Polaris RZR 570 2013 Service Manual Download Page 73

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9926813 R04 - 2013-2016

RZR

570 Service Manual

3.1

ENGINE / COOLING SYSTEM

CHAPTER 3

ENGINE / COOLING SYSTEM

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

ENGINE LUBRICATION SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

OIL PRESSURE TEST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

ENGINE OIL FLOW CHART

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

ENGINE SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

TORQUE SEQUENCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE

. . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

CYLINDER / OIL FILTER / OIL PUMP / BREATHER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER - BLACK HEAD BOLTS

. . . . . . . . . . . . 3.11

CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS

. . . . . . . . . . . . . . . . . . . . . . . . . .3.12

SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

PISTON / CRANKSHAFT / BALANCE SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

INTAKE / EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

AIR BOX / AIR FILTER EXPLODED VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

EXHAUST SYSTEM ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM

. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

COOLING SYSTEM SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

COOLING SYSTEM PRESSURE TEST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

PRESSURE CAP TEST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

RADIATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

COOLANT DRAIN / RADIATOR REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

THERMOSTAT REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

WATER PUMP COVER AND IMPELLER SERVICE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

COOLING SYSTEM BLEEDING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

ACCESSIBLE ENGINE COMPONENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

TOP-END SERVICE (ENGINE IN CHASSIS)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

ENGINE REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

ENGINE INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

ENGINE BREAK-IN PERIOD

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

ENGINE MOUNTING AND TORQUE VALUES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

ENGINE LUBRICATION SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39

VALVE COVER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39

CAMSHAFT / CARRIER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39

CAMSHAFT SPROCKET INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40

CAMSHAFT INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

EXHAUST CAMSHAFT DECOMPRESSION MECHANISM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

Summary of Contents for RZR 570 2013

Page 1: ...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...

Page 2: ...or bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION...

Page 3: ...k 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...

Page 4: ......

Page 5: ...GENERAL INFORMATION CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE COOLING SYSTEM CHAPTER 4 FUEL SYSTEM CHAPTER 5 PVT SYSTEM CHAPTER 6 TRANSMISSION CHAPTER 7 FINAL DRIVE CHAPTER 8 STEERING SUSPENSION CHAPTER...

Page 6: ......

Page 7: ...ORMATION 1 4 REPLACEMENT KEYS 1 4 PUBLICATION NUMBERS 1 4 SPECIAL TOOLS 1 5 GENERAL SPECIFICATIONS 1 6 2013 RANGER RZR 570 1 6 2013 RANGER RZR 570 LE 1 8 2013 RANGER RZR 570 INTL 1 10 2014 RZR 570 1 1...

Page 8: ...ion MODEL NUMBER DESIGNATION 2015 Example R15RUE57AC GROUP MODEL YEAR MAKE CHASSIS CODE ENGINE CODE REGION OPTION 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th R 1 5 R U E 5 7 A C digits that would transfe...

Page 9: ...UE573FG000000 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...

Page 10: ...4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 PUBLICATION NUMBERS MODEL MODEL NO OWNER S MANUAL PARTS MANUAL 2013 RZR 570 R13VH57AD 9924102 9924103 2013 RZR 570 LE R13VH6E...

Page 11: ...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 ma...

Page 12: ...75 26 cm Wheel Base 77 196 cm Ground Clearance 10 25 4 cm Dry Weight 962 lbs 436 kg Front Storage Capacity N A Cargo Box Dimension LxWxH 20 x 40 x 9 51 x 102 x 23 cm Cargo Box Capacity 300 lbs 136 kg...

Page 13: ...mp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power...

Page 14: ...ase 77 196 cm Ground Clearance 10 25 4 cm Dry Weight 999 lbs 453 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension LxWxH 20 x 40 x 9 51 x 102 x 23 cm Cargo Box Capacity 300 lbs 136 kg Maxim...

Page 15: ...mp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power...

Page 16: ...Wheel Base 77 196 cm Ground Clearance 10 25 4 cm Dry Weight 1001 lbs 454 kg Front Storage Capacity N A Cargo Box Dimension LxWxH 20 x 40 x 9 51 x 102 x 23 cm Cargo Box Capacity 300 lbs 136 kg Maximum...

Page 17: ...RZR Yuasa YB14 B2 14 Amp Hr 12 Volt DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Access...

Page 18: ...s 436 kg Gross Vehicle Weight 1719 lbs 780 kg Test GVW Rollover Protection System ROPS 1745 lbs 791 5 kg per OSHA 29 CFR 1928 53 Front Storage Capacity N A Cargo Box Dimension LxWxH 20 x 40 x 9 51 x 1...

Page 19: ...2 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder Engine Control 30 Amp...

Page 20: ...3 kg Gross Vehicle Weight 1719 lbs 780 kg Test GVW Rollover Protection System ROPS 1745 lbs 791 5 kg per OSHA 29 CFR 1928 53 Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension LxWxH 20 x 40 x 9...

Page 21: ...Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder Engine Cont...

Page 22: ...s 436 kg Gross Vehicle Weight 1719 lbs 780 kg Test GVW Rollover Protection System ROPS 1745 lbs 791 5 kg per OSHA 29 CFR 1928 53 Front Storage Capacity N A Cargo Box Dimension LxWxH 20 x 40 x 9 51 x 1...

Page 23: ...12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder Engine Control 30 Am...

Page 24: ...3 kg Gross Vehicle Weight 1719 lbs 780 kg Test GVW Rollover Protection System ROPS 1745 lbs 791 5 kg per OSHA 29 CFR 1928 53 Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension LxWxH 20 x 40 x 9...

Page 25: ...Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder Engine Con...

Page 26: ...s 436 kg Gross Vehicle Weight 1719 lbs 780 kg Test GVW Rollover Protection System ROPS 1745 lbs 791 5 kg per OSHA 29 CFR 1928 53 Front Storage Capacity N A Cargo Box Dimension LxWxH 20 x 40 x 9 51 x 1...

Page 27: ...12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder Engine Control 30 Am...

Page 28: ...3 kg Gross Vehicle Weight 1719 lbs 780 kg Test GVW Rollover Protection System ROPS 1745 lbs 791 5 kg per OSHA 29 CFR 1928 53 Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension LxWxH 20 x 40 x 9...

Page 29: ...Standard 12 Volt Relays EFI Chassis Fan Fuel Pump Headlight Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder Engine Con...

Page 30: ...olant Temperature Sensor 17 ft lb 23 Nm CPS Retaining Bolt 9 ft lb 12 Nm Cylinder Head Bolts Black Torque in sequence for all steps Step 1 21 ft lbs 28 Nm Step 2 26 ft lb 35 Nm ITEM TORQUE Step 3 Addi...

Page 31: ...s 40 ft lbs 54 Nm Seat Belt to Seat Base 40 ft lbs 54 Nm Shift Cable Bracket Bolts 17 ft lbs 23 Nm Shock Mount Bolts 37 ft lb 50 Nm ITEM TORQUE Skid Plate Fasteners 8 ft lbs 11 Nm Snorkel Tube Refer t...

Page 32: ...b 15 Nm Transmission Shift Fork Screws 8 ft lb 11 Nm Transmission Snorkel Tube Locking Screw 8 ft lb 11 Nm Valve Cover Bolts 9 ft lbs 12 Nm Voltage Regulator Fasteners 75 in lb 6 Nm Water Pump Cover B...

Page 33: ...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...

Page 34: ...20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 METRIC BOLT TORQUE SPECIFICATION BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LB NM DRY THREADS M3 0 3 0 5 0 5 0 7 1 1 3...

Page 35: ...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 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4...

Page 36: ...0 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 14 mm 0 5512 9 16 0 562...

Page 37: ...11 ENGINE BREATHER HOSE INSPECTION 2 13 ENGINE AND TRANSMISSION MOUNTS 2 13 COMPRESSION TEST SPECIFICATION 2 13 VALVE CLEARANCE INSPECTION 2 14 EXHAUST SPARK ARRESTOR 2 15 COOLING SYSTEM 2 16 COOLING...

Page 38: ...2 28 TIE ROD END WHEEL HUB INSPECTION 2 28 WHEEL TOE ALIGNMENT INSPECTION 2 29 WHEEL TOE ADJUSTMENT 2 29 SUSPENSION 2 31 SPRING PRELOAD ADJUSTMENT 2 31 BRAKE SYSTEM 2 32 BRAKE FLUID INSPECTION 2 32 BR...

Page 39: ...diately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer BREAK IN PERIOD The break in period consists of the...

Page 40: ...L 25 H Inspect adjust tension after first 25 hours Battery 25 H Monthly 250 400 Check terminals clean test Front Gearcase Oil Demand Drive 25 H Monthly 250 400 Inspect level change yearly Transmission...

Page 41: ...12 M 1000 1600 Inspect Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches Drive and Driven 100 H 12 M 1000 1600 Ins...

Page 42: ...Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Engine Coolant Polaris 50 50 Extended Life Coolant Maintain coolant level in coolant reservoir bottle Check...

Page 43: ...e Add lubricant until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 5 Transmission Polaris AGL Gearcase Lubricant Add lubricant until it is visible at the fill...

Page 44: ...and on the front propshaft yoke Apply grease until all traces of water have been purged out at each of these areas ITEM RECOMMENDED LUBE METHOD FREQUENCY Front Propshaft Yoke s Polaris Premium U Join...

Page 45: ...79002 330 gal tote 2879001 AGL 1 qt 12 2878068 1 gal 4 2878069 2 5 gal 2 2878070 Demand Drive 1 qt 12 2877922 2 5 gal 2 2877923 Gas Shock Oil 1 qt 6 2870995 2 5 gal 2 2872279 Antifreeze Coolant 1 qt 1...

Page 46: ...witch check 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 replace if necessary Ste...

Page 47: ...e dipstick and verify the oil level is in the SAFE XX range Add oil as indicated by the level on the dipstick Do not overfill see NOTE below NOTE A rising oil level between checks in cool weather driv...

Page 48: ...ckwise to remove it Oil Filter Wrench PU 50105 2 5 64 mm 10 Using a clean dry cloth clean filter sealing surface on the crankcase 11 Lubricate O ring on new filter with a film of fresh engine oil Chec...

Page 49: ...rear fender panel NOTE Make sure line is not kinked or pinched ENGINE AND TRANSMISSION MOUNTS Periodically inspect engine and transmission mounts for cracks or damage Refer to Chapter 3 Engine Assemb...

Page 50: ...emove the three T40 bolts retaining the valve cover 5 Remove the valve cover from the engine out of the right hand rear wheel well area 6 Remove the outer PVTcover and drive belt as shown in chapter 6...

Page 51: ...ation 16 Reinstall the cargo box access panel and seats see Chapter 10 EXHAUST SPARK ARRESTOR WARNING Do not clean spark arrestor immediately after the engine has been run as the exhaust system become...

Page 52: ...olant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pr...

Page 53: ...removing the pressure cap 5 Remove the pressure cap Using a funnel add coolant to the top of the filler neck 6 Reinstall the pressure cap NOTE Use of a non standard pressure cap will not allow the rec...

Page 54: ...o relieve any cooling system pressure 3 Place a suitable drain pan underneath the radiator fitting on the front right hand side of the vehicle 4 Drain the coolant from the radiator by removing the low...

Page 55: ...an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result FUEL LINE 1 Che...

Page 56: ...minimal freeplay between the throttle cable and the cable pull lever If there is excessive play due to cable stretch or incorrect adjustment it will cause a delay in throttle response especially at l...

Page 57: ...de 8 Apply a small amount of grease to the inside of the boot u and slide it over the cable adjuster to its original position 9 Reinstall the cargo box access panel ENGINE AND PVT INTAKE PRE FILTER SE...

Page 58: ...ch the six clips and carefully remove the air box cover Be sure not to let the air box cover contact the air filter element during removal 4 Inspect the air filter element and replace if necessary Do...

Page 59: ...6 If hub removal is required remove the hub nut and washers WHEEL INSTALLATION 1 Verify the transmission is still in PARK P 2 Install the wheel hub q washers w and hub nut e if previously removed 3 Pl...

Page 60: ...URE INSPECTION COLD Front Rear 10 psi 55 kPa 12 psi 55 kPa DRIVE SHAFT BOOT INSPECTION Inspect the front and rear drive shaft boots Item 1 for damage tears wear or leaking grease If the boots exhibit...

Page 61: ...th the bottom of the fill plug hole 1 Position vehicle on a level surface 2 Remove the fill plug q and check the lubricant level 3 If lubricant level is not even with the bottom threads add the recomm...

Page 62: ...obtained place the shift cable and inner jam nut into the mount Tighten the outer jam nut against the mount 7 Start engine and shift through all gears to ensure the shift cable is properly adjusted If...

Page 63: ...a drain pan under the front gearcase drain plug 7 Remove the drain plug and allow fluid to drain completely 8 Clean the drain plug magnetic surface 9 Reinstall drain plug with a new O ring and torque...

Page 64: ...outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician Use only genuine Polaris replacement parts TIE ROD...

Page 65: ...urement 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 mm toe out This means the measurement at the front of the...

Page 66: ...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 After alignment is...

Page 67: ...st both the left and right spring preloads equally Suspension Spring Adjustment 1 Position the vehicle on a level surface and stop the engine 2 Raise and safely support the front or rear of the vehicl...

Page 68: ...brake fluid level in the reservoir The level should be between the MAX and MIN level lines q 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5...

Page 69: ...ke cable tension If performing this service is difficult due to conditions or location temporarily disconnect the parking brake switch electrical connector Reconnect the connector as soon as practicab...

Page 70: ...k of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarette...

Page 71: ...he driver s seat BATTERY OFF SEASON STORAGE Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of...

Page 72: ...ay occur if the incorrect spark plug is used 10 Install spark plugs and torque to specification Recommended Spark Plug 2013 2014 Champion XG4YCX 2015 and later NGK MR7F TORQUE Spark Plug 9 ft lbs 12 N...

Page 73: ...IR FILTER EXPLODED VIEW 3 15 EXHAUST SYSTEM ASSEMBLY VIEW 3 16 ENGINE COOLING SYSTEM 3 17 COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM 3 17 COOLING SYSTEM SPECIFICATIONS 3 18 COOLING SYSTEM P...

Page 74: ...ND 3 57 PISTON RING INSTALLATION 3 57 PISTON CONNECTING ROD ASSEMBLY 3 58 CYLINDER INSTALLATION 3 59 CYLINDER HEAD ASSEMBLY 3 59 VALVE SEALING TEST 3 60 CYLINDER HEAD INSTALLATION BLACK BOLTS 3 61 CYL...

Page 75: ...TROUBLESHOOTING 3 87 ENGINE 3 87 SPARK PLUG FOULING 3 87 ENGINE TURNS OVER BUT FAILS TO START 3 87 ENGINE DOES NOT TURN OVER 3 87 ENGINE RUNS BUT WILL NOT IDLE 3 87 ENGINE IDLES BUT WILL NOT ACCELERAT...

Page 76: ...57 or http polaris service solutions com ENGINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Oil Capacity 2 Quarts 1 9 L Oil Filter Wrench PU 50105 or 2 5 64 mm Oil Type Polaris PS 4 Synthetic Engine Oil...

Page 77: ...3 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 3 5 ENGINE OIL FLOW CHART ENGINE COOLING SYSTEM...

Page 78: ...lve Seat Contacting 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 Valv...

Page 79: ...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 R...

Page 80: ...3 8 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc TORQUE SEQUENCE ENGINE COOLING SYSTEM...

Page 81: ...3 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 3 9 CRANKCASE TIMING CHAIN GUIDES OIL PICKUP REGULATOR VALVE ENGINE COOLING SYSTEM...

Page 82: ...3 10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc CYLINDER OIL FILTER OIL PUMP BREATHER ENGINE COOLING SYSTEM...

Page 83: ...pyright Polaris Industries Inc 3 11 CAMSHAFTS CYLINDER HEAD FLYWHEEL STATOR COVER BLACK HEAD BOLTS Apply a drop of Loctite 641 Yellow to the crankshaft taper before assembly Loctite 603 Green can be u...

Page 84: ...3 12 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc CAMS CYL HEAD FLYWHEEL STATOR COVER SILVER HEAD BOLTS ENGINE COOLING SYSTEM...

Page 85: ...3 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 3 13 SPARK PLUGS STARTER THROTTLE BODY VALVE COVER ENGINE COOLING SYSTEM...

Page 86: ...3 14 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc PISTON CRANKSHAFT BALANCE SHAFT ENGINE COOLING SYSTEM...

Page 87: ...ASM AIRBOX MAIN o LID AIRBOX k SCREW w BOOT AIRBOX a CLAMP NARROW BAND l CAP DRAIN e BASE AIRBOX s CLAMP HOSE 1 CLAMP HOSE r CLAMP AIRBOX d FILTER AIRBOX MAIN 2 SCREW t CLIP AIRBOX f DECAL FILTER MAIN...

Page 88: ...ight Polaris Industries Inc EXHAUST SYSTEM ASSEMBLY VIEW q Muffler y Exhaust Seal w Spark Arrestor u Spring e Isolator Mount i Exhaust Pipe r Silencer Screw 8 ft lbs 11 Nm o Exhaust Gasket t Nut a Exh...

Page 89: ...3 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 3 17 ENGINE COOLING SYSTEM COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM ENGINE COOLING SYSTEM...

Page 90: ...ection required in your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine d...

Page 91: ...le 3 The pressure cap relief pressure is 13 psi Replace cap if it does not meet this specification RADIATOR 1 Check radiator air passages A for restrictions or damage 2 Carefully straighten any bent r...

Page 92: ...coolant hose q from the radiator as shown Properly dispose of the coolant 5 Allow coolant to completely drain 6 Place a suitable drain pan underneath the lower engine hose w on the right hand rear sid...

Page 93: ...The water pump cover gasket and impeller can be serviced with the stator cover installed on the engine 1 Allow engine and cooling system to completely cool CAUTION Be sure the engine has cooled and n...

Page 94: ...ring 1 Allow engine and cooling system to completely cool CAUTION Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure cap The coolant may be ho...

Page 95: ...pump impeller uses reverse LH threads 15 Remove the thirteen bolts securing the stator cover to the engine 16 If needed install the stator cover removal handle tool PA 49317 to the water pump cover bo...

Page 96: ...cover 21 Press out the water pump drive shaft bearing u from the stator cover Discard bearing and replace with new Water Pump Assembly 22 Thoroughly clean the stator cover 23 Press in a new water pum...

Page 97: ...e new water pump oil seal with clean engine oil 28 Use the water pump oil seal installation tool in kit 29 PU 50869 to fully install the new water pump oil seal I CAUTION Be sure the oil seal is fully...

Page 98: ...ller 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 Us...

Page 99: ...olant hose to the water pump cover and tighten hose clamp 44 Connect the stator wire connector and install a new tie strap securing the wiring to the front engine mount bracket 45 Install the CPS sens...

Page 100: ...the pressure cap q 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...

Page 101: ...op end engine components can be serviced while the engine is mounted in the chassis ENGINE REMOVAL NOTE Some engine repair procedures can be performed without removing the engine assembly from the veh...

Page 102: ...ntake baffle intake hoses engine crankcase vent tube an assembly as shown below 8 Elevate the rear of the vehicle off the ground using a suitable lift and remove the left rear wheel 9 Remove the outer...

Page 103: ...connector tabs 16 Move fuel line to the left hand side of the engine compartment Make note of line routing for installation 17 Disconnect the ignition coil harness connector and remove the spark plug...

Page 104: ...owels to plug engine and air box intake holes 24 Disconnect the upper engine coolant hose H bypass hose I and ECT J harness connector 25 Remove the three hex bolts K securing the exhaust head pipe to...

Page 105: ...dapter 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 35 Place engine onto the engine stand for se...

Page 106: ...ch center distance 7 The pictures below show the tool properly installed Clutch Center Distance Tool PU 50658 PU 50658 A HOLE YEAR VEHICLE DESCRIPTION 1 2012 RZR 570 2 2011 14 RZR 900 2014 15 RZR XP 1...

Page 107: ...ss pattern torque the four front engine mount fasteners to specification TORQUE Front Engine Mount Fasteners 40 ft lbs 54 Nm 10 Torque the two front center isolator bolts to specification TORQUE Isola...

Page 108: ...n Be sure the routing of the transmission breather hose and wire harness is correct TORQUE Rear Bolt in Brace Fastener 17 ft lb 23 Nm Front Bolt in Brace Fastener 40 ft lbs 54 Nm 23 Connect the igniti...

Page 109: ...e Break In Period page 3 37 upon returning vehicle to customer ENGINE BREAK IN PERIOD The break in period consists of the first 25 hours of operation or the time it takes to use 15 gallons 57 liters o...

Page 110: ...GINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Oil Capacity Approx 2 Quarts 1 9 L Oil Filter Wrench PU 50105 or 2 5 64 mm Oil Type Polaris PS 4 Synthetic Engine Oil Oil Pressure Minimum Specification...

Page 111: ...engine and remove it out of the right hand rear wheel well area 5 Replace isolators w and valve cover seal e if oil leaks are evident 6 Remove the spark plug r Stuff spark plug hole with a shop towel...

Page 112: ...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 Car...

Page 113: ...ed 1 Thoroughly clean and inspect the decompression mechanism q located on the exhaust camshaft 2 Replace the decompression assembly if any excessive wear or binding is evident 3 Be sure the decompres...

Page 114: ...emoved 1 Remove and discard the two outer M6 bolts q that retain the cylinder head w and the cylinder 2 Loosen the four cylinder head bolts e evenly 1 8 turn 60 degrees at a time until all are loose 3...

Page 115: ...e the valve retainer w valve spring e valve stem seal r and valve spring seat t Discard the valve seal NOTE Replace valve seals whenever cylinder head is disassembled Hardened cracked or worn seals wi...

Page 116: ...SUREMENT 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 che...

Page 117: ...e Guide I D 0 2165 0 2171 5 500 5 515 mm 8 Be sure to measure each guide and valve combination individually NOTE The valve guides cannot be replaced COMBUSTION CHAMBER CLEANING WARNING Wear eye protec...

Page 118: ...ide 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 i...

Page 119: ...ace Use the 30 cutter to lower the valve seat If too low use the 70 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 bo...

Page 120: ...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 disca...

Page 121: ...he piston rings they may lose radial tension 3 Remove top ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary...

Page 122: ...od 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...

Page 123: ...finish honing to the final bore size or by rough honing followed by finish honing CAUTION For oversize honing always wet hone using honing oil and a coarse roughing stone Measure piston see piston me...

Page 124: ...grit material Wash the cylinder in a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the aluminum casting Use electrical contact cleaner if necessary to c...

Page 125: ...t should have I marks aligned with gasket surface and the exhaust cam sprocket should have E marks aligned with gasket surface 7 Carefully install the camshaft carrier onto the camshafts 8 Install the...

Page 126: ...timing as needed Reinstall the cam carrier Re check cam timing 12 Remove the Cylinder Holding Camshaft Timing Plate from the end of the camshafts Cylinder Holding Camshaft Timing Plate PU 50563 13 If...

Page 127: ...ots 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 Rem...

Page 128: ...epare 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...

Page 129: ...nder in groove until butt ends are on PTO side of piston see illustration 1 NOTE Ends must butt squarely together and must not overlap 2 Install lower ring with end gap positioned as shown in Step 3 3...

Page 130: ...sition NOTE 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...

Page 131: ...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 engine and position...

Page 132: ...y to install the keepers 10 Install split keepers y with gap even on both sides 11 Repeat this procedure for remaining valves 12 Exercise each valve through its travel to ensure the valve keepers are...

Page 133: ...inder 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 NOTE Do not touch sealing surfaces of the ne...

Page 134: ...inder head bolts using the incorrect procedure may lead to engine component damage 2 Prepare cylinder head gasket sealing surfaces by cleaning thoroughly to remove all residue The new head gasket must...

Page 135: ...prior 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 intak...

Page 136: ...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 specifica...

Page 137: ...e appropriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 15 Install the new tappet NOTE Lubricate the outer portion of the valve bucket upon installa...

Page 138: ...0 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 401 0 425 468 470 472 475 478 480 482 485 488 490 492 495 498 50...

Page 139: ...520 522 525 528 530 532 535 538 540 542 0 401 0 425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0...

Page 140: ...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 ca...

Page 141: ...from 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...

Page 142: ...r 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 co...

Page 143: ...04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 3 71 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 COO...

Page 144: ...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 outwa...

Page 145: ...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 asse...

Page 146: ...s Install a new gasket and torque the two fasteners to specification TORQUE Crankcase Breather Cover Bolts 9 ft lbs 12 Nm CRANKCASE SEPARATION NOTE Before the crankcase can be separated be sure the en...

Page 147: ...4 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 NOTE D...

Page 148: ...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 NOTE The con...

Page 149: ...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...

Page 150: ...aring 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...

Page 151: ...ASS 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 pressur...

Page 152: ...oval Installation Tool PU 50784 Install plate q over adapter w Evenly attach the assembly onto the PTO side crankcase using the four bolts as shown Place the nut and large washer onto the crankshaft i...

Page 153: ...nkshaft 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 cran...

Page 154: ...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 indi...

Page 155: ...e 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...

Page 156: ...ch retaining bolts threads w Place hub on flywheel and install bolts 4 Torque screws to specification TORQUE One Way Clutch Retaining Bolts 9 ft lbs 12 Nm Apply Loctite 272 FLYWHEEL INSTALLATION 1 Cle...

Page 157: ...lywheel key on the crankshaft 8 By hand lightly press the flywheel inward while rotating the starter gear counter clock wise Fully install the flywheel until seated on the crankshaft taper 9 Install t...

Page 158: ...ply 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 CAUTION The flywheel contains powerful m...

Page 159: ...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 enteri...

Page 160: ...pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose impeller Thermistor failure Cooling fan inoperative or turning too slowly perform current draw test Low oil le...

Page 161: ...12 FUEL INJECTORS 4 13 OPERATION OVERVIEW 4 13 FUEL INJECTOR TROUBLESHOOTING 4 13 FUEL INJECTOR TEST 4 14 FUEL INJECTOR REPLACEMENT 4 14 FUEL TANK 4 16 FUEL LINES QUICK CONNECT 4 16 EXPLODED VIEW 4 1...

Page 162: ...4 38 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 38 SPECIAL TOOLS DIGITAL WRENCH 4 38 DIGITAL WRENCH SOFTWARE VERSION AND UPDATE ID 4 38 DIGITAL WRENCH UPDATES 4 39 DIGITAL WRENCH COMMUNICATION ERRO...

Page 163: ...once you have completed the fuel pressure test Fuel Pressure Gauge Kit PU 43506 A Fuel Pressure Gauge Adaptor PV 48656 Digital Wrench Diagnostic Software PU 47063 A This dealer only software installs...

Page 164: ...Diagnostic Connector Located under the driver seat Digital Wrench Download Website Located at www polaris diagsys com Download Digital Wrench Updates NOTE For the most recent information on Digital W...

Page 165: ...l remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system...

Page 166: ...4 6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc EFI SYSTEM EXPLODED VIEW FUEL SYSTEM...

Page 167: ...s seat 2 Temperature and Manifold Absolute Pressure Sensor T MAP Located in the rubber intake boot between the throt tle body and the cylinder head 3 Crankshaft Position Sensor CPS Located in the magn...

Page 168: ...sition Sensor TPS Located on the right hand side of the throttle body below the IAC motor 8 Idle Air Control Motor IAC Located on the upper right hand side of the throttle body above the TPS 9 Engine...

Page 169: ...4 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 4 9 EFI SYSTEM ELECTRICAL DIAGRAM FUEL SYSTEM...

Page 170: ...led 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 i...

Page 171: ...of itself each of the sensors and system performance If a fault is detected the ECU turns on the Check Engine light in the speedometer and stores the fault code in its fault memory Depending on the s...

Page 172: ...nsure that all essential data contained within the original ECU is transferred to the replacement ECU NOTE Refer to this procedure and carefully follow all instructions provided in Digital Wrench 1 Ca...

Page 173: ...uching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running...

Page 174: ...eat and disconnect the negative battery cable 4 Thoroughly clean the fuel injector area if all dirt and debris 5 Disconnect the fuel injector harness lead 6 Hold a shop towel over the fuel line fittin...

Page 175: ...n the area around the fuel injector port on the cylinder head 13 Lightly lubricate the injector O rings and reinstall the fuel rail injector assembly into the cylinder head 14 Install the fuel rail mo...

Page 176: ...e to catch any dripping fuel Squeeze the connector tabs together and push the locking slide back 2 Pull on the fuel line for removal 3 To install the line s verify the connections are clean and free o...

Page 177: ...Service Manual Copyright Polaris Industries Inc 4 17 EXPLODED VIEW ITEM DESCRIPTION 1 PFA Nut 70 ft lbs 95 Nm 2 Fuel Pump 3 Preliminary Fuel Filter 4 Fuel Sender Float Arm 5 Gasket replace if removed...

Page 178: ...erviceable fuel filters When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off the pump preventing the continued delivery of...

Page 179: ...ons are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during starting the battery voltage drops below 7 0 volts the ECU will fail to operate the system WARNING Fu...

Page 180: ...tage to ensure a minimum of 7 volts is present NOTE If the voltage was below 7 VDC test the battery ignition switch relay s wiring harness and ECU 7 If the reading is between 7 and 14 volts turn key s...

Page 181: ...ded to allow the vehicle to sit 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 NOTE A small amount of f...

Page 182: ...light and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly NOTE It is recommended to remove the fuel tank from t...

Page 183: ...ause incorrect function 17 While maintaining downward pressure thread new PFA nut onto fuel tank and hand tighten Use care when starting PFA nut ensuring threads are properly aligned Verify orientatio...

Page 184: ...d passenger seats along with the rear service panel 2 Disconnect the negative battery cable from the battery located under the driver s seat 3 While holding a shop towel over the fuel line connector d...

Page 185: ...age 10 18 9 Remove the lower bolt retaining the seat belt mechanism near the rear RH portion of the fuel tank Once removed place the mechanism in the rear cargo box to keep it out of the way 10 Remove...

Page 186: ...pport bracket fasteners 4 Reinstall the rear RH fender well and secure with fasteners 5 Reinstall the seat belt mechanism and secure the lower bolt 6 Reinstall the RH rocker panel and all previously r...

Page 187: ...rovides the ECU with engine load data T MAP SENSOR TEST The T MAP sensor is a non serviceable item If it is faulty it must be replaced NOTE This sensor should only be tested using the Digital Wrench D...

Page 188: ...the following method Set your meter to read Ohms Check the resistance values at each of the following pin locations of the IAC If any of the readings are out of specification replace the IAC Always t...

Page 189: ...for the amount of engine load The correct position of the throttle body stop screw is established and set at the factory DO NOT loosen the throttle body stop screw or alter its position in any manner...

Page 190: ...and disconnect the negative battery cable 2 Remove the cargo box access panel The TPS sensor screws can also be accessed through the right hand rear wheel well area 3 Disconnect the vehicle harness fr...

Page 191: ...unting screws 8 Rotate the TPS until your display reading is within specification TPS Output Reading Digital Wrench 0 46 0 03 Vdc 9 Retighten the TPS mounting screws and torque to specification TORQUE...

Page 192: ...r ring missing tooth creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing by the ECU Synchronization of...

Page 193: ...cement page 4 33 procedure to inspect CPS and flywheel encoder ring for damage 5 If the resistance is incorrect follow theCPS Replacement page 4 33 procedure CPS REPLACEMENT 1 If not done already disc...

Page 194: ...de s are not displayed use the MODE button to toggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers...

Page 195: ...ure Too High 16 P0217 Engine Overheat Shutdown 0 P1217 System Power Battery Potential Power Input Voltage Too High 168 3 P0563 C1063 Voltage Too Low 4 P0562 C1064 Engine Speed Received Engine Speed Ha...

Page 196: ...it AWD Driver Circuit Open Grounded 520207 5 P1836 Driver Circuit Short to B 3 P1835 Driver Circuit Grounded 4 P1834 Idle Air Control Valve IAC M17 IAC Stepper Pin 1 Driver Circuit Open Grounded 52027...

Page 197: ...gh 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 sp...

Page 198: ...Kit PU 47063 B PU 47063 B listed above INCLUDES Digital Wrench Software PU 48731 Standard Interface Cable PU 47151 SmartLink Module Kit PU 47471 USB Serial Adapter Cable PU 50621 Fluke 73 Digital Mul...

Page 199: ...website at www polarisdealers com NOTE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Locate the Service and Warranty drop down me...

Page 200: ...gital Wrench related problem visit the Digital Wrench Knowledge Base for the most current troubleshooting information FAQs downloads and software updates at http polaris diagsys com DIGITAL WRENCH DIA...

Page 201: ...guided diagnostics are also available for many other electrical sub systems Diagnostic procedures are added to subsequent versions of Digital Wrench as they become available Check your release version...

Page 202: ...or and ECU information in a grid meter or chart format Enter customer and vehicle information and view ECU Identification View information from the main ECU sensors Load the Vehicle Home Page Set up d...

Page 203: ...t is used by a variety of people and in several applications around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE L...

Page 204: ...ed to the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be...

Page 205: ...r in the upper left corner of the screen Copy this key exactly as it appears 13 Enter or paste the Authorization Key in the box located on the Digital Wrench screen Click the Continue button and follo...

Page 206: ...n the link to download the app Android Device Minimum Specifications Minimum operating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred Dual core processor 2 GB internal memory e...

Page 207: ...PVT DISASSEMBLY 5 8 PVT ASSEMBLY 5 9 DRIVE BELT 5 11 BELT REMOVAL 5 11 BELT INSPECTION 5 11 BELT INSTALLATION 5 12 PVT BREAK IN DRIVE BELT CLUTCHES 5 13 CLUTCH CENTER DISTANCE 5 13 INSPECTION 5 13 AD...

Page 208: ...laris Industries Inc DRIVEN CLUTCH DISASSEMBLY 5 29 DRIVEN CLUTCH BUSHING SERVICE 5 31 CLUTCH BUSHING REMOVAL 5 32 CLUTCH BUSHING INSTALLATION 5 33 DRIVEN CLUTCH ASSEMBLY 5 33 DRIVEN CLUTCH ASSEMBLY V...

Page 209: ...h Retaining Bolt 47 ft lbs 64 Nm Driven Clutch Retaining Bolt 36 ft lbs 49 Nm Engine to Transmission Coupler Bolts 55 ft lbs 75 Nm PVT Inner Cover Bolts 12 ft lbs 16 Nm PVT Outer Cover Bolts 50 in lbs...

Page 210: ...d contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the...

Page 211: ...troubleshooting checklist at the end of this chapter for more information 1 Belt Inspection 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rolle...

Page 212: ...Low only Plowing snow dirt etc utility use Use Low only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttl...

Page 213: ...NENTS q DUCT OUTLET CLUTCH a DUCT CLUTCH AIR INLET w SCREW s SEAL OUTER CLUTCH COVER e CLAMP NARROW BAND d HOSE INTAKE CLUTCH r RTV SILICONE f O RING t NUT g DECAL BELT CAUTION CHECK y CLAMP NARROW BA...

Page 214: ...Belt Removal page 5 11 CAUTION Non LE and INTL Models ONLY RZR 570 Base and International models use a B O S S Built on Secondary Shaft driven clutch Inner and outer clutch sheaves will come off separ...

Page 215: ...and inner PVTcover 4 Apply RTV silicone sealant to the back side of the inner clutch cover to ensure a water tight fit between the engine and inner clutch cover Both surfaces must be clean to ensure a...

Page 216: ...UE Drive Clutch Retaining Bolt 47 ft lbs 64 Nm 14 Install the drive belt noting direction of belt rotation see Chapter 6 Belt Installation page 5 12 If a new belt is installed install so numbers can b...

Page 217: ...spread the clutch sheaves 5 LE Models Insert clutch spreader tool 2877408 into the driven clutch as shown NOTE Make sure the tool is square with the moveable sheave surface of the driven clutch 6 Rot...

Page 218: ...lutch sheaves 3 LE Models ONLY Insert the belt removal tool PN 2877408 into the driven clutch as shown NOTE Make sure the tool is square with the moveable sheave surface of the driven clutch 4 Rotate...

Page 219: ...CENTER DISTANCE INSPECTION 1 Remove the outer PVT cover drive belt drive clutch and driven clutch as outlined in this chapter NOTE The inner PVTcover does not need to be removed to check the clutch ce...

Page 220: ...ith the engine and transmission mounting fasteners loose install the Clutch Center Distance Tool PU 50658 as shown in the inspection process 6 With the tool now properly installed in sequence torque t...

Page 221: ...ave a Pin w Washers s Washer e Needle Bearing non EBS models One Way Clutch EBS models d Button r Spacer f Limiter Spacer t Bushing g Clutch Spring y Moveable Sheave h Cover Bushing u Spider 225 ft lb...

Page 222: ...e and the assembly MUST be replaced 3 Remove the six cover bolts evenly in a cross pattern and remove cover plate 4 Inspect cover bushing q The outer cover bushing is manufactured with a Teflon coatin...

Page 223: ...T system It is also one of the easiest to service Due to the severe relaxation the spring is subject to during operation it should always be inspected during any clutch operation diagnosis or repair C...

Page 224: ...ed or stuck roller in the spider assembly SeeRoller Pin and Thrust Washer Inspection page 5 19 SPIDER REMOVAL 1 Install clutch in holding fixture q in a vise Loosen the spider counterclockwise using C...

Page 225: ...NSPECTION 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 rollers pins an...

Page 226: ...one way bearing should rotate clockwise when viewed from cover plate side with only a slight amount of drag When rotated counter clockwise the one way bearing should lock to the shaft without slippin...

Page 227: ...kness Standard 030 76 mm Service Limit 025 64 mm BUSHING SERVICE NOTE Special Tools Required EBS Clutch Bushing Tool Kit 2201379 ITEM QTY PART DESCRIPTION PART A B 1 EBS Puller Tool 5132027 C 1 EBS Pu...

Page 228: ...A B into center of sheave with A side toward sheave NOTE Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using...

Page 229: ...ool into center of clutch cover 31 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 32 Install nut on rod and hand tighten Turn puller barrel to apply more...

Page 230: ...on using the holding fixture and spider tool i Torque spider to specification TORQUE Spider 225 ft lb 305 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 7 Install shift weights using new l...

Page 231: ...s built on or after 09 10 12 Early build 2013 driven clutch assemblies use a shorter compression spring 3 85 98 mm Red White color and a washer Late build 2013 driven clutch assemblies use a longer co...

Page 232: ...sembly and maintains clutch balance after reassembly 2 Remove the driven clutch from the vehicle See PVT Disassembly page 5 8 3 Place the driven clutch into a universal clutch compressor Spin the tool...

Page 233: ...e replaced 11 Inspect driven clutch sheave faces for wear or damage 12 Clean and inspect splines on helix and transmission input shaft 13 Lube splines with a light film of grease Do not lubricate the...

Page 234: ...Inc 6 Place the clutch into the universal clutch compressor Apply and hold downward pressure on the spring cup Torque the retaining ring screws e to specification TORQUE Clutch Spring Retaining Ring B...

Page 235: ...clutch puller to remove driven clutch 2 It is important to mark the position of the shaft cam cover and sheave with a grease marker or tape before disassembly or use the X s on the components for ref...

Page 236: ...spider dampener y Inspect the spider dampener for wear and replace if needed 8 Remove the E clips u washers i and the clutch rollers o Inspect the rollers for wear replace if worn 9 Remove the clutch...

Page 237: ...s worn or the shaft does not fit snug into the bushing replace the cam helix assembly 15 Inspect the sheaves for excessive wear or damage DRIVEN CLUTCH BUSHING SERVICE NOTE Special Tools Required for...

Page 238: ...Remove the driven clutch as previously outlined 2 Install the handle end of the Piston Pin Puller securely into the bench vise and lightly grease puller threads Piston Pin Puller 2870386 3 Remove nut...

Page 239: ...nto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 8 Remove nut from pulle...

Page 240: ...in into the sheave assembly on both sides The flat side of the roller pin faces towards the sheaves 6 Install the spring pins t to secure the roller pins Install until flush with sheave surface 7 Inst...

Page 241: ...e skip tooth on the shaft and the spider are aligned Once the spider passes the retaining ring notch on the shaft install the retaining ring s 14 Install the cam helix assembly over the shaft Line up...

Page 242: ...ht Polaris Industries Inc DRIVEN CLUTCH ASSEMBLY VIEW q Snap Ring i Spring w Bearing o Spider Insert e Stationary Sheave a Spider Dampener r Pin s E Clip t Roller d Washer y Moveable Sheave f Helix Ca...

Page 243: ...ch spring too high spring rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift weights Drive clutch binding Disassem...

Page 244: ...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 Maintenanc...

Page 245: ...6 TRANSMISSION REMOVAL 6 6 TRANSMISSION INSTALLATION 6 10 SERVICING NO DIFFERENTIAL 6 14 TRANSMISSION DISASSEMBLY 6 14 GEAR SHAFT BEARING INSPECTION 6 20 SNORKEL GEAR BACKLASH PROCEDURE 6 21 TRANSMISS...

Page 246: ...12 ft lbs 16 Nm Rear Transmission Isolator Mount Bolt 40 ft lbs 54 Nm Snorkel Tube Refer to Snorkel Gear Backlash Procedure Snorkel Tube Locking Screw 8 ft lbs 11 Nm Starter Mounting Bolts 7 ft lb 10...

Page 247: ...6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 6 3 TRANSMISSION MOUNTING AND TORQUE VALUES TRANSMISSION...

Page 248: ...driver Remove the console from the vehicle 3 Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever 4 Remove the retaining ring and slide...

Page 249: ...n pivot bushings and dust boot Replace if worn or damaged 3 If adjustment is required loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut 4 Adjust the shift cable so...

Page 250: ...falls Be sure machine is secure before beginning this procedure Always wear eye protection 5 Remove rear wheels from the vehicle 6 From the right hand front wheel well locate the propshaft roll pin Us...

Page 251: ...lamp that secures the air box to the throttle body Cut the tie strap that secures the wire harness to the right hand side of the air box Remove the air box assembly 15 Place a shop to beneath the fuel...

Page 252: ...n removal 21 Disconnect the vehicle speed sensor F and gear position switch G harness connectors Cut tie strap H Note harness routings for reassembly 22 Remove the transmission vent tube I 23 INTL Rem...

Page 253: ...ssembly 28 Place a support in between the main frame and the engine crankcase to support the engine in its current position Do not pinch brake line 29 Remove the eight engine to transmission coupler b...

Page 254: ...LLATION 1 With the help of an assistant lift transmission into the vehicle frame through the left rear wheel well area as shown below 2 Carefully rotate the top of the transmission upward into its pro...

Page 255: ...bolts to specification 7 In sequence torque the eight engine coupler bracket bolts to specification TORQUE Engine to Trans Coupler bolts In Sequence 55 ft lbs 75 Nm 8 Remove the clutch center distance...

Page 256: ...ring the rear bolt in brace to the vehicle main frame Note the routing of the transmission breather hose and wire harness Torque fasteners to specification 19 Lubricate the transmission splines with P...

Page 257: ...ting Bolts 44 ft lbs 60 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 28 Install rear wheels and wheel...

Page 258: ...D flat washer D and gear switch E Remove the switch 5 Remove the sector cover bolts F and remove the sector cover G NOTE Removal can be aided by using your thumbs to press in on the shafts while pulli...

Page 259: ...ing surfaces Use only the designated pry points on 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 d...

Page 260: ...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 18 Remove all sea...

Page 261: ...e reverse shaft see Figure 8 2 24 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 com...

Page 262: ...the transmission case 28 Remove the snap ring Y and shim Z from the snorkel shaft 29 Use an arbor press to remove the snorkel tube from the snorkel shaft 30 Remove the snap ring A and shim B retaining...

Page 263: ...6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 6 19 32 Remove the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft TRANSMISSION...

Page 264: ...6 20 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc GEAR SHAFT BEARING INSPECTION TRANSMISSION...

Page 265: ...er and new retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly NOTE Failure to press the gear back...

Page 266: ...NOT install 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...

Page 267: ...r lash appears to be too tight rotate the snorkel shaft clockwise 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 s...

Page 268: ...Assemble the reverse shaft assembly and input shaft assembly if previously disassembled see illustrations 19 Install the idler gear shaft assembly A and gear cluster assembly B into the transmission...

Page 269: ...embly Be sure the shift forks are engaged into the engagement dogs NOTE Shift fork pins should be offset towards the input shaft as shown above 23 Inspect the shift drum for any damage or wear Inspect...

Page 270: ...t seal G should be pressed in until it seats flush with the housing The rear output shaft seals H can be installed using a standard bushing installation tool Seals should be installed just past the ca...

Page 271: ...sector cover 34 Clean the transmission and gear sector cover mating surfaces thoroughly 35 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 36 Install the...

Page 272: ...6 28 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc TRANSMISSION ASSEMBLY VIEW TRANSMISSION...

Page 273: ...ing 68 Gear 46T 13 Pin Dowel 41 Tube Snorkel 69 Gear Snorkel 13T 14 Pin Spring 42 Cover Sector Gears 70 Shaft Shift 15 Retaining Ring External 43 Case LH 71 Weldment Rear Mount Bracket 16 Snap Ring 44...

Page 274: ...cal 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...

Page 275: ...6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 6 31 TRANSMISSION...

Page 276: ...cover bolts F and remove the sector cover G NOTE 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 R...

Page 277: ...on the transmission 13 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 transmis...

Page 278: ...then lift shift fork Y and torsion spring out of transmission housing 20 Using a 5 mm Allen wrench remove the screws that secure the pinion shaft assembly V Lift the pinion shaft assembly straight up...

Page 279: ...r gear and needle bearing from the reverse shaft see Figure 8 2 27 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 dis...

Page 280: ...kel tube and shaft assembly from the transmission case 31 Remove the snap ring Y and shim Z from the snorkel shaft 32 Use an arbor press to remove the snorkel tube from the snorkel shaft 33 Remove the...

Page 281: ...ETARY DIFFERENTIAL DISASSEMBLY NOTE If the gearcase is completely assembled perform the Gearcase Disassembly Inspection page 7 30 procedure 1 Use a scribe to mark the differential cover and ring gear...

Page 282: ...If bushing replacement is required proceed to Chapter 8 Planetary Differential Bushing Replacement page 6 38 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT NOTE If the differential is completely assembled...

Page 283: ...n 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 Differenti...

Page 284: ...ide 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 PLANET...

Page 285: ...3 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 6 41 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification TORQUE Differential Cover Screws 21 ft lb 28...

Page 286: ...6 42 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc GEAR SHAFT BEARING INSPECTION TRANSMISSION...

Page 287: ...retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly NOTE Failure to press the gear back against th...

Page 288: ...NOT install 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...

Page 289: ...kwise 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 TOR...

Page 290: ...two screws T and install with retaining plates over shift fork Torque to specification TORQUE Shift Fork Screws 8 ft lb 11 Nm 20 Slide engagement dog U onto retaining pins of shift fork 21 Assemble th...

Page 291: ...ith engagement dog Ensure bearing is fully seated upon assembly 24 Assemble shift shaft rail if previously disassembled NOTE Both shift forks need to be orientated the same way so that the shift fork...

Page 292: ...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 17 ft lbs 23 Nm 30 Install new s...

Page 293: ...roughly clean the shift shaft housing Be sure the transmission is in High gear prior to reassembly 33 Install the sector gear 16T onto the shift drum shaft Install the shift shaft assembly and sector...

Page 294: ...ankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 40 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the b...

Page 295: ...6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 6 51 TRANSMISSION ASSEMBLY VIEW INT L TRANSMISSION...

Page 296: ...85 Solenoid 17 Pin Spring 51 Gear Sector 16T 86 Switch Rotary 2 Pin 18 Retaining Ring External 52 Gear Sector 31T 87 O Ring 19 Snap Ring 53 Pawl Detent 88 O Ring 20 Retaining Ring External 54 Star Det...

Page 297: ...s Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the trans...

Page 298: ...6 54 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc NOTES TRANSMISSION...

Page 299: ...11 DRIVE SHAFT EXPLODED VIEW 7 11 FRONT DRIVE SHAFT REMOVAL 7 11 FRONT DRIVE SHAFT INSTALLATION 7 12 REAR DRIVE SHAFT REMOVAL 7 14 REAR DRIVE SHAFT INSTALLATION 7 15 DRIVE SHAFT CV JOINT HANDLING TIPS...

Page 300: ...lbs 4 Nm Clutch Cover Outer Screws 100 in lbs 12 Nm Drive Clutch Cover Plate Screws 100 in lb 12 Nm Front Gearcase Mounting Bolts 30 ft lbs 41 Nm Front Hub Castle Nut 80 ft lb 108 Nm Rear Hub Castle N...

Page 301: ...r pin and loosen the front wheel hub castle nut Remove the nut and two cone washers from the front wheel hub assembly 5 Remove the fastener retaining the steering tie rod end to the front bearing carr...

Page 302: ...ring out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4 Inspect the bearing carrier housing for scratches wear or...

Page 303: ...y grease to drive shaft axle splines 5 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 6 Install brake caliper mounting bolts and torq...

Page 304: ...th ends of cotter pin around end of spindle in different directions REAR BEARING CARRIER INSPECTION REMOVAL 1 Elevate rear of vehicle and safely support machine under the frame area CAUTION Serious in...

Page 305: ...e the bearing carrier from the rear drive shaft 10 Rotate bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion NOTE Due to extremely close tolerances a...

Page 306: ...ge Replace rear bearing carrier if damaged Bearing Installation 5 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed...

Page 307: ...h a drift punch Install new bushings by pressing them into the bearing carrier REAR BEARING CARRIER INSTALLATION 1 Install drive shaft axle through the backside of the bearing carrier Be sure bushings...

Page 308: ...ing agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 6 Torque wheel hub nut to specification and install a NEW cotter pin Tighten nut slightly if necessa...

Page 309: ...r wheel nuts and remove the front wheel 3 Remove the cotter pin and loosen the front wheel hub castle nut Remove the nut and two cone washers from the front wheel hub assembly 4 Remove the two front b...

Page 310: ...se FRONT DRIVE SHAFT INSTALLATION 1 Install new spring ring on drive shaft Apply an anti seize compound to splines 2 Align splines of drive shaft with front gearcase and reinstall the drive shaft Use...

Page 311: ...ly if necessary to align cotter pin holes TORQUE Front Wheel Hub Castle Nut 80 ft lb 108 Nm 9 Install brake caliper mounting bolts and torque to specification TORQUE Front Caliper Mounting Bolts 30 ft...

Page 312: ...move the rear wheel 3 Remove the cotter pin and loosen the rear wheel hub castle nut Remove the nut and two cone washers from the rear wheel hub assembly 4 Remove and discard the two brake caliper att...

Page 313: ...the axle splines and CV boots for any damage REAR DRIVE SHAFT INSTALLATION 1 Install new spring ring on drive shaft Apply anti seize compound to splines 2 Align splines of drive shaft with rear gearc...

Page 314: ...ssembly cone washers and hand tighten the castle nut Install washers with domed side out 7 Install NEW brake caliper mounting bolts and torque to specification TORQUE Rear Caliper Mounting Bolts 44 ft...

Page 315: ...g hold of the interconnecting shaft to avoid dis assembly or potential damage to the drive shaft joints Over angling of joints beyond their capacity could re sult in boot or joint damage Make sure sur...

Page 316: ...int to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure circlip w is on the shaft and not left in the joint 6 Re...

Page 317: ...he joint 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...

Page 318: ...location on the shaft 20 Install and tighten the small clamp r on the boot using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 INNER PLUNGING JOINT BOOT REPL...

Page 319: ...11 Install a new circlip on the end of the shaft 12 Grease the joint with the special joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joi...

Page 320: ...eats and the engine service panel as outlined in Chapter 5 2 Disconnect the negative battery cable 3 Raise and support vehicle and remove the left hand rear wheel CAUTION Serious injury may result if...

Page 321: ...ider upward in order to allow the prop shaft to pass beneath them 11 Slide prop shaft back far enough to remove it from the front gearcase input shaft splines 12 Pull sharply forward to remove the pro...

Page 322: ...Junction Block Mounting Screws 36 in lbs 4 Nm DISASSEMBLY 1 Remove internal or external snap ring from bearing caps CAUTION Always wear eye protection NOTE If yoke or bearing is removed cross bearing...

Page 323: ...in one side Continually check for free movement of bearing cross as bearing caps are assembled 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Install oute...

Page 324: ...g 1 5 Ball Bearing 2 23 Spring Wireform 2 6 Ball Bearing Double Row 1 24 H Clip Spring 20 7 Bushing 1 26 Nylon Spacer 2 8 Bushing 1 27 Torsion Spring Retainer 1 9 Oil Seal 2 28 Backlash Spacer 1 10 Oi...

Page 325: ...s engaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which create...

Page 326: ...er If only one band of wear is present or if there is 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 whic...

Page 327: ...rom the front gearcase 3 Remove the propshaft from the front gearcase see Chapter 7 PROPSHAFT SERVICE page 4 Disconnect the wire harness above the front gearcase and remove the harness from the retain...

Page 328: ...nd properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the seven cover screws and remove the cover plate assembly 3 Remove the LH output hub assembly from...

Page 329: ...e Refer to Chapter 7 AWD Diagnosis page 7 28 for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the top of the ring gear 6 Remove the clutch housing ring gear...

Page 330: ...WD Diagnosis page 7 28 for detailed inspection process Replace the cover plate seal and O ring 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housin...

Page 331: ...lace if needed 16 Clean and inspect all remaining front gearcase components Check each for excessive wear or damage GEARCASE ASSEMBLY 1 As mentioned during gearcase disassembly section replace all O r...

Page 332: ...t the ring gear grooves line up with the roll cage slots see below 6 Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear 7 Align the spring retainer dow...

Page 333: ...gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTE Be sure the square O ring is placed flat on the cover surface If the O ring is twisted fl...

Page 334: ...propshaft 3 Install the four bolts that secure the front gearcase to the frame and torque to specification 4 Install the vent line TORQUE Front Gearcase Mounting Bolts 30 ft lbs 41 Nm 5 Connect the A...

Page 335: ...7 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 7 37 WHEEL HUBS FRONT HUB EXPLODED VIEW FINAL DRIVE...

Page 336: ...7 38 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc REAR HUB EXPLODED VIEW FINAL DRIVE...

Page 337: ...ERING UNIT REMOVAL 8 9 LOWER STEERING SHAFT REMOVAL EPS MODELS 8 10 LOWER STEERING SHAFT INSTALLATION EPS MODELS 8 10 POWER STEERING UNIT INSTALLATION 8 11 UPPER STEERING SHAFT INSTALLATION EPS MODELS...

Page 338: ...Nm Seat Belt to Seat Base 40 ft lbs 54 Nm Tilt Shock Upper Fastener 7 ft lbs 10 Nm Tilt Shock Lower Fastener 12 ft lb 16 Nm Stabilizer Bushing Retaining Nuts 37 ft lbs 50 Nm Stabilizer Bar Mounting Bo...

Page 339: ...8 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 8 3 STEERING SYSTEM EXPLODED VIEW NON EPS MODELS STEERING SUSPENSION...

Page 340: ...STEERING SHAFT BEARING REPLACEMENT NOTE Replacement pivot tube assembly comes with new upper and lower bearings installed Use this procedure if replacing just the bearings only 1 Perform the Steering...

Page 341: ...ortion of the steering shaft onto the steering gear box assembly see Figure 5 16 Torque the lower pinch bolt to specification TORQUE Lower Pinch Bolt 36 ft lb 48 Nm 12 Install the two fasteners that r...

Page 342: ...8 6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc EXPLODED VIEW EPS MODELS STEERING SUSPENSION...

Page 343: ...vehicle 2 Remove the pinch bolt retaining the upper steering shaft to the power steering unit 3 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube Swing...

Page 344: ...to Upper Steering Shaft Removal EPS Models page 8 7 CAUTION Striking the steering wheel or steering shaftwhile installed in the vehicle can permanently damage the EPS unit and cause aPower Steering Fa...

Page 345: ...steering wheel or steering shaftwhile installed in the vehicle can permanently damage the EPS unit and cause aPower Steering Fault 2 Disconnect the two electrical harnesses from the power steering uni...

Page 346: ...stub shaft and gear box to aid installation 3 Remove the power steering unit see Chapter 5 Power Steering Unit Removal page 8 9 procedure 4 Remove the pinch bolt retaining the lower steering shaft to...

Page 347: ...power steering stub shaft with the opening in the lower steering shaft 4 Place power steering mount bracket over the brake pedal mount studs and finger tighten the four nuts 5 Position the lower steer...

Page 348: ...pivot tube and torque fasteners to specification TORQUE Pivot Tube Fasteners 23 ft lb 31 Nm 3 Install tilt shock and torque fastener to specification TORQUE Upper Tilt Shock Fastener 7 ft lbs 10 Nm 4...

Page 349: ...Joint Replacement section 10 Insert new A arm bushings and pivot tube into new A arm 11 Install new upper A arm assembly onto vehicle frame Torque new bolt to specification TORQUE Front Upper Lower A...

Page 350: ...stall lower ball joint pinch bolt E into the bearing carrier and torque bolt to specification WARNING Upon A arm installation completion test vehicle at low speeds before putting into service 23 Insta...

Page 351: ...8 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 8 15 EXPLODED VIEW STEERING SUSPENSION...

Page 352: ...aliper from the brake disc see Chapter 9 Caliper Removal page 9 21 Remove and discard the upper ball joint pinch bolt If necessary remove the lower front shock fastener from the A arm to gain enough c...

Page 353: ...By hand install the NEW ball joint into the A arm 2 Position the Installation Adapter D over the face of the ball joint 3 Position the Spacer A over the shaft of the ball joint so it is against the A...

Page 354: ...applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 10 Install wheel and four wheel nuts Torque wheel nuts to specification TORQUE Wheel Nut...

Page 355: ...ove the two upper radiator retaining bolts A and remove the four bolts B retaining the lower radiator mount bracket and remove the bracket from the frame 5 Allow radiator to sag down to allow access t...

Page 356: ...ght Polaris Industries Inc 9 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 10 Reverse the procedure for installation Torque the linkage fasteners to specificat...

Page 357: ...nt on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 7 Insert new A arm bushings and pivot tube...

Page 358: ...zer bar to the lower A arm Torque shock fastener to specification TORQUE Shock Mounting Bolts 37 ft lb 50 Nm 5 Install upper A arm assembly onto vehicle frame Torque new fastener to specification TORQ...

Page 359: ...ilizer bar from the vehicle NOTE Rotate the stabilize bar 180 degrees so the linkage hole C is facing rearward to aid in stabilizer bar removal 5 Inspect the stabilizer bar for straightness Inspect th...

Page 360: ...VIEW 2013 2016 Front Suspension 2013 Rear Suspension 2014 2016 Rear Suspension q NUT FLANGED 37 ft lbs 50 Nm w RETAINER SPRING Retainer gap should be 180 from spring end e SCREW r SPRING MATTE BLACK...

Page 361: ...ket to remove and install the LR upper shock bolt 4 Reverse the procedure to reinstall the shock Torque new fasteners to specification refer to exploded views SHOCK REPLACEMENT 1 Using a spring compre...

Page 362: ...8 26 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc NOTES STEERING SUSPENSION...

Page 363: ...9 9 PARKING BRAKE INSPECTION 9 10 PARKING BRAKE CABLE ADJUSTMENT 9 10 PARKING BRAKE CALIPER SERVICE INTL MODEL 9 12 CALIPER EXPLODED VIEW 9 12 CALIPER REMOVAL 9 13 CALIPER DISASSEMBLY INSPECTION 9 13...

Page 364: ...30 REAR CALIPER SERVICE 9 31 CALIPER EXPLODED VIEW 9 31 CALIPER REMOVAL 9 32 CALIPER DISASSEMBLY 9 32 CALIPER INSPECTION 9 33 CALIPER ASSEMBLY 9 34 CALIPER INSTALLATION 9 34 REAR BRAKE DISC 9 35 DISC...

Page 365: ...IFICATIONS ITEM TORQUE Front Caliper Mounting Bolts 30 ft lbs 41 Nm Rear Caliper Mounting Bolts 44 ft lbs 60 Nm Brake Line Flare 14 ft lbs 19 Nm Brake Line Banjo Bolts Master Cylinder and Caliper Atta...

Page 366: ...within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port within the cylinder and starts to build pressure within the brake system As the press...

Page 367: ...its tightly on fitting 5 Have an assistant slowly pump foot pedal until pressure builds and holds 6 Hold brake pedal on to maintain pedal pressure and open bleeder screw Close bleeder screw and releas...

Page 368: ...9 6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc BRAKE SYSTEM EXPLODED VIEW RZR 570 BRAKE SYSTEM...

Page 369: ...d will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Make note of front and rear brake line locations to master cylinder 4 Loosen the brake line banj...

Page 370: ...edal lever L and remove the master cylinder clevis pin B and clip A 2 Remove the E ring E from the pedal mount and remove the brake pedal lever L from the vehicle PEDAL INSTALLATION 1 Reverse Removal...

Page 371: ...9 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 9 9 PARKING BRAKE INTL MODEL EXPLODED VIEW BRAKE SYSTEM...

Page 372: ...e parking brake indicator and activation of the limiting feature If this occurs inspect and adjust parking brake cable tension If performing this service is difficult due to conditions or location tem...

Page 373: ...nut D Back out the outer jam nut D 1 1 2 turns 8 Now hold the outer jam nut D and turn in the inner jam nut C clockwise until the jam nut is tight against the bracket 9 Repeat Step 3 and Step 4 until...

Page 374: ...9 12 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc PARKING BRAKE CALIPER SERVICE INTL MODEL CALIPER EXPLODED VIEW BRAKE SYSTEM...

Page 375: ...hift cable bracket 3 Lift the parking brake caliper off the brake disc and remove it from the vehicle CALIPER DISASSEMBLY INSPECTION NOTE Refer to the Electronic Parts Catalog for parking brake calipe...

Page 376: ...r the brake disc and compare to gap specification Disassemble and add shim s between thrust washer and the inside brake pad as needed to close the gap to 207 217 in 5 25 5 51 mm 3 Once you have determ...

Page 377: ...er over the brake disc Align the caliper mounting sleeves with the holes in the mount bracket 2 Install and tighten the two caliper mount shift cable bracket fasteners to specification TORQUE Parking...

Page 378: ...pter 9 Disc Replacement page 9 16 DISC REPLACEMENT 1 Remove the parking brake caliper from the disc see Chapter 9 Caliper Removal page 9 13 2 Using a 1 2 socket and ratchet remove the brake disc retai...

Page 379: ...remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper so to avoid kinking or bending brake line 5 Push caliper piston into caliper bore slo...

Page 380: ...rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other WARNING If brake pads are contaminated with grease oil or...

Page 381: ...nd torque wheel nuts to specification TORQUE Wheel Nuts Steel Rims 27 ft lbs 37 Nm Aluminum Rims 30 ft lbs 41 Nm 90 BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed a...

Page 382: ...9 20 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc FRONT CALIPER SERVICE CALIPER EXPLODED VIEW BRAKE SYSTEM...

Page 383: ...et screw 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove and discard the two caliper mounting bolts and remove the caliper assembly from the front hub CALIPER DISASSEMBLY 1...

Page 384: ...er body CALIPER INSPECTION 1 Inspect caliper body for nicks scratches pitting or wear Measure bore size and compare to specifications Replace if damaged or worn beyond service limit MEASUREMENT Front...

Page 385: ...ess the mounting bracket and make sure the dust seal boots are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or greas...

Page 386: ...ft lbs 37 Nm Aluminum Rims 30 ft lbs 41 Nm 90 7 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...

Page 387: ...n Brake Disc Runout Service Limit 010 254 mm DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Use a 0 1 micrometer and measu...

Page 388: ...0 ft lbs 41 Nm CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 Install wheel hub assembly washers and castle nut Torque ca...

Page 389: ...caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper piston in...

Page 390: ...Inc 7 Remove the inner brake pad PAD INSPECTION 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Rear Brake...

Page 391: ...e the new mounting bolts to specification TORQUE Rear Caliper Mount Bolt 44 ft lbs 60 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...

Page 392: ...stallation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently d...

Page 393: ...9 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 9 31 REAR CALIPER SERVICE CALIPER EXPLODED VIEW BRAKE SYSTEM...

Page 394: ...when removing the line Remove brake line from caliper 5 Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed 6 Remove and discard the two caliper mounting...

Page 395: ...Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit MEASUREMENT Rear Caliper Piston Bore I D Standard 1 191 30 25 mm Service Limit 1 192 30 28...

Page 396: ...seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease CALIPER INSTALLATION 1 Install the new rear caliper...

Page 397: ...a dial indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 010 254 m...

Page 398: ...E Rear Hub Castle Nut 110 ft lbs 149 Nm 7 Install rear caliper see Chapter 9 REAR CALIPER SERVICE page 9 31 Follow bleeding procedure outlined earlier in this chapter 8 Field test unit for proper brak...

Page 399: ...et 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 Brake disc warped or e...

Page 400: ...9 38 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc NOTES BRAKE SYSTEM...

Page 401: ...RUMENTS CONTROLS GLOVEBOX 10 5 HOOD FRONT BODY WORK 10 6 FRONT BUMPER 10 7 REAR BUMPER 10 8 SEAT ASSEMBLY 10 9 SEAT BELTS MOUNTING 10 10 FLOOR ROCKER PANELS 10 11 REAR CARGO BOX FENDERS 10 12 CHASSIS...

Page 402: ...MULTI FUNCTION PLIERS Included in the tool kit the multi function pliers is designed to remove the plastic push rivets used to fasten body components TORQUE SPECIFICATIONS ITEM TORQUE VALUE Cab Frame...

Page 403: ...d 5 16 18 nuts Tighten bolts to 16 18 ft lbs 22 24 Nm Fasten the two self tapping screws to the rear inner portion of the bracket on each side Tighten screws to specification 3 Place the straps from t...

Page 404: ...10 4 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc BODY ASSEMBLY VIEWS SIDE SAFETY NETS BODY FRAME...

Page 405: ...10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 10 5 DASH INSTRUMENTS CONTROLS GLOVEBOX BODY FRAME...

Page 406: ...10 6 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc HOOD FRONT BODY WORK BODY FRAME...

Page 407: ...10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 10 7 FRONT BUMPER BODY FRAME...

Page 408: ...10 8 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc REAR BUMPER BODY FRAME...

Page 409: ...10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 10 9 SEAT ASSEMBLY BODY FRAME...

Page 410: ...10 10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc SEAT BELTS MOUNTING BODY FRAME...

Page 411: ...10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 10 11 FLOOR ROCKER PANELS BODY FRAME...

Page 412: ...10 12 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc REAR CARGO BOX FENDERS BODY FRAME...

Page 413: ...10 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 10 13 CHASSIS MAIN FRAME BODY FRAME...

Page 414: ...remove the seat from the vehicle REAR SERVICE PANEL 1 Remove driver and passenger seats 2 Turn both latches 1 4 turn to disengage the panel 3 Lift the panel upward and towards the front of the vehicl...

Page 415: ...od 2 Tilt the hood back to disengage the front tabs and remove the hood from the vehicle Front Body Dash Removal 3 Remove the hood as previously described 4 Remove the front bumper see Chapter 10 BODY...

Page 416: ...oval 11 If dash is installed remove the two push rivets that attach the lower portion of the fender flair to the rocker panels 12 Remove the six push rivets and remove fender flairs from the dash asse...

Page 417: ...o box 7 Remove the four T 27 Torx Screws B from the front of the cargo box 8 Remove the six T 27 Torx Screws C from both sides of the cargo box rocker panels 9 Remove the two push pins D from both sid...

Page 418: ...the vehicle Console and Lower Floor Removal 2 Remove both seats and rocker panels see Chapter 10 BODY COMPONENT REMOVAL page 3 Remove the T27 screws retaining the console to the floor 4 Remove the shi...

Page 419: ...flame treating procedure can also be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted pla...

Page 420: ...10 20 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc NOTES BODY FRAME...

Page 421: ...ION SWITCH 11 14 TURN SIGNAL SWITCH INTL 11 14 HAZARD SWITCH INTL 11 15 BRAKE LIGHT SWITCH 11 16 PARKING BRAKE SWITCH INTL MODEL 11 16 SPEED SENSOR LOCATION 11 17 SPEED SENSOR TESTING 11 18 DIFFERENTI...

Page 422: ...LESHOOTING 11 37 VOLTAGE DROP TEST 11 37 STARTER MOTOR REMOVAL 11 38 STARTER MOTOR INSTALLATION 11 38 STARTER SOLENOID BENCH TEST 11 39 STARTER SOLENOID OPERATION 11 39 ELECTRICAL TESTING 11 40 ELECTR...

Page 423: ...the resistance The re sistance of the component is equal to tested value mi nus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test...

Page 424: ...lay functions and descriptions NOTE 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 us...

Page 425: ...indicate the engine is overheating The indicators will stay lit and not flash if a severe overheating condition exists i Service Interval Indicator Preset at the factory and adjustable by the user a...

Page 426: ...ays 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...

Page 427: ...s displayed Clock The clock displays the time in a 12 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 To...

Page 428: ...high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If voltage dro...

Page 429: ...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 prese...

Page 430: ...TE Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens 1 Disconnect the wire harness connector from the back side of the instrument cluster 2 Push the instru...

Page 431: ...the rubber mount more easily 2 Be sure the rubber mount inside the dash is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash 3 Hold the dash securel...

Page 432: ...continuity between switch pins C and D E and F Turn the ignition key to START There should be con tinuity between switch pins A and B C and D E and F IGNITION KEY SWITCH INTL 1 Disconnect the key swit...

Page 433: ...and 3 Move the switch to 2WD NONE OFF There should be no continuity between any pins AWD 2WD TURF SWITCH LE INTL 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pul...

Page 434: ...harness by lifting the connector lock and pulling on the connector Do not pull on the wiring 3 Test the transmission switch continuity readings for each gear position and compare to the specification...

Page 435: ...assembly 1 2 3 4 6 7 8 9 HI BEAM O O LO BEAM O O L TURN O O R TURN O O HORN O O HAZARD SWITCH INTL 1 Disconnect wires or harness from the Hazard switch 2 Test between the outputs ON NONE OFF If any of...

Page 436: ...PARKING BRAKE SWITCH INTL MODEL The parking brake switch is located within the parking brake lever Remove the rubber boot covering the parking brake lever to locate the internally mounted switch The s...

Page 437: ...test Replace switch if necessary Park Brake Indicator This warning is used to notify the operator that the park brake lever is engaged When the parking brake is fully engaged BRAKE appears in the ride...

Page 438: ...locks and unlocks the rear differential Refer to Chapter 8 for more information DIFFERENTIAL SOLENOID CIRCUIT OPERATION The Rear Diff Solenoid Relay is attached to the lower airbox bracket and can be...

Page 439: ...D switch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below AWD Hub Coil Re...

Page 440: ...the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test WARNING Never start the engine with a...

Page 441: ...to Ground 3 Each test should measure Open Line OL TEST CONNECT METER LEADS TO OHMS READING Battery Charge Coil Y1 Y2 or Y3 to Ground Open Line NOTE Any measurement other than Infinity open will indica...

Page 442: ...The stator cover can be removed with the engine installed in the chassis Be sure to thoroughly drain the engine coolant and clean the area around the stator cover prior to removal See chapter 3 REGUL...

Page 443: ...stries Inc 11 23 NOTE If the regulator rectifier overheats the unit will turn itself off to cool down The unit will turn on again after it has cooled down If it turns off verify the cooling fins are c...

Page 444: ...yright Polaris Industries 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 cond...

Page 445: ...FTER HANDLING WARNING Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing ANTIDOTE External Flush with water Internal Drink large qua...

Page 446: ...battery Never add electrolyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full po...

Page 447: ...ement is calculated Conductance testing is more accurate than voltage specific gravity or load testing Authorized Polaris dealers distributors are required to use the conductance analyzer when testing...

Page 448: ...till may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is...

Page 449: ...hrough the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differen...

Page 450: ...ss At 80 F NOTE Subtract 01 from the specific gravity reading at 40 F NOTE Lead acid batteries should be kept at or near a full charge as possible Electrolyte level should be kept between the low and...

Page 451: ...cables WARNING To avoid the possibility of explosion connect positive cable first and negative cable last 5 After connecting the battery cables install the cover on the battery and attach the hold dow...

Page 452: ...he most intense part of the headlight beam should be aimed 8 in 20 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included in the seat while performing this procedure 5 Adjus...

Page 453: ...3 Insert new bulb Reinstall the wire harness onto the headlamp assembly NOTE Make sure the tabs on the bulb locate properly in the housing HEADLAMP HOUSING REMOVAL 1 Disconnect the wire harness from...

Page 454: ...eadlight Adjustment procedure in this section BULB REPLACEMENT Before replacing the bulb s use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path...

Page 455: ...11 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 11 35 COOLING SYSTEM COOLING SYSTEM BREAK OUT DIAGRAM ELECTRICAL...

Page 456: ...tart the engine After a few seconds the fan should start running and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly 3 If t...

Page 457: ...page 11 37 Engine problem seized or binding can engine be ro tated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive g...

Page 458: ...ded 2 Lubricate the starter motor O ring with fresh engine oil 3 Place the lower starter motor fastener C through the lower mounting boss in the starter motor 4 Install the starter motor onto the engi...

Page 459: ...etween terminals A and B If resistance measurement is out of specification replace the starter solenoid STARTER SOLENOID OPERATION To energize the Starter Solenoid the following must occur The brake m...

Page 460: ...11 40 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc ELECTRICAL TESTING Condition Starter fails to turn over the engine ELECTRICAL...

Page 461: ...the vehicle will have no power steering operation You will be able to connect and communicate with the vehicle s Engine Controller but not the Power Steering Controller while using Digital Wrench NOTE...

Page 462: ...11 42 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON ELECTRICAL...

Page 463: ...11 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc 11 43 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL OFF ELECTRICAL...

Page 464: ...11 44 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc EPS TROUBLESHOOTING USING DIGITAL WRENCH ELECTRICAL...

Page 465: ...steering column and contains system fuses and relays A small auxiliary fuse box w contains three 30A fuses and is located on the driver s side front engine mount The cooling fan circuit breaker e is...

Page 466: ...ower to fuel pump Red Dark Blue A5 Coil power from ECM B splice key switch WIRE COLOR FUSE BOX PIN FUNCTION Dark Green Yellow B4 Ground from ECU Red Green B5 High side power from 10A Fuel Pump fuse FA...

Page 467: ...and a yellow wire CAN SYSTEM TESTING A component not displaying information correctly could be the cause of damaged CAN wiring or a faulty component The easiest location to test the CAN system is at t...

Page 468: ...11 48 9926813 R04 2013 2016 RZR 570 Service Manual Copyright Polaris Industries Inc NOTES ELECTRICAL...

Page 469: ...A Wiring Diagrams Topics Covered in this Appendix A 1 Wiring Diagrams Click Here for wiring diagrams 49...

Page 470: ......

Page 471: ...ions 9 3 Special Tools 9 4 Torque Specifications 9 3 Break In Period 2 3 Break In PVT System Belt 5 5 Breather Hose Inspection 2 13 C Cab Frame Assembly Removal RZR RZR S 10 3 Caliper Front 9 20 Calip...

Page 472: ...g 3 52 Camshaft Sprocket Inspection 3 40 Camshaft Timing Quick Reference 3 55 Combustion Chamber Cleaning 3 45 Cooling System 3 18 Cylinder Head Inspection 3 43 Cylinder Head Installation Black Bolts...

Page 473: ...smission 6 2 M MAG Side Crankcase Bearing Service 3 78 Main Frame RZR RZR S 10 13 Maintenance Fuel System 2 19 Maintenance Quick Reference Chart 2 6 Master Cylinder Removal 9 7 Master Cylinder Install...

Page 474: ...Coolant Sensor Resistance 11 36 Specifications Cooling System 3 18 Cylinder Head Warp 3 44 Engine 3 6 Engine Lubrication 3 4 3 38 Valve Seat Contact Width 3 46 Valve Spring 3 42 Valve Stem Diameter 3...

Page 475: ...emoval Disassembly 6 14 Transmission Assembly 6 21 Transmission Output Shaft Backlash Procedure 6 21 Troubleshooting Cooling System 3 88 Engine 3 87 Fuel Injectors 4 13 Fuel System 4 37 Troubleshootin...

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