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3.68

ENGINE / COOLING SYSTEM

9923523 - 2012

RANGER

RZR 570 Service Manual

ENGINE DISASSEMBLY / INSPECTION - LOWER END

Crankcase Disassembly

NOTE: The en gine t op e nd, st arter motor, s tator

cover, st arter drive , flywhee l, st ator, cam chain, oil

pump and sprockets can be serviced with the engine

installed in the vehicle.

Flywheel / Stator Housing Removal

1. Remove the sta tor cover as ou tlined in the ” Water

Pump Mecha nical Seal / Oil Seal Replacement”

procedure” in this chapter.



2. Remove star ter drive ge ar and sha ft. Inspect ge ar

teeth for damage. Inspect fit of shaft inside gear and

replace ge ar a ssembly if clea rance is e xcessive.

Inspect shaft and shaft bearing surfaces in case and

stator housing for wear.

3. Hold flywheel with a com mercially a vailable stra p

wrench and remove flywheel nut and washer. Discard

the flywheel nut and replace for assembly.

NOTE: The flywheel nut has standard rotation (right

hand) threads.

4. Back the center screw of flywh eel puller PA-49316

completely ou t and screw puller onto

flywheel

completely.

5. Tighten cen ter b olt of too l PA-49 316 an d r emove

flywheel.

CAUTION

The flywheel contains powerful magnets.

Use caution when removing the stator cover.

DO NOT place fingers between cover and

crankcase at any time during the removal

process or injury could result.

CAUTION

Be sure engine coolant does not contaminate

the engine oil during stator cover service.

PA-49316

Содержание 2012 RANGER RZR 570

Страница 1: ...edures outlined in th is Service Manual contact an authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please...

Страница 2: ...instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite...

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

Страница 4: ......

Страница 5: ...IAL NUMBER LOCATION 1 2 VEHICLE INFORMATION 1 3 PUBLICATION NUMBERS 1 3 REPLACEMENT KEYS 1 3 SPECIAL TOOLS 1 3 GENERAL SPECIFICATIONS 1 4 2012 RANGER RZR 570 1 4 2012 RANGER RZR 570 1 5 2012 RANGER RZ...

Страница 6: ...ber The VIN can be found stamped on a portion of the left hand rear upper frame rail above the left rear wheel see Figure 1 1 The engine model and serial number can be found on a decal applied to the...

Страница 7: ...umber SPECIAL TOOLS Special toolsmay be required while servicing this vehicle Some of the tools listed or depicted are mandatory while other tools maybe substituted with a similar tool if ava ilable P...

Страница 8: ...05 cm Width 50 in 127 cm Height 69 in 175 26 cm Wheel Base 77 in 196 cm Ground Clearance 10 in 25 4 cm Dry Weight 970 lbs 440 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension LxWxH 20 x 4...

Страница 9: ...ontrolled Spark plug Gap RG4YCX 0276 0315 7 8 mm Battery RZR Yuasa YB14 B2 14 Amp Hr 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays EFI Chassis Fan Fuel Pum...

Страница 10: ...dth 50 in 127 cm Height 69 in 175 26 cm Wheel Base 77 in 196 cm Ground Clearance 10 in 25 4 cm Dry Weight 1001 lbs 454 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension LxWxH 20 x 40 x 9 51...

Страница 11: ...ariable ECU Controlled Spark plug Gap RG4YCX 0276 0315 7 8 mm Battery RZR Yuasa YB14 B2 14 Amp Hr 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays EFI Chassis...

Страница 12: ...1 8 GENERAL INFORMATION 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C...

Страница 13: ...3 32 35 48 50 69 7 16 14 30 40 50 69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Bolt Size Grade 4 6 4 8 8 8 8 9 10 9 12 9 Ft Lbs Nm Dry Threads M3 3 5 5 7...

Страница 15: ...2 12 THROTTLE PEDAL INSPECTION 2 12 THROTTLE FREEPLAY ADJUSTMENT 2 13 ENGINE AND PVT INTAKE PRE FILTER SERVICE 2 13 AIR FILTER SERVICE 2 14 ENGINE 2 16 ENGINE OIL LEVEL 2 16 ENGINE OIL AND FILTER SER...

Страница 16: ...NG 2 33 STEERING INSPECTION 2 33 STEERING WHEEL FREEPLAY 2 34 TIE ROD END WHEEL HUB INSPECTION 2 34 WHEEL TOE ALIGNMENT INSPECTION 2 35 WHEEL TOE ADJUSTMENT 2 35 SUSPENSION 2 36 SPRING PRELOAD ADJUSTM...

Страница 17: ...ange oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period co...

Страница 18: ...ners Pre Ride E Engine Oil Level Pre Ride E Air Filter Pre Ride Inspect replace as needed Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation a...

Страница 19: ...ce lines every two years E Spark Plug 100 H 12 M 600 1000 Inspect replace as needed E Engine Oil Filter Change 100 H 6 M 1000 1600 Perform a break in oil change at 2 5 hours orone month always replace...

Страница 20: ...per level on dipstick Change after 1st month or first 25 hours of operation 100 hours thereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Engine Cool...

Страница 21: ...r or under severe loads III Item Lube Rec Method Frequency 4 Front Gearcase Polaris Demand Drive Plus Add lubricant until it is visible at the fill hole threads Check level every 25 hours change fluid...

Страница 22: ...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 Joint Grease Grease fittings every 50...

Страница 23: ...se Lubricant 1 Gal 4 Count 2878070 AGL Plus Gearcase Lubricant 2 5 Gal 2 Count 2877922 Demand Drive Plus Quart 2877923 Demand Drive Plus 2 5 Gallon 2870465 Oil Pump for 1 Gallon Jug Grease Specialized...

Страница 24: ...vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Check all front and rear suspension components for wear or damage Frame Nuts Bolt...

Страница 25: ...to th e fu el ta nk connection for signs of wear de terioration da mage or leakag e Replace if necessary 2 Be sure fuel line is routed and retained properly IMPORTANT Make sure line is no t kinked or...

Страница 26: ...eck fuel tan k fr ont gearcase an d transmission vent lines for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed and secured properly IMPORTANT Ens...

Страница 27: ...hrottle pedal NOTE While adj usting li ghtly move th e t hrottle pedal in and out 4 Re tighten the jam nut after final adjustment is made 5 Apply a small am ount of grease to the inside of the boot an...

Страница 28: ...ps and carefully remove the air box cover Be sure notto let the air box cover contact the air filter element during removal 4 Inspect the air filter element and replace if necessary Do not attempt to...

Страница 29: ...11 Polaris Sales Inc Air Box Air Filter Exploded View Clip 6 Boot Air Intake Duct Air Intake Air Filter Clamps Clamp Clamp Air Box Cover Box Grommets Mount Drain Clamp Engine Pre filter PVT Pre filter...

Страница 30: ...ke certain the dipstick is thr eaded all the way into the engine case 8 Unscrew and remove dipstick and verify the oil level is in the SAFE XX range Add oil as indicated by the level on the dips tick...

Страница 31: ...ine oil Check to make sure the O ring is in good condition 12 Install new filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 13 Remove the engine...

Страница 32: ...his en gine does ha ve decompression components A smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Valve Cleara...

Страница 33: ...of specification 9 If the valve clearance is out of specification proceed to Valve Clearance Adjustment see Chapter 3 10 Repeat steps 8 9 u ntil all 4 valves h ave b een inspected 11 Inspect the valve...

Страница 34: ...e if needed 5 Reinstall the arrestor and torque the screw to 40 in lbs 4 5 Nm WARNING Do not clean spark arrestor immediately after the engine has been run as the exhaust system becomes very hot Serio...

Страница 35: ...cted Transmission Lubricant Level Check The fill plug is located on the rear portion of the transmission gearcase Access the fill plug at the rear of the vehicle Maintain lubricant level even with the...

Страница 36: ...t to dr ain completely 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O ring and torque to specification 6 Add the recommended amount of lubricant through the fill plug hole...

Страница 37: ...fillplug through theright frontwheel well Maintain fluid level ev en with the bottom ofthe fillplug hole 1 Position vehicle on a level surface 2 Remove the fill plug and check the fluid level 3 If fl...

Страница 38: ...Maintain the fluid le vel ev en wit h t he b ottom threads of the fill plug hole 7 Reinstall fill plug with a new O ring an d tor que to specification 8 Check for leaks Dispose of used fluid properly...

Страница 39: ...0 Service Manual Copyright 2011 Polaris Sales Inc COOLING SYSTEM Cooling System Exploded View Water Pump Upper Engine Hose Lower Engine Hose Bypass Hose Radiator Recovery Bottle Upper Radiator Hose Pr...

Страница 40: ...e coolant level should be between theupper and lower marks on the coolant re covery bo ttle If no t per form the fo llowing procedure 1 Position the vehicle on a level surface 2 Remove the hood from t...

Страница 41: ...Coolant Drain 1 Remove the hood from the front cab 2 Slowly remove thepressure cap to relieve any cooling system pressure 3 Place a su itable drain pan underneath the radiator fitting on the front ri...

Страница 42: ...que Table NOTE Do not lubricate the stud or the lug nut Wheel Removal 1 Position the vehicle on a level surface 2 Place the tra nsmission in PARK P and stop th e engine 3 Loosen the wheel nuts slightl...

Страница 43: ...tter pin after the hub nut has been tightened Tire Inspection Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of no...

Страница 44: ...vehicle s stator alternator to charge a new battery CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Tire Pressure Inspection Cold Front Rear 10 ps...

Страница 45: ...tery charging procedure in Chapter 10 Electrical before installing the battery 1 Ensure the battery is fully charged 2 Place thebattery in thebattery holder and secure with hold down strap 3 Coat the...

Страница 46: ...necessary by carefully bending the side electrode 9 If n ecessary r eplace spa rk p lug with p roper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 10 Apply Anti seiz...

Страница 47: ...make sure all cotter pins are in place If cotte r pins are removed they mu st not be re used Always use new cotter pins Replace any wor n or da maged steer ing com ponents Steering should move freely...

Страница 48: ...rod end grasp the steering tie rod pull in all directions feeling for movement Replace any worn steering components Steering should move freely through entire range of travel without binding Elevate...

Страница 49: ...axle center line 5 Again measure the distance between the marks and record Call t his m easurement B Su btract measurement B from me asurement A The difference between measurements A and B is the veh...

Страница 50: ...ustable by rotating the adjustment cam to change spring tension preload Suspension Spring Adjustment 1 Position the vehicle on a lev el surface and stop the engine 2 Raise and safely su pport th e fr...

Страница 51: ...lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the br ake pedal forcefully fo r a fe w se conds a nd ch eck for fluid leakage a...

Страница 52: ...econnect th e co nnector as so on as practicable an d adjust the parking brake cable to proper tension 1 Pull back onthe parking brake lever located indash 2 After 3 t o 4 clic ks BRAKE should display...

Страница 53: ...RADIATOR 3 16 COOLANT DRAIN RADIATOR REMOVAL 3 17 THERMOSTAT REPLACEMENT 3 18 COOLING SYSTEM BLEEDING PROCEDURE 3 18 WATER PUMP SERVICE 3 20 WATER PUMP COVER AND IMPELLER SERVICE 3 20 WATER PUMP MECH...

Страница 54: ...NSTALLATION 3 67 ENGINE DISASSEMBLY INSPECTION LOWER END 3 68 CRANKCASE DISASSEMBLY 3 68 FLYWHEEL STATOR HOUSING REMOVAL 3 68 STARTER ONE WAY CLUTCH INSPECTION 3 69 STARTER ONE WAY CLUTCH INSTALLATION...

Страница 55: ...e PU 50824 Engine Stand Sleeve Adapter Use With 2 Bore Stand PU 50625 Engine Stand Sleeve Adapter Use With 2 375 Bore Stand PW 47054 Flywheel Puller PA 49316 Oil Filter Wrench PU 50105 Oil Pressure Ga...

Страница 56: ...ndication NOTE Test results ar e bas ed on the us e of the recommended engine oil Pola ris PS 4 Plus at operating temperature and may vary considerably if any ot her oil is used or if engine is not up...

Страница 58: ...d 0 0393 0 0039 1 0 0 10 mm Valve Seat Contacting Width Intake Service Limit 0 0551 1 4 mm Valve Seat Co ntacting Width Exhaust Standard 0 0590 0 0039 1 5 0 10 mm Valve Seat Contacting Width Exhaust S...

Страница 59: ...Second Ring Standard 0 0094 0 0196 0 24 0 50 mm Second Ring Service Limit 0 0220 0 56 mm Oil Control Rails Standard 0 0098 0 0401 0 25 1 02 mm Oil Control Rails Service Limit 0 0480 1 22 mm Ring to G...

Страница 60: ...GINE COOLING SYSTEM 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc ENGINE DETAIL TORQUE VALUES SEQUENCES ASSEMBLY NOTES Main Engine Components Torque Specification and Seq...

Страница 61: ...3 9 ENGINE COOLING SYSTEM 3 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc Crankcase Timing Chain Guides Oil Pickup Regulator Valve Replace Bolts if Loosened or Removed...

Страница 62: ...3 10 ENGINE COOLING SYSTEM 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc Cylinder Oil Filter Oil Pump Breather Replace Bolts if Loosened or Removed Apply Loctite 272...

Страница 63: ...0 Service Manual Copyright 2011 Polaris Sales Inc Camshafts Cylinder Head Flywheel Idler Gears Stator Cover Replace Bolts if Loosened or Removed Apply Loctite 272 Loosened or Removed Replace Gasket if...

Страница 64: ...12 ENGINE COOLING SYSTEM 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc Spark Plugs Starter Throttle Body Valve Cover Apply Anti seize Replace Bolts if Loosened or Remove...

Страница 66: ...Manual Copyright 2011 Polaris Sales Inc ENGINE COOLING SYSTEM Cooling System Exploded View and Coolant Flow Diagram Water Pump Upper Engine Hose Lower Engine Hose Bypass Hose Radiator Recovery Bottle...

Страница 67: ...ap and pressure test the cooling system using a commercially available pressure tester 3 The system must maintain 10 psi for five minutes or longer If pressure loss is evident within five minutes chec...

Страница 68: ...he pressure cap r elief pressure is 13 psi Re place cap if it does not meet this specification Radiator 1 Check ra diator A air passages for r estrictions or damage 2 Carefully straighten any bent rad...

Страница 69: ...e hose on the right hand rear side ofthe vehicle 7 Remove the hose and completely drain the engine Radiator Removal 1 Remove the front bumper see Chapter 5 2 Remove the upper engine outlet hose and re...

Страница 70: ...the radiator or if there are leaks in th e system the coolant system will not draw coolant from the reservoir tank NOTE It may be necessary to safely raise the front of the vehicle 1 2 30 c m to blee...

Страница 71: ...cation to p o ff coolant and properly install the pressure cap 9 Start the engine and allow it to idle until the coolant fan has cycled 10 Allow engine and cooling system to completely cool down see C...

Страница 72: ...ht hand rear wheel 9 Remove the 8 bolts A attaching the water pump cover to the stator cover 10 Remove the water pump cover B and water pump cover gasket C Discard the water pump gasket C 11 Using an...

Страница 73: ...ngine as outlined in this chapter 8 Raise and safely support the vehicle Rem ove the right hand rear wheel 9 Disconnect the stator wire connector and cut the tie strap securing the wiring to the front...

Страница 74: ...ift re move th e water pum p dr ive shaft Be sur e not to da mage the threads Inspect shaft for wear or damage replace if necessary 20 Extract the mechanical seal E and the oil seal F from the stator...

Страница 75: ...de grease the water pump drive shaft H 4 Press in th e wa ter pu mp dr ive shaft H into the bearing using PU 50869 Item 1 5 Install the water pump drive shaft holding tool Item 1 in kit PU 50869 Hold...

Страница 76: ...fully seated in the cover 9 Install a new stator cover gasket onto the engine 10 Align the water pump drive slot as shown below 11 Align th e water p ump dr ive sh aft b lade as sh own below 12 Apply...

Страница 77: ...al s eal as outlined in this chapter 17 Install the water pu mp impeller K Finger tighten only NOTE The water pump impeller K uses reverse LH threads 18 Install a new water pump cover gasket CAUTION T...

Страница 78: ...lined in Chapter 2 DO NOTrun the engine until coolant has been added to the cooling system 28 Fill cooling s ystem with rec ommend coolant and bleed the system of air as outlined in this chapter 29 Ch...

Страница 79: ...ork 2 Thoroughly clean the engine and chassis 3 Drain the engine oil and engine coolant prior to engine removal see Chapter 2 4 Remove the sea ts an d en gine service pan el see Chapter 5 5 Disconnect...

Страница 80: ...from the stator cover on the right hand side of the engine Plug CPS h ole with clean shop towel Inspect CPS O ring and replace if needed 12 Disconnect the IACvalve A TPS B T MAP sensor C harness leads...

Страница 81: ...emove negative cable from the starter mounting bolt 22 Loosen the hose clamp F securing the throttle body to the air box Lift air box up and rearward as an assembly to disengage it from the throttle b...

Страница 82: ...M securing theengine to the front motor mount bracket 30 Remove the 8 b olts N securing th e cou pler brackets to the engine and transmission 31 Loosen the 2 bolts and nuts O so the e ngine mount brac...

Страница 83: ...e the eng ine in and out of the vehicle while using an engine hoist to prevent pe rsonal injur y or dama ge to vehicle components 4 By hand install the 4 front engine mount bolts and nuts A Do not tig...

Страница 84: ...t hangers new exhaust seal and the 3 head p ipe bo lts To rque he ad pipe b olts to specification 12 Install the 3 coolant hoses onto the engine 13 Install the throttle body and air box Tighten the ho...

Страница 85: ...nstall the CPS andmounting bolt into the stator cover and torque to specification 23 Connect the stator wire connector and install a new tie strap to secure the wiring tothe front engine mount bracket...

Страница 86: ...ngine Break In Period The break in period con sists o f the first 25 h ours o f operation or the time it takes to use 15 gallons 57 liters of fuel Careful treatment of a ne w e ngine a nd d rive compo...

Страница 87: ...PS 4 Plus Synthetic Engine Oil Oil Pressure Minimum Specification using Polaris PS 4 Plus at operating temperature 10 PSI 1200 RPM Minimum 40 PSI 7000 RPM Minimum Front Engine Mount Isolator Mount Ex...

Страница 88: ...e so the cam lobe s a re facing ou tward a nd th e Cylin der Hold ing a nd Camshaft Timing Plate PU 50563 can be installed into the slots of the camshafts as shown below This will set TDC of the compr...

Страница 89: ...from the engine and remove it out of the right hand rear wheel well area 5 Replace isolators B and valve co ver seal C if oil leaks are evident 6 Remove the spark plug D Stuff spark plug hole with a s...

Страница 90: ...he camshafts NOTE The crankcase has a lower guide t o prevent the chain from falling off the crankshaft 5 Attach a hook or other tool to the camshaft chain to prevent it from dropping down into the en...

Страница 91: ...ications Replace camshafts or cylinde r he ad if wo rn beyond s ervice limit or if any surface is pitted or damaged 1 Visually inspect each cam lobe for wear or damage 2 Measure the height of each cam...

Страница 92: ...n der head assembly is required NOTE Replace cy linder he ad if camshaft jour nal bores are damaged or if worn past the service limit 7 Calculate o il cle arance by su btracting ca mshaft journal O D...

Страница 93: ...chain g uide t hat pre vents th e ch ain f rom disengaging the crankshaft during engine service NOTE The c am c hain ca m cha in guide s a nd c am chain tensioner ca n b e re placed wit h t he eng ine...

Страница 94: ...Tap cylinder head lightly with a soft faced hammer until loose Tap only in reinforced areas or on thick parts of the cylinder head casting 5 Remove the cylinder head B and head gasket D Cylinder Head...

Страница 95: ...alve seals whenever cylinder head is disa ssembled Harde ned cr acked or worn s eals will cause excessive oil consumption 6 Lift up the cylinder head and push the valve M out keeping it in order for r...

Страница 96: ...a soft wire wheel or brush 2 Check valve face for excessive runout pitting and burnt spots 3 To chec k for bent v alve st ems mo unt va lve in V blocks and measure with a dial indicator 4 Check the e...

Страница 97: ...ombustion Chamber Cleaning 1 Clean a ll accumulated car bon dep osits fro m combustion chambers and valve seat area NOTE Carbon Clean Fuel Treatment 2871326 can be used to help remove carbon deposits...

Страница 98: ...act area is less than 75 of the circumference of the seat r otate the pilot 180 and make another light cut If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks...

Страница 99: ...pound to the face ofthe valve NOTE Lapping is no t req uired if an interference angle reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a sect...

Страница 100: ...inder from the engine 6 Remove and discard cylinder base gasket Cylinder Inspection 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder for warpage using...

Страница 101: ...he piston slightly with a heat gun CAUTION Do not apply heat to the piston rings they may lose radial tension 3 Remove top ring Using a piston ring pliers Carefully expand ring and lift it off the pis...

Страница 102: ...fr om th e ma ximum cylinder size measurement from cylinder inspection Piston Rod Inspection 1 Measure piston pin bore 2 Measure piston pinO D Replace piston and or piston pin if out of tolerance Pist...

Страница 103: ...a feeler gauge at location A NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings Piston Pin Degree of Fit Pin should be a pus h fit by hand with piston...

Страница 104: ...re Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Pay c...

Страница 105: ...ration 1 IMPORTANT Ends must butt squarely together and must not overlap 2 Install lower rail with end gap positioned as shown in illustration 1 3 Install upper rail with end gap positioned as shown 4...

Страница 106: ...until itseats against the installed circlip IMPORTANT Do not tap on pin or cau se any sideways force to connecting rod Warm piston crown with a heat gun if pin cannot be installed by hand or use a pi...

Страница 107: ...ve 5 Verify all ring end gaps are correctly located on piston Place cam chain and guides in alignment with chain room 6 Carefully compressrings with fingers or commercially available spring compressio...

Страница 108: ...l the valve spr ing D with tigh tly spaced coils facing down toward the cylinder head NOTE Valve s prings to be ins talled with the pa int mark facing up 8 Place the valve retainer E on the spring 9 C...

Страница 109: ...procedure f or proper shim selection IMPORTANT If a ny va lve tr ain compo nents were replaced refer to Valve Clea rance Adjust ment procedure prior to Camsh aft Installation Timing procedure Valve Se...

Страница 110: ...cam chain D through a new head gasket E and install the g asket on the cylinder locating it on the alignment pins 3 Carefully set th e cylin der he ad F in pla ce on alignment pins IMPORTANT Install...

Страница 111: ...of the shafts 3 Lubricate the camshaft bearing journal surfaces with Polaris PS 4 Plus engine oil prior to installation 4 Carefully install the camshafts into the cylinder head The camshaft lobes sho...

Страница 112: ...r that valve along with the 3 digit shim number 14 Refer to the appropriate shim selection matrix Intake or Exha ust on the fo llowing pag es an d se lect th e proper shim 15 Install the new adjustmen...

Страница 113: ...232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300 0 401 0 425 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260...

Страница 114: ...8 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 0 451 0 475 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 25...

Страница 115: ...is PS 4 Plus en gine oil pr ior to installation 4 Place the exha ust cam in to th e cylin der he ad and align the timing marks as shown below 5 Wrap the camchain around theexhaust cam sprocket and hol...

Страница 116: ...nd er Holding an d Ca mshaft Timing Plate PU 50563 into theend of camshafts as shown 10 Verify cam timing is correct and the piston is a TDC 11 If timing marks are not aligned Remove the Camshaft Timi...

Страница 117: ...s in seq uence to specification 15 Insure the new sealing washer G is in place 16 Install the hydraulic cam chain tensioner H into the cylinder and torque to specification 17 Rotate crankshaft through...

Страница 118: ...uick Reference Align Marks with Surface Exhaust Cam Intake Cam Alignment Hole 1 4 Drive Extension Stator Cover Flywheel Removed Stator Cover Flywheel Installed Align Marks with Surface PU 50563 Cam Lo...

Страница 119: ...aling sur faces by clean ing thoroughly to remove all residue 3 Apply a sm all am ount of crankcase sealant to the cylinder head half moon cutouts E as shown 4 Install a new valve cover seal B 5 Insta...

Страница 120: ...ge ar a ssembly if clea rance is e xcessive Inspect shaft and shaft bearing surfaces in case and stator housing for wear 3 Hold flywheel with a com mercially a vailable stra p wrench and remove flywhe...

Страница 121: ...hly without binding 3 Rotate ge ar co unterclockwise T he g ear sh ould immediately lock in position and not slip 4 Inspect inside of hub A for wear galling or uneven surface 5 Inspect cra nkshaft be...

Страница 122: ...Starter One Way Clutch Installation 1 Install one way clutch in clutch hu b with fla nge of clutch F engaged in recess IMPORTANT The one way clutch can be in stalled into t he hub inc orrectly This wi...

Страница 123: ...on the MAG side crankshaft DO NOT apply engine oil to the crankshaft taper 4 Rotate crankshaft so the flyw heel key A is facing upward 5 Fully install starter gear onto the crankshaft as shown 6 Alig...

Страница 124: ...gasket 3 Remove the 3 bolts C that secure the stator to the stator cover 4 Remove the 2 bolts that secure the stator wire routing bracket D to the stator cover 5 Remove the stator E from the stator c...

Страница 125: ...ankshaft to TDC position by aligning the timing hole in crankcase with a timing hole in the crankshaft Insert a 1 4 drive so cket extension through th e cra nkcase an d in to the cr ankshaft locating...

Страница 126: ...heoil pump shaft and pull it outward to remove the shaft oil pump cover and inner oil pump geroter This will prevent the oil pumpdrive pin from falling out and into the crankcase IMPORTANT The gerotor...

Страница 127: ...he oil pump cover D onto the shaft assembly 7 Grasp the complete oil pump assembly by the drive shaft and install the assembly into the crankcase 8 Install the 3 oil pump cover bo lts and torque to sp...

Страница 128: ...case and breather cover mating surfaces Install a new gasket and torque the 2 fasteners to specification Crankcase Separation NOTE Before th e cr ankcase ca n be sep arated b e sure the entire top end...

Страница 129: ...ing surfaces for scoring or signs of wear 5 Inspect replace the balance shaft bearings in both crankcase halves Se e Crankcase Be aring Inspection Removal procedure in this chapter NOTE Due to ext rem...

Страница 130: ...pter B 4 With the help of an assistant holding the crankshaft slowly t ighten th e screw C unt il the crankcase is completely separated from the crankshaft 5 Remove all special tools from the crankcas...

Страница 131: ...by feel Look for signs of discoloration scoring or g alling T urn t he inn er ra ce of each bearing T he be arings sho uld turn smoot hly an d quietly Th e out er ra ce of ea ch be aring s hould f it...

Страница 132: ...AG Side Crankcase Bearing Service Bearing Removal 1 Support the cr ankcase a nd dr ive pr ess or extra ct the bala nce shaft bea ring with a blind bea ring remover IMPORTANT The MAG side crankshaft pl...

Страница 133: ...ate with clean engine oil 6 Press the pickup assembly into the crankcase unt il fully seated Oil Pressure Regulator Bypass Valve Inspection The oil pressure regulator bypass valve is located in the MA...

Страница 134: ...o the PTO side crankcase using the 4 bolts as shown below Place the nut and large washer onto the crankshaft installation screw D Insert the crankshaft installation screw D through the threaded portio...

Страница 135: ...haft removal installation tool PU 50784 to properly drive the cran kshaft seal into the crankcase Center plate A over the crankshaft so it is resting on the crankshaft seal Center adaptor B over the c...

Страница 136: ...crankcase and verify timing marks are correct Final Crankcase Assembly 1 Prepare MAG side crankcase by clean ing se aling surface Be sure the oil pickup and oil pressure valve are fully installed 2 Ap...

Страница 137: ...t s to in sequenc e to specification 8 Install the engine stand adapter PU 50824 onto the engine PTO side mounting ears as shown below 9 Select the proper engine stand sleeve adapter and install it on...

Страница 138: ...usted or mechanical failure Engine Runs But Will Not Idle Restricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken...

Страница 139: ...ition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Cooling System Overheating Low coolant level Air in cooling system Wrong type mix...

Страница 141: ...SOR REPLACEMENT 4 13 CRANKSHAFT POSITION SENSOR CPS 4 14 FUEL INJECTORS 4 15 OPERATION OVERVIEW 4 15 FUEL INJECTOR TROUBLESHOOTING 4 16 FUEL INJECTOR TEST 4 16 FUEL INJECTOR REPLACEMENT 4 17 FUEL PUMP...

Страница 142: ...under high pressure Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Severe burns may result Do not overfill the tank The tank is at full...

Страница 143: ...nterface Cable PU 47469 and PC Int erface Cab le PU 4 7470 This module kit is u sed on all 8pin co nnector based Polaris EFI systems This kit is availa ble to Pola ris dealers through our tool supplie...

Страница 144: ...ts with plastic if they will 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 dir...

Страница 145: ...ure Manifold Absolute Pressure Sensor T MAP 3 Crankshaft Position Sensor CPS 4 Fuel Injector 5 Fuel Filter 6 Fuel Pump Regulator Fuel Level Sender located in fuel tank 7 Fuel Rail Regulator 8 Engine C...

Страница 146: ...ot b etween the throttle body and the cylinder head 3 Crankshaft Position Sensor CPS Located in the magneto cover on the right hand side of the Engine 4 Fuel Injectors Fuel Rail Regulator Attached to...

Страница 147: ...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 Coolant Temperature Sensor ECT Lo cated in the cylin...

Страница 148: ...CTION 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc FUEL TANK Exploded View Fuel Flow Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line Fuel Rail Fuel Injector Pres...

Страница 149: ...ing 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 of debris 4 Snap the...

Страница 150: ...el requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel n eeded for one firing of a cylinder is injected...

Страница 151: ...r Trouble Co de Display a nd Diagnostic T rouble Cod e T able or by using Digit al Wrench The ECU requires a minimum of 7 0 volt s to operate T he memory in the ECU is operational the moment the batte...

Страница 152: ...up on the tab Remove the retaining screw that attaches the ECU to the left rear fender well 3 With the ign ition turned off d isconnect the wire harness from theECU Lift the connector locking lever an...

Страница 153: ...des 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 IMPORTANT This sensor should only be te sted using the Dig ital Wrenc...

Страница 154: ...ing tooth creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a r eference for the con trol of ig nition timing by the ECU Synch ronization o f the CP...

Страница 155: ...tion FUEL INJECTORS Operation Overview The fuel injec tor is mountedinto the cylinder head w ith the fuel rail retaining it fr om the top end O rings on b oth ends of the injector prevent external fue...

Страница 156: ...ly but inrare instances itcan be internal past the tip of th e valve needle or external weeping around the injector body The loss of system pressure from the leakage can cause hot restart problems and...

Страница 157: ...n the fuelrailand injector to remove them from the engine as an assembly If the injector stays in the cylinder head grab the injector with your fingers and gently pull and twist theinjector unit it ca...

Страница 158: ...cargo box access panel FUEL PUMP Operation Overview An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank This assembly includes th e fue l pu mp fuel fil...

Страница 159: ...If a fuel delivery problem is suspected make certain the fuel pump filters are not plugged that the pump is being activated through the ECU all electrical connections are properly secured the fuses ar...

Страница 160: ...7 volts is present NOTE If t he volt age was be low 7 VDC t est the battery ignition switch relay s wiring harness and ECU 7 If th e r eading is between 7 a nd 14 vo lts tu rn key switch off an d co n...

Страница 161: ...ump is removed 7 Place the Fuel Pump Service Tool PU 50326 over the fuel pump PFA nut Using a 1 2 drive ratchet or breaker bar loosen and remove the PFA nut Discard the PFA nut NOTE Apply down ward fo...

Страница 162: ...equire flashlight and mirror If d ebris like m ud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly IMPORTANT It is r ecommended to r emove...

Страница 163: ...is centered 16 Roughly align orientation mark on fuel pump between the orientation marks on fuel tank to ensure float arm does not get bent or snagged 17 While maintaining down ward pr essure th read...

Страница 164: ...y several times to prime the system Fuel Tank Removal IMPORTANT Syphon as much fuel from the tank as possible before at tempting to remo ve it from th e vehicle 1 Remove the dr iver and passenger seat...

Страница 165: ...s retaining the rear seat base 7 Remove the shift knob and center console from the vehicle 8 Remove the push rivets and screws retaining the RH rocker panel and remove panel from the vehicle see Chapt...

Страница 166: ...ut of the way of the fuel tank but do not remove or cut the plastic wire harness retainer 12 Remove the 2 tank bracket fasteners that retain the fuel tank in the chassis Swing the tank brackets clear...

Страница 167: ...k for leaks 12 Finally install the rear service panel along with the seats IDLE AIR CONTROL IAC Operation Overview The Idle Air Control IAC is used to stabilize the idle quality of the engine at cold...

Страница 168: ...iew The th rottle po sition senso r TPS is used to ind icate throttle plate angle to the ECU Mo unted on the throttle body and operated directly off the end of the throttle shaft the TPS works like a...

Страница 169: ...e body is established and set at the factory If the TPS is replaced or has been loosened it must be repositioned to obtain the proper voltage reading 1 Remove the drivers seat and disconnect the negat...

Страница 170: ...propriate ve hicle an d op en the da ta display grid C lick on the meter ic on next to TPS Volts 3 Loosen the TPS mounting screws 4 Rotate the TPS un til your d isplay r eading is within specification...

Страница 171: ...ts during operation The ECU also uses th is signal to deter mine when to a ctivate the fan during operation ECT Sensor Test To quickly rule out other components and wiring related to the ECT disconnec...

Страница 172: ...and p roperly bleed the cooling system see Chapter 3 IGNITION COIL Operation Overview The ignition coil is used to provide high voltage to fire the spark plug When the ignition key is on DC volt age i...

Страница 173: ...pa rk plug 5 Remove the fasteners retaining the ignition coil and remove the coil assembly from the vehicle 6 Install the new igni tion co il asse mbly an d tighten fasteners to specification NOTE Be...

Страница 174: ...t he tro uble co de s ar e not dis played use th e MODE button to toggle until CK ENG displays on the information display area 2 Press an d ho ld th e MODE bu tton to en ter the diagnostics code menu...

Страница 175: ...tage Too High 168 3 P0563 C1063 Voltage Too Low 4 P0562 C1064 Engine Speed Received Engine Speed Has Error 190 0 C1059 Engine Speed Too High 0 C1066 Gear Sensor Signal Voltage Too Low 523 4 P0916 ECU...

Страница 176: ...Driver Circuit Open Grounded 520271 5 P1505 Driver Circuit Short to B 3 P1509 Driver Circuit Grounded 4 P1508 Idle Air Control Valve IAC M17 IAC Stepper Pin 3 Driver Circuit Open Grounded 520268 5 P15...

Страница 177: ...y exha ust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel qualit...

Страница 178: ...acement Although the ne ed for ECU r eplacement is u nlikely a specific replacement procedure is required to ensure that all essentia l da ta con tained within the original ECU is transferred to the r...

Страница 179: ...Connector Located under the dash connected to a sealed plug Follow these steps to con nect the d iagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble the SmartLink Module an...

Страница 180: ...r update is a vailable it should be downloaded be fore us ing Dig ital Wr ench see Digital Wrench Updates IMPORTANT Always operate with the latest update Digital Wrench Updates Updates are released fo...

Страница 181: ...link shown above save the file to y our hard disk and then double click the icon to start the update process NOTE Do n ot run or o pen the f ile from wh ere they are Select save and download t hem to...

Страница 183: ...mpt to reprogram DEDICATED LAPT OP Best result s are obt ained using a lap top com puter tha t is dedicated to Digital W rench A la ptop th at is u sed b y a variety of pe ople and in sever al ap plic...

Страница 184: ...and information 1 Verify the most current update has been downloaded and lo aded in to Di gital Wre nch See Digital Wrench Version and Update ID on page 4 40 2 Connect the SmartLink Module cables to...

Страница 185: ...e NOTE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen 10 Go t o www polarisdealers com an d click on ReFlash Au thorization fro m the Service and Warranty dr...

Страница 186: ...n Key in the box located on the DigitalWrench screen Click the Continue button and follow instructions provided on the screen to complete the re programming procedure 15 At this point the reflash proc...

Страница 189: ...RONT BUMPER 5 12 REAR BUMPER 5 12 HOOD AND FRONT BODY WORK 5 13 REAR FENDER FLAIR REMOVAL 5 14 CARGO BOX ASSEMBLY REMOVAL 5 14 ROCKER PANELS CONSOLE AND FLOOR 5 15 STEERING ASSEMBLY 5 16 EXPLODED VIEW...

Страница 190: ...aring Carrier 40 ft lbs 54 Nm Outer Tie Rod to Bearing Carrier Housing 42 5 ft lbs 58 Nm Front Ball Joint Pinch Bolts 23 ft lbs 31 Nm Shock Mounting Bolts 37 ft lbs 50 Nm Wheel Hub Castle Nuts 80 ft l...

Страница 191: ...rear mount holes Fasten the rear cab frame brackets to vehiclewith four 5 16 18 bolts and 5 16 18 nuts Tighten bolts to 16 18 ft lb s 22 24 Nm Fasten the two self tapping screws to the rear inner port...

Страница 193: ...ual Copyright 2011 Polaris Sales Inc Dash Instruments Controls Glovebox A Instrument Cluster Speedo B AWD 2WD TURF Switch C Headlight Switch or Hazard Switch INT L D 12 Volt Accessory Receptacle E Key...

Страница 194: ...570 Service Manual Copyright 2011 Polaris Sales Inc Hood Front Body Work Center Access Hood Hood Dash Front Bumper Front RH Fender Flair Front LH Fender Flair Winch Pocket Cover Push Rivets Push Rivet...

Страница 195: ...ice Manual Copyright 2011 Polaris Sales Inc Front Bumper Rear Bumper Headlight O Ring T25 Screw T27 Screw T30 Screws Bulb Front Bumper Support Front Bumper Radiator Screen Winch Pocket Cover RH Tail L...

Страница 196: ...s Mounting Seat Base Asm Cap Plate Spring Lever Latch Body Grommets Seat Seat Back Seat Bottom Hoop Tube Nuts 41 57 in lbs 4 6 6 4 Nm 48 in lbs 5 4 Nm 41 57 in lbs 4 6 6 4 Nm Driver Rear Seat Base Lat...

Страница 197: ...Console Cover LH Rocker Lower Floor Rear Front Push Rivets U Type Support Bracket Rear Support Bracket Push Rivets Support Bracket Front Support Bracket Self Tapping Screws Self Tapping Screw T27 Scre...

Страница 198: ...al Copyright 2011 Polaris Sales Inc Rear Cargo Box Fenders Cargo Box Access Panel Rear Cargo Box Intake Grill LR fender RR Fender LH Panel Cover Heat Shield Divider LH Panel Divider Engine Service Pan...

Страница 199: ...Service Manual Copyright 2011 Polaris Sales Inc Chassis Main Frame Main Frame Bolt In Brace Skid Plate Rear Bumper Support 6 8 ft lbs 8 11 Nm Washer Plug 17 ft lbs 23 Nm Front Cross Member Bolt In Bra...

Страница 200: ...4 turn to disengage the panel 3 Lift the p anel up ward an d towar ds the fr ont of the vehicle to remove it Front Bumper 1 Remove the 4 push rivets from the sides of the front bumper 2 Remove th e 6...

Страница 201: ...e thefront bumper see BODY COMPONENT REMOVAL Front Bumper 3 Remove the front portion of the cab frame assembly to allow dash removal Refer to appropriate CAB FRAME Asse mbly Remo val p rocedure for as...

Страница 202: ...rom the vehicle Cargo Box Assembly Removal 1 Remove the seats and the engine service panel 2 Disconnect the harness connectors at the tail lights 3 Disengage th e tail lig ht ha rness from the r outin...

Страница 203: ...y lift andguide the cargo box assembly up and off of the vehicle frame Make note of wire and hose routings for reassembly Rocker Panels Console and Floor Rocker Panel Removal 1 Remove the p ush rivets...

Страница 204: ...Steering Shaft Cotter Pin Gear Box Bearing Bushing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm Nut 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm 12 14 ft lbs 16 19 Nm 27 33 f...

Страница 205: ...llow any of t he Loctite to get in the bearing NOTE Be sure the lower washers and spacers are still on the steering shaft 8 Apply Loctite 271 Red to the outer circumference of the new upper bearing ra...

Страница 206: ...new upper A arm assembly onto vehicle frame Torque new bolt to specification 12 Insert u pper A arm ball jo int e nd into the b earing carrier Install upper ball jo int pinch bolt B into the bearing...

Страница 207: ...NG Upon A arm installation completion test vehicle at low speeds before putting into service T Front Upper Lower A arm Bolts 39 ft lbs 53 Nm T Front Ball Joint Pinch Bolts 23 ft lbs 31 Nm T Shock Moun...

Страница 208: ...to use in the following process 4 Use a press and correct size driver to remove the ball joint from the A arm NOTE The driver must fit the ball joint housing in the A arm This will allow the ball join...

Страница 209: ...A a rm on ea ch side of the vehicle see Exploded View 3 Remove the up per portion of the linkage from the stabilizer bar on each s ide of the v ehicle see Exploded View 4 Inspect the linkage assemblie...

Страница 210: ...ews fro m recovery bo ttle an d filler neck Allow the recovery bottle and filler neck to hang down to access the 4 bolts retaining the upper radiator mount bracket 7 Remove th e 4 bo lts re taining t...

Страница 211: ...SION 5 9923523 2012 RANGER RZR 570 Service Manual Copyright 2011 Polaris Sales Inc Exploded View Stabilizer Bushings Spacer Bar Washer Linkage 37 ft lbs 50 Nm T30 Screws Grease Zerk Linkage Linkage Bu...

Страница 212: ...A arm bushings and pivot tubes into new A arm Lower A arm Removal 1 Disengage the rear brake line from the routing clip on the lower A arm 2 Remove the fastener C retaining the lower portion of the s...

Страница 213: ...pper A a rm a ssembly o nto vehicle frame Torque new fastener to specification 6 Attach upper A arm to bearing carrier Torque new fastener to specification 7 Install wheel and torque wheel nuts to spe...

Страница 214: ...OTE Rotate th e st abilize b ar 18 0 de grees s o th e linkage hole C is facing rearward to aid in stabilizer bar removal 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace...

Страница 215: ...nd lower fasteners retaining the shock and remove the shock from the vehicle NOTE It may be necessary to use a commercially available swivel socket to remove and install the LR upper shock bolt 4 Reve...

Страница 216: ...cab isbent flexed or damaged To flame treat the decal area 1 Pass the fla me o f a pr opane tor ch ba ck a nd for th quickly over the area where the decal is to be applied until the surface appears sl...

Страница 217: ...EMBLY 6 5 PVT ASSEMBLY 6 7 DRIVE BELT 6 8 BELT REMOVAL 6 8 BELT INSPECTION 6 8 BELT INSTALLATION 6 9 PVT BREAK IN DRIVE BELT CLUTCHES 6 9 CLUTCH CENTER DISTANCE 6 10 INSPECTION 6 10 ADJUSTMENT 6 10 DR...

Страница 218: ...h Holding Wrench 9314177 Clutch Holding Fixture 2871358 A Drive Clutch Spider Removal and Installation Tool 2870341 Roller Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Pulle...

Страница 219: ...ptimum engine RPM At full thrott le a perfectly matched P VT system should hold engine RPM at the peak of the power curve This RPM should be ma intained dur ing clu tch upshift and backshift In this r...

Страница 220: ...n exposed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexib...

Страница 221: ...minal 3 Place transmission in neutral 4 Raise and support the vehicle 5 Remove the left rear wheel Inner Clutch Outer Cover Outer Outlet Duct Screws Clutch Cover Clutch Cover Cover Seal Bolt Washer In...

Страница 222: ...drive clutch using the Drive Clutch Puller PA 48595 IMPORTANT Be sure to use the correct Drive Clutch Puller PA 48595 to prevent damage to crankshaft 11 Loosen hose clamp attaching the PVT inlet duct...

Страница 223: ...smission input shaft 9 Apply a light film of grease to the splines on the shaft 10 Install the dr iven clutch washer and retaining bolt Torque to specification 11 Clean the end of the taper on the cra...

Страница 224: ...ard a nd outward on belt a nd ro tate d riven clutch clockwis e to walk the be lt off of the driven clutch 6 Walk the belt out of the driven clutch and drive clutch Remove the belt from the vehicle Be...

Страница 225: ...rly seat thebelt in the driven clutch 4 Install the outer clutch cover and 8 screws Torque screws to specification PVT Break In Drive Belt Clutches A proper break inof the clutches anddrive belt will...

Страница 226: ...show the too l PU 50658 p roperly installed 3 If the tool fits as shown above the clutch center to center distance is correct 4 If the tool does not fit as shown above adjustment is needed Adjustment...

Страница 227: ...e the 8 engine to transmission coupler bolts to specification 7 Torque the 2 rear transmission isolator fasteners B to specification 8 Remove the Clu tch Ce nter Distan ce tool a nd reassemble the P V...

Страница 228: ...CE Drive Clutch Exploded View Washers Spring Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bushing Spider Button Non Braking Bearing Bushing Spacer 100 i...

Страница 229: ...The outer cover bushing is manufactured with a Te flon coa ting We ar is determined by the amount of Teflon remaining on the bushing 5 Remove and insp ect the clu tch spring See Drive Clutch Spring S...

Страница 230: ...ve shift weight bolts and weights Inspect the contact surface of the weight The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and bolts for wear or galling If...

Страница 231: ...pider during assembly Be sure to note the number and thickness of these washers Moveable Sheave Bushing Inspection 2 Inspect the Teflon coating on the moveable sheave bushing Clutch Holding Fixture PN...

Страница 232: ...ation 2 Rubber backed buttons can be used in all RANGER clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pi...

Страница 233: ...d th rust wa shers D off shaft Replace as a n assembly if wor n d amaged o r if problems were noted 4 Inspect sur face of shaft for p itting gr ooves or damage Measure the outside diameter and compare...

Страница 234: ...d 7 Install removal tool Item A B into center of sheave with A side toward sheave EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 51...

Страница 235: ...l bushing is seated 8 Remove nut from puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool Cover Bushing Removal 1 Install main adapter Item 8 on puller 2 Install adapter r...

Страница 236: ...original quantity and thickness of washers spacers beneath the spider during assembly 3 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlie...

Страница 237: ...isassembly or use th e X s o n th e shea ves for reference T his a ids in re assembly an d m aintains clutch balance after reassembly Stationary Moveable Inner Compression Spring Outer Retaining Sprin...

Страница 238: ...spring pressure NOTE Spring is c ompression only a nd h as no torsional wind 4 With the snap ring A removed and spring pressure relieved re move the outer sprin g r etainer B compression spring C spa...

Страница 239: ...oveable sheave 10 Inspect the Teflon coating on the moveable sheave bearings 11 Inspect d riven cl utch sh eave fa ces for wear or damage 12 Clean and inspect splines on helix and transmission input s...

Страница 240: ...e ach of the she aves during reassembly 3 Install the spring into the inner retainer 4 Install the spacer over the shaft 5 Install the outer retainer on top of the spring 6 Place the clutch into the U...

Страница 241: ...ed operating range Incorrect drive clutch spring too high spring rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy...

Страница 242: ...terrain as ou tlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on gu idelines for operati...

Страница 243: ...LLATION 7 12 PROPSHAFT U JOINT SERVICE 7 14 DISASSEMBLY 7 14 ASSEMBLY 7 15 FRONT GEARCASE CENTRALIZED HILLIARD 7 16 CENTRALIZED HILLIARD EXPLODED VIEW 7 16 ALL WHEEL DRIVE OPERATION 7 17 AWD DIAGNOSIS...

Страница 244: ...front wheel 4 Remove the cotter pin and loosen the front wheel hub castle nut Remove the nut and 2 cone washers from the front wheel hub assembly 5 Remove thefastener retaining the steering tie rod en...

Страница 245: ...eplace bearing if mois ture dir t co rrosion or roughness is evident NOTE Due to ex tremely clos e t olerances an d minimal wea r the be arings mu st be inspected visually an d by f eel While rot atin...

Страница 246: ...earing into the b earing carrier housing NOTE Use ca re to not allow any of t he L octite compound to get in the bearing 8 Wipe the housing clean of any excess compound and install the snap ring Bear...

Страница 247: ...fication and install a new cotter p in Tigh ten n ut slightly if ne cessary to align cotter pin holes 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification 11 Rotate wheel and check for...

Страница 248: ...rom the bra ke disc see Chapter 9 CAUTION Do not hang the caliper by the brake line Use wire to h ang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove the upp...

Страница 249: ...e ca pacity of CV joints and CV joint boots Outer CV Joint Boot Replacement NOTE Refer the Electronic Parts Catalog for the required parts to service the drive shaft Some drive shafts have Boot Replac...

Страница 250: ...ip with the lead in chamfer on the inner race 12 Use a soft faced hammer to tap the CV joint into the splines of the ax le Pull on the joint to ensure it s securely installed 13 Add the remaining grea...

Страница 251: ...he 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 s plined hole in the joint s inner race Pack the bal...

Страница 252: ...lar ge cla mp using th e earless clamp pliers Drive Shaft Installation 1 Install new spring ring on drive shaft Apply an anti seize compound to splines 2 Align splines of d rive shaft with fro nt gea...

Страница 253: ...r m ounting b olts and tor que to specification 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification 11 Rotate wheel and check for smooth operation Bend both en ds of cotte r pin aroun...

Страница 254: ...ove the o uter clutch cover drive belt and drive clutch as outlined in Chapter 6 6 Disconnect the ha rness con nector at the bra ke switch Remove the 2 screws securing thebrake line junction block and...

Страница 255: ...pshaft fr om transmission shaft 13 Position prop shaft to the right hand side of the front gearcase as shown 14 Maneuver the rear of the propshaft towards the left hand side of the vehicle under the d...

Страница 256: ...earing must be re placed Note orientation of grease fitting and mar k inner and o uter yo ke f or c orrect r e positioning during installation 2 Support inner yoke as sh own and drive outer yoke down...

Страница 257: ...ring cap in one side Continu ally ch eck for fr ee 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 I...

Страница 258: ...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 Oil Seal 1 29 Ring Gea...

Страница 259: ...dexes the rollers inside the ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels lose traction O...

Страница 260: ...if there is wear between the two bands inspect the coil ar ea as indicate d in Step 5 A wear band with an interrupted wear mark may indicate a warped pla te which may ca use inter mittent operation S...

Страница 261: ...shafts from the front gearcase 3 Remove the propshaft from the front gearcase see PROPSHAFT SERVICE 4 Disconnect the wire harness above the front gearcase and remove the harness from the retaining da...

Страница 262: ...e dr ain plu g magnet 2 Remove the 7 cover screws and remove the cover plate assembly 3 Remove the LH output hub assembly from the clutch housing or outer cover plate assembly NOTE Nylon spacer is no...

Страница 263: ...assembly fr om the gearcase housing 8 Remove pinion seal internal retaining ring and pinion gear assembly from the gearcase housing Inspect and clean the gearcase housing and replace all o il seals a...

Страница 264: ...and in and out freely within the ro ll cage B sliding surfaces and H springs IMPORTANT Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assemb...

Страница 265: ...staller press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub into the gearcase housing 5 Carefully install the rollersinto the roll cage ass...

Страница 266: ...in the ring gear grooves 10 Carefully install the ring gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTE Be su re the sq uare O ring is p l...

Страница 267: ...hat secure the front gearcase to the frame and torque to 30 ft lbs 41 Nm 4 Install the vent line 5 Connect the AWD wire harness 6 Refer to FR ONT D RIVE SHAFT Drive Shaft Installation and install both...

Страница 268: ...pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 5 Remove and discard the two brake caliper mounting bolts CAUTION Do not hang the calipe...

Страница 269: ...rings sh ould tur n smoothly and quietly with no de tectable up and down moveme nt and minimal movement sideways between inner and outer race 10 Replace bearing if mois ture dir t co rrosion or roughn...

Страница 270: ...e aring into the bearing ca rrier housing NOTE Use ca re to no t allow any of the L octite compound to get in the bearing 4 Wipe the housing clean of any excess compound and install the snap ring Bear...

Страница 271: ...nuts to specification 3 Apply grease to drive shaft axle splines 4 Install rear wheel hub assembly cone washers and hand t ighten th e castle n ut Install w ashers wit h domed side out 5 Install new b...

Страница 272: ...a 2 Remove th e 4 wheel n uts and re move th e r ear wheel 3 Remove the cotter pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 4 Remove...

Страница 273: ...to the upper A arm 7 Slide the rear drive shaft out of the bearing carrier by pulling the bearin g carrier ass embly outward and tipping it down to remove the shaft 8 Grasp the rear drive shaft and pu...

Страница 274: ...int to avoid binding IMPORTANT Tap on inner race only 5 Make sure the circlip is on the shaft and not left in the joint 6 Remove the CV boot from the shaft IMPORTANT If the grease in the joint is obvi...

Страница 275: ...grease provided in the boot replacement kit Fill the cavity behind the balls and the splined holein the joint sinner race Pack the ball tracks an d outer face flush with grease Place any remaining gr...

Страница 276: ...the small end of the boot andthe shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure...

Страница 277: ...faced hammer or brass drift strike the inner race of th e joint to dr ive the joint off th e drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Mak...

Страница 278: ...the ball tracks and outer face flush with grease Place any remaining grease into the boot NOTE The amount of grease that s provided is pre measured so use all the grease 13 Fully compress the joint a...

Страница 279: ...oot and the joint housing and lift up to equalize the air pressure in the boot 21 Position the boot lip in its groove Install and tighten the large clamp using the appropriate clamp tool Drive Shaft E...

Страница 280: ...ary NOTE Take care when installing the drive shaft to prevent damaging the seal 3 Slide the rear drive shaft into the rear bearing carrier 4 Lift bea ring carrier into place an d install th e bolt att...

Страница 281: ...y if necessary to align cotter pin holes 9 Install wheel and 4 wheel nuts Torque wheel nuts to specification T Rear Caliper Mounting Bolts 44 ft lbs 60 Nm CAUTION New bolts have a pre applied locking...

Страница 282: ...Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Washers 80 ft lbs 108 Nm Ring Carrier Studs Front Rim Steel Front Rim INTL Aluminum Rear Rim Castle Nut Cot...

Страница 283: ...STALLATION 8 8 TRANSMISSION DISASSEMBLY 8 12 GEAR SHAFT BEARING INSPECTION 8 18 SNORKEL GEAR BACKLASH PROCEDURE 8 19 TRANSMISSION ASSEMBLY 8 21 TRANSMISSION SERVICE INTL 8 26 DIFFERENTIAL OPERATION 8...

Страница 284: ...Nm Support and Shift Cable Bracket Bolts 17 ft lbs 23 Nm Transmission Case Screws 15 20 ft lbs 20 27 Nm Speed Sensor Screw 7 9 ft lbs 9 12 Nm PART NUMBER TOOL DESCRIPTION PA 50231 Snorkel Tool 2871698...

Страница 285: ...T30 Torx driver Remove theconsole 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 an...

Страница 286: ...e 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 there is the same amount of cable tr...

Страница 287: ...72608 to remove th e r oll pin from the fro nt gearcase 7 Remove the g ear sele ctor cap an d remove the retaining screw and handle 8 Remove the Torx screws retaining the center console to access the...

Страница 288: ...res the air box to the throttle body Cut the t ie 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 line quick c...

Страница 289: ...ness routings for reassembly 22 Remove the transmission vent tube I INTL Remove the parking break cable and asm 23 Remove and discar d the 4 rear br ake ca liper mounting bolts on the RH and LH side a...

Страница 290: ...rear mount as an assembly 30 Rotate the top of thetransmission to the left hand side of the vehicle With the help of an assistant lift the assembly up and out of the vehicle frame Transmission Install...

Страница 291: ...n the clu tch ce nter distance The pictures below sho w the too l PU 50658 p roperly installed 6 Torque the rear tran smission m ount fasteners to specification 7 In sequence torque the 8 engine coupl...

Страница 292: ...hrottle cable is routed correctly 14 Connect the IAC valve G TPS H T MAP sensor I harness leads from the throttle body 15 Connect the fuel line to the fuel rail Be sure routing is correct 16 Install t...

Страница 293: ...e splines 25 Install the rear drive shaft splines into transmission splines In stall the fa steners th at atta ch th e r ear bearing carrier to the upper andlower A arms Torque new nuts to specificati...

Страница 294: ...the exploded view at the end of this chapter as a reference 1 Place t he tr ansmission in Hig h g ear be fore disassembly 2 Drain an d p roperly dispose of the tran smission lubricant see Chapter 2 3...

Страница 295: ...O rings P from each shaft and discard Use new O rings upon assembly 11 Remove a ll th e tr ansmission case bolts Using suitable pr y b ars rem ove the cover using the designated pry points indicated...

Страница 296: ...n housing by pulling both assemblies straight up 16 Place the gear cluster assembly on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly 17 Using a 5 mm Allen...

Страница 297: ...washer needle bearing and sprocket from the reverse shaft see Figure 8 1 22 Tilt the two shafts towards each other and remove the silent chain from the two shafts 23 If necessary disassemble the other...

Страница 298: ...27 Remove thesnorkel tube and shaft assembly from the transmission case 28 Remove the sna p rin g Y and shim Z fro m th e snorkel shaft 29 Use an arbor press to remove the snorkel tube from the snorke...

Страница 299: ...R 570 Service Manual Copyright 2011 Polaris Sales Inc 31 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 32 Remove the retaining ring to r emove the remaining wash...

Страница 300: ...earing Inspection Inspect all gear sets and shafts for excessive wear or damage IMPORTANT If gear replacement is required be sure to also replace the corresponding gear or gear shaft Inspect all beari...

Страница 301: ...etaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly IMPORTANT Failure to press the gear back against the wash er a nd re taining ring will le ad t o...

Страница 302: ...se using the snorkel too l PA 50231 u ntil the snorkel g ear and pinion gear have zero backlash IMPORTANT DO NOT ov ertighten t he s norkel tub e when backing it out At the zero backlash position you...

Страница 303: ...ansmission Assembly IMPORTANT The snorkel shaft and pinion shaft must be inst alled pr ior to t ransmission ass embly The snorkel shaft cannot be installed after assembling the transmission 1 Clean bo...

Страница 304: ...me side of the rail 6 Install the shift shaft ra il D and shift fo rks into the transmission housing as a n assembly Be sure the shift forks are engaged into the engagement dogs NOTE Shift fork pins s...

Страница 305: ...The snorkel shaft se al F sho uld be pr essed in until it seats against the housing counter bore The input shaft seal G should be pressed in until it seats flush with the housing The r ear ou tput sh...

Страница 306: ...detent pawl onto the shiftshaft and carefully install the compression spring 17 Install a new O ring on each shift shaft Apply a small amount of white lithium grease on the O rings shift shafts an d...

Страница 307: ...d rain plu g an d torq ue to specification 22 Install the bellcrank onto the shift shaft Note the key splined on the bellcrank and shift shaft Install the nut and torque to specification 23 Refer to T...

Страница 308: ...e now dependent on the differential allowing for tighter turns When Differential Lock is selected power is re moved from the electrical solenoid allowing the solenoid plunger to retract Spring tension...

Страница 309: ...your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J...

Страница 310: ...erneath the gear or by tapping the shaft from the opposite side If use of a pr y bar is necessary take care not to pry on sealing surfaces of case 16 Remove the idler gear shaft assembly T and gear cl...

Страница 311: ...es and clean the cases in preparation for assembly Gear Cluster Disassembly 22 Remove the b earing from the r everse shaft using a bearing puller Remove the r etaining ring and slide the washers 53T g...

Страница 312: ...end of the shift rail on either side Snorkel Shaft Removal Disassembly 28 Extract the seal from the snorkel shaft to access the snorkel tube for removal 29 Using the Snorkel Tool PA 50231 fully loose...

Страница 313: ...ing Y an d sh im Z fr om the snorkel shaft 32 Use an arbor press to remove the snorkel tube from the snorkel shaft 33 Remove the snap ring A and shim B retaining the bearing in the snorkel tube 34 Lig...

Страница 314: ...male side gear A male side gear B planet g ears C a nd r ing gear D Replace components or bushings as needed Bushin g replacement can be per formed on all ne cessary differential com ponents If bu shi...

Страница 315: ...nted burs 3 Press the new bushing into the planet gear until it is flush on each en d Repeat th is procedure for the remaining planet gears Differential Cover Bushing Replacement 1 Press the old bushi...

Страница 316: ...e bushing split Using a small chisel or flat blade scr ewdriver peel ba ck an d re move the old bushing fro m the side g ear be ing careful no t to damage the side gear 2 Thoroughly clean the bore of...

Страница 317: ...e scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification Gear Shaft Bearing Inspection Planet Gears Side Gears T Diff...

Страница 318: ...ear back against the washer and retai ning ring w ill l ead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads o...

Страница 319: ...cklash position you should still be able to tur n the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorke...

Страница 320: ...the transmission 1 Clean both tra nsmission case ha lves thor oughly Inspect case half mating surfaces for damage 2 Install shift for k S and torsion sp ring i nto transmission housing asan assembly L...

Страница 321: ...cluster assembly B into thetransmission housing all at the same time 7 Install th e rear o utput s haft as sembly C R otate output shaft assembly to align slots with engagement dog Ensure bearing is...

Страница 322: ...mage or wear Inspect the splines of the shift drum 11 Install the shif t drum E into th e transmission housing Lift up o n the s hift sh aft rail D a nd m ove the r ail assembly towards the shift drum...

Страница 323: ...the ca se lead in ch amfer 07 0 or 1 8 mm fr om outer face of bore 15 Install the brake disc onto the pinion shaft Install the washer an d app ly Lo ctite 26 2 o r 2760 to the mounting bo lt thr eads...

Страница 324: ...nsmission and gear sector cover mating surfaces thoroughly 23 Apply Cr ankcase Se alant 3 Bond PN 28 71557 onto the coverand transmission case mating surface 24 Install the se ctor cover and alig n th...

Страница 325: ...shings Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is c aused by an int ernal tra nsmission pro blem isolate...

Страница 326: ...SSEMBLY Apply White Lithium Based Grease Apply Polaris Crankcase Sealant Apply Loctite to the bolt threads 12 18 ft lbs 16 24 Nm 10 14 ft lbs 14 19 Nm 8 10 ft lbs 11 14 Nm 242 242 Refer to Snorkel Gea...

Страница 327: ...Shift 18 1 Retaining Ring External 63 1 Sprocket 48T 6 Face 19 1 Retaining Ring Internal 64 1 Gear Low 67T 20 2 Retaining Ring External 65 1 Engagement Dog 6 Face 21 2 Retaining Ring External 66 1 Ge...

Страница 328: ...rease Apply Polaris Crankcase Sealant Apply Loctite to the bolt threads 12 18 ft lbs 16 24 Nm 10 14 ft lbs 14 19 Nm 8 10 ft lbs 11 14 Nm 242 242 Refer to Snorkel Gear Backlash Procedure 10 14 ft lbs 1...

Страница 329: ...Retaining Ring External 74 1 Gear 53T 24 2 Retaining Ring External 75 1 Gear 46T 25 3 Retaining Ring External 76 1 Gear Snorkel 13T 26 1 Retaining Ring External 77 1 Shaft Shift 27 2 Washer Thrust 78...

Страница 331: ...VAL 9 13 PAD INSPECTION 9 14 PAD ASSEMBLY INSTALLATION 9 14 BRAKE BURNISHING PROCEDURE 9 15 FRONT CALIPER SERVICE 9 16 CALIPER EXPLODED VIEW 9 16 CALIPER REMOVAL 9 16 CALIPER DISASSEMBLY 9 17 CALIPER...

Страница 332: ...Disc Thickness 188 4 78 mm 170 4 32 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Front Caliper Mounting Bolts 31 34 42 46 Rear Caliper Mounting Bolts 18 24 Brake Line Flare 12 15...

Страница 333: ...ucts BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the mostcommon cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake n...

Страница 334: ...becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid levelis critical to propersystem operation T oo little fluid will a...

Страница 335: ...Bleed Screws 47 in lbs 5 3 Nm Master Cylinder View Cross MC Rear Brake Line RH Rear Line RH Front Brake Line Front Calipers Brake Master Cylinder LH Front Rear Calipers Brake Line LH Rear Line 1 2 2...

Страница 336: ...e the master cylinder to the frame Installation 1 Reverse Ste ps 1 5 fo r master cylin der installation Refer to t he to rque specifications in th e illustration 2 After installing the foot brake chec...

Страница 337: ...ay b e d rawn in to ma ster cylinder 7 Repeat procedure until clean fluid appears in bleeder hose and all air ha s be en purged Add fluid as necessary to maintain level in reservoir 8 Tighten bleeder...

Страница 338: ...NG BRAKE INTL MODEL Exploded View Parking Brake Lever Nuts Clip Cable Parking Brake Caliper Parking Brake Caliper Shift Cable Bolts Clevis Pin Mounting Assembly 16 ft lbs 22 Nm 37 ft lbs 50 Nm Bolts S...

Страница 339: ...itch electrical connector Reconnect the conn ector as soo n a s practicable a nd adjust the parking brake cable to proper tension 1 Pull back on parking brake lever located in thedash 2 After 3 to 4 c...

Страница 340: ...ve the clip pin and pin A fro m th e pa rking brake cable NOTE Be sure the parking brake is not engaged 2 Remove the two fasten ers B retaining the p arking brake caliper mount shift cable bracket 3 L...

Страница 341: ...pad specifications New Brake Pad Installation 1 Install new pads and assemble the caliper with one shim For shim location seeFigure 9 1 on page 9 11 2 Measure gap for the brake disc and compare to gap...

Страница 342: ...Measure the brake d isc with a microm eter If th e thickness of the disc is less than specified replace the brake disc see Disc Replacement Disc Replacement 1 Remove the parking brake caliper from th...

Страница 343: ...so t o avo id kinking or bending brake line 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be fo rced t hrough compensating...

Страница 344: ...boots 2 Compress mo unting b racket and ma ke sur e dust boots ar e fu lly se ated In stall pads with friction material facing each other 3 Install caliper onto front hub and torque new mounting bolts...

Страница 345: ...servoir cap 7 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend ser...

Страница 346: ...ine fr om caliper 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove and discard the two ca liper mounting bolts and remove the caliper...

Страница 347: ...a commercially available caliper piston pliers to extract the pistons from the caliper IMPORTANT Do not remove the caliper pistons with a st andard p liers The piston se aling su rfaces will become d...

Страница 348: ...e of residue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Pisto n sh ould slide in and ou t of b ore...

Страница 349: ...hen back off 1 2 turn counterclockwise 5 Perform brake bleeding procedure as outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification 7 Field test unit for proper brakin...

Страница 350: ...spection 1 Visually inspect disc fo r s coring scratches o r gouges Replace the disc if an y deep scratches are evident 2 Use a 0 1 micro meter a nd m easure the disc thickness a t eight different po...

Страница 351: ...Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install the front brake caliper see FRONT CALIPER SERVICE 8 Follow blee din...

Страница 352: ...iper so as not to kink or bend brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be f orced t hrough compensatin...

Страница 353: ...silicone grease and install rubber dust boots 2 Compress mo unting b racket and ma ke sur e dust boots ar e fu lly se ated In stall pa ds with fric tion material facing each other 3 Install caliper a...

Страница 354: ...reservoir cap 7 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure It is r equired that a burnishing procedure be performed after installation of new brake pads to extend...

Страница 355: ...ke 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 bolts and remove the caliper A Br...

Страница 356: ...t the edge and remove from the caliper 3 Remove mounting bracket B and dust boots G and H 4 Using a h ammer and a small p unch r emove the piston C from the ca liper bo dy D Rem ove the square O rings...

Страница 357: ...e is clean and free of residue or brakes may drag upon assembly 2 Coat piston with clean Polaris DOT 4 Brake Fluid PN 2872189 In stall piston D with a twisting motion while pushing inward Piston shoul...

Страница 358: ...inspect disc fo r s coring scratches o r gouges Replace the disc if an y deep scratches are evident 2 Use a 0 1 micro meter a nd m easure the disc thickness a t eight different po ints around the pa d...

Страница 359: ...38 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install rear caliper see REAR CALIPER SERVICE Follow blee ding procedure...

Страница 360: ...ted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness...

Страница 361: ...SPEED SENSOR 10 9 SPEED SENSOR LOCATION 10 9 SPEED SENSOR TESTING 10 9 INSTRUMENT CLUSTER 10 10 OVERVIEW 10 10 RIDER INFORMATION DISPLAY 10 11 INFORMATION DISPLAY AREA 10 11 DIAGNOSTIC MODE 10 15 INS...

Страница 362: ...IVATION 10 28 BATTERY REMOVAL INSTALLATION 10 28 BATTERY OFF SEASON STORAGE 10 29 BATTERY TESTING 10 29 BATTERY CONDUCTANCE ANALYZER 10 29 OCV OPEN CIRCUIT VOLTAGE TEST 10 30 LOAD TEST 10 30 SPECIFIC...

Страница 363: ...to th e Owner s Manual included with your meter for more information Voltage am perage and re sistance valu es included in this m anual a re ob tained with a Fluke 77 Dig ital Mu ltimeter PV 43568 Th...

Страница 364: ...should be continuity between switch pins C and D E and F Turn the ignition key to START There should be continuity between switch pins A and B C and D E and F Ignition Key Switch INTL 1 Disconnect th...

Страница 365: ...pins 2 and 3 Move the switch to 2WD NONE OFF There should be no continuity between any pins AWD 2WD TURF Switch INTL 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and...

Страница 366: ...witch ha rness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 5 sets of output s HI BEAM LO BEAM L TURN R TURN HORN If any ofthe tests fail...

Страница 367: ...witchterminals Re test and replace switch if necessary Parking Brake Switch INTL Model The p arking brak e s witch is located within the p arking brake lever Remove the rubber boot covering the parkin...

Страница 368: ...ew The differential solenoid is located on the rear portion of the transmission case The solenoid actuates a shift fork with an engagement dog whichlocks and unlocks the r ear differential Refer to Ch...

Страница 369: ...c Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wireharness from the speed sensor and remove the sensor from the transmission 2 Connect th e wi res fr om the...

Страница 370: ...display functions and descriptions NOTE Some features are not applicable to all models IMPORTANT The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a...

Страница 371: ...justable by the user a flashing wre nch sym bol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon...

Страница 372: ...oggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button un til the distance display changes to 0 Tachometer RPM Engine RPM can be displayed digitally Engine Temperature Engine te...

Страница 373: ...ODE bu tton to incre ase the ser vice interval hours in 5 hour increments to a maximum of 100 hours 4 To tu rn off th e ser vice in terval fu nction togg le the MODE button until OFF is displayed Cloc...

Страница 374: ...ings Under Over Voltage This warning usually indicatesthat the vehicle is operating at an RPM toolow tokeep the battery charged Itmay also occur when the engine is at idle and a high electrical load i...

Страница 375: ...ayed u se the MODE button to toggle until CK ENG displays on the information display area 2 Press an d ho ld th e MODE button to en ter the diagnostics code menu 3 A set of three numbers will appear i...

Страница 376: ...the instrument cluster 2 Push the instrument cluster out from the back side of the dash while securely holding the dash and rubber mount NOTE Do no t re move t he ru bber mount f rom th e dash p anel...

Страница 377: ...b coil If the criteria is met theEngine Controller provides a ground path brown white wire When this occurs the AWD icon should display in the instrument cluster The AWD system must be grounded to ope...

Страница 378: ...his procedure 5 Adjust the beam to the desired position by loosening the adjustment screw A and moving the lamp to the appropriate height 6 Adjust th e b eam to de sired po sition Repe at the procedur...

Страница 379: ...rew B 3 Reconnect wire harness or re insert bulb if previously removed 4 Adjust h eadlights using the Headlight Adj ustment procedure in this section TAIL BRAKE LIGHTS Bulb Replacement Before replacin...

Страница 381: ...should d isplay on the instrument cluster This indic ates al l other components are working properly 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition and mec...

Страница 382: ...t su rface U sing a n O hm meter measure the resistance of the fuel sen der as shown below 3 Allow the sender f loat to sitin the empty position and compare to specification 4 Slowly tilt the tank so...

Страница 383: ...ps battery discharge 3 Shift transmission into park and start the engine With the engine running at idle observe meter readings 4 Increase engine RPM while observing ammeter and tachometer Note the RP...

Страница 384: ...hold ing the eng ine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4...

Страница 385: ...under the LH panel divider below the ECU NOTE If the regulator re ctifier overheats the unit will turn itself off to cool down The unit will turn on again after it has cooled down If it t urns off ver...

Страница 386: ...elow the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the regulator and the stator for remove the stator cover Inspect the flywheel magne...

Страница 387: ...Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive h...

Страница 388: ...at the same rate NOTE This is t he la st time t hat e lectrolyte sh ould be added If the level becomes low after this point add only distilled water 8 When charging is complete install the filling plu...

Страница 389: ...d uring the s torage period a nd w ill au tomatically c harge th e b attery if the voltage drops below a pre determined point Battery Testing Whenever a ser vice comp laint is related to e ither the s...

Страница 390: ...rge 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 differences between cells in a m...

Страница 391: ...s or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty...

Страница 392: ...O ring if needed 2 Lubricate the starter motor O ring with fre sh engine oil 3 Place the lower starter motor fastener C through the lower mounting boss in the starter motor 4 Install the starter motor...

Страница 393: ...b etween ter minals A an d B If r esistance measurement is ou t of specif ication replace the starter solenoid Starter Solenoid Operation To energize the Starter Solenoid the following must occur The...

Страница 394: ...he 2 wire connection With the solenoid energized resistance should read about 0 5 10 between the two terminals If resistance measurement is out of specification replace the starter solenoid see Starte...

Страница 399: ...ront 9 16 Caliper Rear 9 25 Cam Chain and Guide Service 3 41 Cam Shaft Removal 3 37 Camshaft Installation Timing 3 63 Camshaft Sprocket Inspection 3 39 Camshaft Timing Quick Reference 3 66 Cargo Box R...

Страница 400: ...gnation Number 1 2 Engine Disassembly Inspection Top End 3 37 Engine Exploded Views 3 9 3 10 3 11 3 12 3 13 Engine Installation 3 31 Engine Lubrication 3 3 3 34 3 35 Engine Mounting Exploded View 3 35...

Страница 401: ...Valve Lash Shim Selection Matrix 3 61 K Key Reprogramming Authorization 4 46 Keys Replacement 1 3 L Leakdown Test 2 18 Lubrication Grease Points 2 8 Lubrication Specifications 3 3 3 35 Lubrication Tr...

Страница 402: ...int Boot Replacement 7 32 Rear Drive Shaft Plunging Joint Boot Replacement 7 35 Rear Driveshaft Installation 7 38 Rear Driveshaft Removal 7 30 Rear Fender Flair and Tie Down Removal 5 14 Rear Fenders...

Страница 403: ...s Engine Components 3 8 Torque Specifications Body Steering Suspension 5 2 Torque Specifications Brakes 9 2 Torque Specifications Clutching 6 2 Torque Specifications Final Drive 7 2 Torque Specificati...

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