlight from the brackets HEADLIGHT HOUSING INSTALLATION 1 Install the headlight housing by pressing the headlight tabs back into the brackets 2 Secure the he...

Page 549: ...gital multi meter to test the harness to ensure the lamp is receiving 12 14 DC volts and that a ground path is present Lamps can be bench tested by applying 12 14 volts directly as the LED tail brake lamp units are internally regulated 3 If the LED lamp does not function with power and ground applied to the lamp directly replace the lamp assembly Apply dielectric grease PN 2871329 to the new lamp ...

Page 550: ... cooling system is full and purged of air Refer to Chapter 2 Maintenance for cooling system information FAN CONTROL CIRCUIT BYPASS TEST 1 Disconnect harness from the engine coolant temperature sensor located in the cylinder head of the engine 2 With the vehicle in park turn the key on After a few seconds you should hear the cooling fan turn on and remain running 3 If the fan does not run or runs s...

Page 551: ...tion This 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 the voltage from the primary to the secondary coil windings to fire the spark plug IGNITION COIL TESTS The ignition coil can be tested by using an Ohm meter Use the following specification ta...

Page 552: ...tension lead cap q from the spark plug 4 Remove fasteners w retaining the ignition coil and remove coil assembly from the vehicle 5 Install new ignition coil assembly and tighten fasteners to specification NOTICE Be sure to reinstall the coil mounting spacers upon assembly if equipped TORQUE Ignition Coil Retaining Bolt 75 in lbs 8 5 Nm 6 Connect harness connection to the ignition coil 7 Reconnect...

Page 553: ...ar 1 30 Dark Green Yellow ECU controlled ground Chassis Relay controlled by the key switch supplies B to the chassis circuits CHASSIS RELAY FUSE BOX PIN WIRE COLOR OPERATION 33 Red Blue Relay coil 12v from EFI Splice 34 Red High side 12v from Start Solenoid 37 Red 12v output to Splice Chassis 38 Gray ECU controlled ground EFI Relay controlled by the ECM supplies power to EFI components and sensors...

Page 554: ...ower to the EPS unit EPS RELAY FUSE BOX PIN WIRE COLOR OPERATION 3 Orange Relay coil 12v from R S B Splice 2 4 Red High side 12v from EPS fuse 7 Orange 12v output to EPS unit 8 Brown Chassis ground 2 Rear Differential Solenoid Relay controlled by the AWD 2WD TURF switch and ECM operates the differential solenoid to unlock the rear end ELECTRICAL ...

Page 555: ...ses located in the relay fuse box under driver s seat base provide current protection for components such as the EFI system main harness lights and accessories FUSE SIZE FEATURE SUPPORTED 5 A Brake Light 10 A Drive System Fuel Pump 20 A EFI Power Steering if equipped Lights Accessories 20 A Circuit Breaker Fan ELECTRICAL ...

Page 556: ...ted in the relay fuse box under driver s seat base provide current protection for components such as the EFI system main harness lights and accessories FUSE SIZE FEATURE SUPPORTED 10 A Brake Light Drive System Fuel Pump 20 A EFI Power Steering if equipped Lights Accessories 20 A Circuit Breaker Fan ELECTRICAL ...

Page 557: ...efore checking the value Vehicles will vary but electronic components will take time to fully go to sleep after switched power is removed 8 Maximum allowable is 10 milliamps If your meter is ranged to the 10 Amp scale this will appear as 0 010 Amps Current Draw Key Off Maximum of 01 DCA 10 mA 9 If over 10 milliamps go to the fuse block and start systematically removing one fuse at a time until the...

Page 558: ...elow 2000 RPM CHARGING SYSTEM ALTERNATOR TESTS Three tests can be performed using a multimeter to determine the condition of the stator alternator TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2 to Y3 2 Each test should measure 0 15 Ω 20 TEST CONNECT METER LEADS TO OHMS READING Battery Charge Coil Y1 to Y2 Less tha...

Page 559: ...hile holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 8 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table 9 Example The alternator voltage output reading should be approxim...

Page 560: ...Manual Copyright Polaris 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 good condition connected and not exposed or pinched ELECTRICAL ...

Page 561: ...p sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN WARNING The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it Should there be contact with battery acid wash the affected area ...

Page 562: ...er and baking soda solution paying particular attention that any acid is washed off the terminals Dry the battery case BATTERY INSPECTION The battery is located under the seat on the drivers side 1 Inspect the battery case for obvious damage such as cracks or leaks Look for discoloration warping or raised top which may indicate the battery has overheated or been overcharged 2 Make sure the battery...

Page 563: ...harged 11 9 V or less VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection 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 ...

Page 564: ... the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge at 0 1Ah for max of 15 hours The battery is faulty if it does not achieve a specific gravity of 1 270 after 15 hours 3 Install battery in vehicle Coat threads of battery bolt with a corrosion resistant dielectric grease Dielectric Grease PN 2871329 4 Connect battery cables WARNING To avoid the possibility...

Page 565: ...gear or loose flywheel STARTER DRIVE Pinion Gear Anti Kick out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly The replacement spring is PN 7042039 Use either of the following methods to remove and install a new garter spring 1 Screw the overrun clutch out to the engaged position on the pinion shaft assembly Use a small piece of wire wi...

Page 566: ...erminals A and B If there is no continuity or high resistance replace the starter solenoid STARTER SOLENOID OPERATION To energize the starter solenoid the following must occur The brake must be applied to provide a ground path via the Brown Yellow wire The key switch must be turned to the start position to provide 12V power via the White Red wire Once the pull in coil is energized the solenoid pro...

Page 567: ...12 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc 12 35 STARTING SYSTEM TESTING FLOW CHART ELECTRICAL ...

Page 568: ...12 36 9850043 R01 2017 2021 RANGER 500 570 Service Manual Copyright Polaris Inc NOTES ELECTRICAL ...

Page 569: ...t 12 25 Break In Brake System 2 4 Engine and Drivetrain 2 4 PVT 2 4 Vehicle 2 4 Breather Hose 2 13 Valve Inspection 2 13 C Caliper Front CREW 10 20 Camshaft Bore Inspection 3 49 3 95 Chain and Guide Service 3 50 3 96 Decompression Mechanism 3 50 3 95 Inspection 3 49 3 95 Installation Timing 3 65 3 116 Removal 3 48 3 93 Sprocket Inspection 3 49 3 94 Timing Quick Reference 3 67 3 119 Cargo Box Insta...

Page 570: ...ctrical Break Even Test 12 25 Charging System Tests 12 26 Connector Probing Guidelines 1 103 Continuity Resistance 1 104 Current Draw Key Off 1 107 12 25 Digital Multi Meter DMM 1 102 Open Circuit Voltage Test 12 31 Service Notes 1 102 Static and Dynamic Testing 1 102 Testing Current Flow Amperage 1 106 Testing For A Short To Ground 1 104 Testing For A Short To Voltage 1 105 Testing for Intermitte...

Page 571: ... Assembly View 11 3 Assembly View Crew 11 4 Front Bumper 11 16 Front Fascia 11 8 Front Fenders 11 16 Front Gearcase Assembly 8 18 Assembly View 8 12 Disassembly Inspection 8 15 Disassembly Inspection ADC 8 24 Exploded View 4WDC 8 21 Installation 8 10 Operation 4WDC 8 23 Reassembly ADC 8 28 Removal 8 10 Front Gearcase Lubrication 2 25 Front Strut Assembly View 9 15 Cartridge Replacement 9 16 Fuel F...

Page 572: ...ump Removal 3 72 3 124 Open Circuit Voltage Test 12 31 Outer CV Joint Boot Replacement 8 39 Overview ETC 4 4 P Pad Inspection Brakes 2 35 10 12 10 27 Pedal Position Sensor 4 6 Test 4 6 Periodic Maintenance Chart 2 5 Periodic Maintenance Chart Key 2 5 Power Steering Unit EPS Installation 9 11 Removal 9 11 PPS 4 6 Replacement 4 6 Pre Ride Daily Inspection 2 3 Pressure Cap Test 3 21 Propshaft Removal...

Page 573: ...val EPS 9 10 Steering Shaft Bearing Replacement 9 8 Removal EPS 9 10 Steering Wheel Removal EPS 9 10 Suspension Inspection 2 32 Pivot Lubrication 2 33 Shock Analysis 1 101 2 34 9 3 Spring Adjustment 2 32 Switch AWD 2WD TURF 12 5 Brake 10 8 12 6 Headlight 12 5 Ignition 12 5 T T MAP 4 5 Overview 4 5 Sensor Test 4 5 TDC 3 18 Terminal Block 12 29 Thermostat Replacement 3 23 Throttle Pedal Inspection 2...

Page 574: ...Cover Installation 3 68 3 120 Removal 3 48 3 93 Valve Sealing Test 3 112 Valve Seat Inspection 3 54 Valve Spring Removal 3 51 3 97 Vehicle Identification Model Number Designation 1 4 Vehicle Identification Number 1 4 Vent Line Termination Fitting 5 11 Vent Lines 2 22 VIN 1 4 VIN Location 1 4 Voltage Drop Test 12 31 W Water Pump Mechanical Seal Oil Seal 3 25 Removal Installation 3 25 Wheel Installa...

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