Polaris RANGER RZR 570 INTL (2012) Service manual

2012 RANGER RZR 570 / INTL
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a p roperly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Some pro cedures ou tlined i n th is man ual re quire a sou nd kn owledge of me chanical t heory, to ol use, and sho p procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you ha ve any doubt as to yo ur ab ility to perform any of th e procedures outlined in th is Service Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in he lping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'.
.
Consumers, please provide your feedback in writing to: Polaris Indu 2100 Hwy 55, Medina, MN 55340.
stries Inc. ATTN: Service Publications Department,
Publication Printed November 2011 (PN 9923523) Rev. 3
© Copyright 2011 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Dep ictions an d/or p rocedures in this pu blication are int ended for re ference use only. N o liability can be accept ed for omissions or inaccura cies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
WA RN I N G
CA U T I O N
CA U T I ON
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING ind icates a po tential hazard that may result in severe injury or death to the o perator, bystander or person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates a potential h vehicle.
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE provides key information by clarifying
IMPORTANT provides key reminders during disassembly
instructions.
azard that may r esult in min or personal in jury or damage to th e
NOTE:
IMPORTANT:
, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of
Torx, Registered Trademark of Textron
Hilliard, Trademark of the H
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Pola ris factor y pu blications can be do wnload www.purepolaris.com or by contacting the nearest Polaris dealer.
illiard Corporation
Neward Enterprises, Inc.
ed fro m www.polarisindustries.com, pu rchased fr om
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
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . .
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 RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
. . . . . . . . . . . . . . . . . . . . . 1.2
1
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
1.1
GENERAL INFORMATION
}
Machine Model Number Identification
}
}
Model Year Designation
Basic Chassis
Designation
Engine Designation
Emissions & Model Option
R 1 2 V H 5 7 A D
}
4 X A V H 5 7 A * B P 0 0 0 0 0 0
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Description
Vehicle Identifier
Check Digit
Model
Year
Body Style
Plant No.
Individual Serial No.
* This could be either
a number or a letter
Powertrain
Emissions
Figure 1-1
Engine Serial
Figure 1-2
Number
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
1204286.............................................................................. Single Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification
Vehicle and Engine Serial Number Location
Whenever corresponding about a Polaris ORV, refer to the ve hicle identification number (VIN) and the engine serial number.
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 crankcase on the front of the engine. (see Figure 1-2)
1.2
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
VEHICLE INFORMATION
Key Series Number
KEY COVER P/N 5533534
Publication Numbers
Model Model No. Owner’s Manual Parts Manual
GENERAL INFORMATION
1
2012 RANGER RZR
2012 RANGER RZR 570 INTL. R12VH57FX 9923521 9924058
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris fa ctory pu blications c an be fo und a www.purepolaris.com.
570 R12VH57AD 9923521 9923522
t www.pola risindustries.com or p urchased f rom
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.
Series# Part Number
20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe su bstituted with a similar to ol, if ava ilable. Polaris recommends the use of Polaris Special Tools whe n servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at
http://polaris.spx.com/
.
1.3
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2012 RANGER RZR 570
MODEL NUMBER: R12VH57AD ENGINE NUMBER: 1204286
Category Dimension / Capacity
Length 107.5 in. / 273.05 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
Cargo Box Dimension (LxWxH)
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight Ca
pacity (Payload)
Hitch Towing Capacity 1500 lbs. / 680 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
(Inclu
25 lbs. / 11.3 kg
20 x 40 x 9" (51 x 102 x 23 cm)
740 lbs. / 335.6 kg des rider(s), cargo, accessories and trailer tongue weight)
1.4
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2012 RANGER RZR 570
MODEL NUMBER: R12VH57AD ENGINE NUMBER: 1204286
Engine
Platform
Engine Number 1204286
Engine Displacement 567cc
Number of Cylinders 1
Bore & Stroke (mm) 99 x 73.6 mm
Compression Ratio 10:1
Compression Pressure 80 - 120 psi (decompression)
Engine Idle Speed 1200 ± 100 RPM
Engine Max Operating RPM 7750 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 Plus Synthetic
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.25 qts. (4 l)
Overheat Warning Instrument Cluster Indicator
Exhaust System
Fuel System
Fuel System Type Bosch M17 EFI
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 43-48 psi (296.5 - 331 KPA)
Fuel Filters In tank, See Chapter 4
Fuel Capacity / Requirement
Electrical
Alternator Max Output 650 Watts @ 7000 RPM
Headlights 2 - Halogen: Single Beam 55W
Tail / Brake 2 - 6 Watts / 2 - 27 Watts
Starting System Electric Start
Ignition System Bosch M17 (ECU Controlled)
Ignition Timing (Variable) ECU Controlled
Spark plug / Gap
Battery (RZR)
Instrument Type Multifunction Instrument Cluster
DC Outlet Standard 12 Volt
Relays
Circuit Breaker Fan Motor: 20 Amp
Fuses (Fuse/Relay Box)
Fuses (Power Fuse Holder)
Domestic Single Cylinder, Liquid
Cooled, 4-Stroke, DOHC
Single Headpipe / Single Silencer
7.25 gal. (27.4 liters)
87 Octane (minimum)
RG4YCX / .0276” - .0315”
.7 - .8 mm)
(
Yuasa YB14-B2 /
14 Amp Hr. / 12 Volt
EFI / Chassis / Fan / Fuel Pump /
dlight
Hea
Drive / Fuel Pump: 10 Amp
ghts / EFI / Accessory: 20 Amp
Li
EFI: 30 Amp
Chassis: 30 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Drive Ratio - Front 3.818:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Front Gearcase
Fluid Type / Capacity
Transmission: Main Gearcase
Fluid Type / Capacity
Belt 3211143
Steering / Suspension
Front Suspension
Front Travel 9 in. / 23 cm
Rear Suspension
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear
Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)
Wheels / Brakes
Front Wheel Size
Front Tire Type / Size
Rear Wheel Size
Rear Tire Type / Size
Tire Pressure
Brake - Front / Rear
Brake Fluid DOT 4
Polaris Demand Drive Plus
6.75 oz. (200 ml)
Polaris AGL Plus
44 oz. (1300 ml)
Independent Dual A-arm
w/Anti-Sway Bar
Independent Dual A-arm
w/Anti-Sway Bar
Cam Adjustment
Cam Adjustment
12 x 6 / Steel
Ancla / 25 x 8 R12
12 x 8 / Steel
Ancla / 25 x 10 R12
Front: 10 psi (69 kPa)
Rear: 12 psi (83 kPa)
Foot Actuated - 4 Wheel
Hydraulic Disc
CLUTCH CHART
Shift
Weight
25-52
(5632409)
25-48
(5632408)
Meters
(Feet)
Altitude
0-1500
(0-5000)
1500-3700
(50
00 - 12000)
1
Drive
Spring
Black
(7043594)
Black
(7043594)
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
1.5
GENERAL INFORMATION
MODEL: 2012 RANGER RZR 570 INTL
MODEL NUMBER: R12VH57FX ENGINE NUMBER: 1204286
Category Dimension / Capacity
Length 107.5 in. / 273.05 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 1001 lbs. / 454 kg
Front Storage Ca
pacity
Cargo Box Dimension (LxWxH)
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight
pacity (Payload)
Ca
Hitch Towing Capacity 1500 lbs. / 680 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
(I
25 lbs. / 11.3 kg
20 x 40 x 9" (51 x 102 x 23 cm)
740 lbs. / 335.6 kg
ncludes rider(s), cargo, accessories
and trailer tongue weight)
1.6
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2012 RANGER RZR 570 INTL
MODEL NUMBER: R12VH57FX ENGINE NUMBER: 1204286
Engine
Platform
Engine Number 1204286
Engine Displacement 567cc
Number of Cylinders 1
Bore & Stroke (mm) 99 x 73.6 mm
Compression Ratio 10:1
Compression Pressure 80 - 120 psi (decompression)
Engine Idle Speed 1200 ± 100 RPM
Engine Max Operating RPM 7750 RPM
Lubrication Pressurized Wet Sump
Oil Requirements PS-4 Plus Synthetic
Oil Capacity 2 qts. / 1.9 liters
Coolant Capacity 4.25 qts. (4 l)
Overheat Warning Instrument Cluster Indicator
Exhaust System
Fuel System
Fuel System Type Bosch M17 EFI
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 43-48 psi (296.5 - 331 KPA)
Fuel Filters In tank, See Chapter 4
Fuel Capacity / Requirement
Electrical
Alternator Max Output 650 Watts @ 7000 RPM
Headlights (INTL) 2 - Halogen: 55W Low / 60W High
Tail / Brake 2 - 6 Watts / 2 - 27 Watts
INTL Features
Starting System Electric Start
Ignition System Bosch M17 (ECU Controlled)
Ignition Timing (Variable) ECU Controlled
Spark plug / Gap
Battery (RZR)
Instrument Type Multifunction Instrument Cluster
DC Outlet Standard 12 Volt
Relays
Circuit Breaker Fan Motor: 20 Amp
Fuses (Fuse/Relay Box)
Fuses (Power Fuse Holder)
Domestic Single Cylinder, Liquid
Cooled, 4-Stroke, DOHC
Single Headpipe / Single Silencer
7.25 gal. (27.4 liters)
87 Octane (minimum)
Turn Signals, Rear Diff. Control,
rn, Lic. Plate Light
Ho
RG4YCX / .0276” - .0315”
.7 - .8 mm)
(
Yuasa YB14-B2 /
14 Amp Hr. / 12 Volt
EFI / Chassis / Fan / Fuel Pump /
dlight
Hea
Drive / Fuel Pump: 10 Amp
Lights / EFI / Accessory: 20 Amp
EFI: 30 Amp
Chassis: 30 Amp
Drivetrain
Transmission Type Polaris Automatic PVT
Drive Ratio - Front 3.818:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
Front Gearcase
Fluid Type / Capacity
Transmission: Main Gearcase
Fluid Type / Capacity
Belt 3211143
Steering / Suspension
Front Suspension
Front Travel 9 in. / 23 cm
Rear Suspension
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear
Toe Out
Wheels / Brakes
Front Wheel Size
Front Tire Type / Size
Rear Wheel Size
Rear Tire Type / Size
Tire Pressure
Brake - Front / Rear
Brake Fluid DOT 4
Parking Brake Equipped
Polaris Demand Drive Plus
6.75 oz. (200 ml)
Polaris AGL Plus
44 oz. (1300 ml)
570 INTL: 41 oz. (1200 ml)
Independent Dual A-arm
w/Anti-Sway Bar
Independent Dual A-arm
w/Anti-Sway Bar
Cam Adjustment
Cam Adjustment
1/8 - 1/4 in. (3 - 6.4 mm)
12 x 6 Aluminum
Ancla / 25 x 8 R12
12 x 8 Aluminum
Ancla / 25 x 10 R12
Front: 10 psi (69 kPa)
Rear: 12 psi (83 kPa)
Foot Actuated - 4 Wheel
Hydraulic Disc
CLUTCH CHART
Shift
Weight
25-52
(5
632409)
25-48
(5632408)
Meters
(Feet
Altitude
)
0-1500
(0-5000)
1500-3700
(50
00 - 12000)
1
Drive
Spring
Black
(7043594)
Black
(7043594)
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
1.7
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
1.8
°C to °F:
9/5
(°C + 32) = °F °F to °C:
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
5/9
(°F - 32) = °C
Standard Bolt Torque Specification
Grade 2
Grade 5
Grade 8
GENERAL INFORMATION
1
Bolt Size
1/4-20 5 (7) 8 (11) 12 (16)
1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 ( 15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (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)
Grade 2
. Lbs. (Nm)
Ft
Grade 5
Ft. Lbs. (Nm)
Grade 8
Ft. Lbs. (Nm)
Metric Bolt Torque Specification
Grade
Bolt Size
M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)
M4 .8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)
M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)
M6 3 (4) 4 (5.5) 7.5 (10) 11 ( 15) 13 (18)
M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)
M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85)
M12 26 (35) 33 (45) 63 (85) 97 (130) 11 ( 150)
M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240)
M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370)
M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)
4.6 4.8 8.8 / 8.9 10.9 12.9
Ft. Lbs. (Nm) Dry Threads
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
1.9
GENERAL INFORMATION
SAE Tap / Drill Sizes
Decimal Equivalents
Metric Tap / Drill Sizes
1.10
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
MAINTENANCE
CHAPTER 2
MAINTENANCE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 500 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE AND TRANSMISSION MOUNTS. . . . . . . . . . . .
COMPRESSION TEST SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
TRANSMISSION AND FRONT GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
. . . . . . . . . . . . . . . . . . . . . . . 2.18
. . . . . . . . . . . . . . . . . . . . . . . . 2.27
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9923523 - RANGER RZR 570 Service Manual
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2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
PARKING BRAKE CABLE ADJUSTMENT (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
PARKING BRAKE PAD INSPECTION (INTL)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
SPECIAL TOOLS
SPX Corporation: 1-800-328-6657 or on-line at http://polaris.spx.com/.
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MAINTENANCE
WA RN I N G
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, ad just and replace parts as necessar parts, use genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service a nd ad justments are critic al. If y ou’re no t fa miliar w ith sa fe s ervice a nd adjustment procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon aver approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in m
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold we
Pay special attention to the oil level. A oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
ather operation
ud, water or sand
rise in oil level during cold weather can indicate contaminants collecting in the
y. When inspection r eveals the need for r eplacement
age riding conditions and an average vehicle speed of
Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
2
• Drive vehicle slowly at first while varying the thr
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.
ottle position. Do not operate at sustained idle.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be p erformed by a n
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
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MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Maintenance Interval
Item
Hours Calendar
 Steering - Pre-Ride -
Front Suspension - Pre-Ride -
Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
Brake Fluid Level - Pre-Ride -
Brake Pedal Travel - Pre-Ride -
Brake Systems - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
Engine Oil Level - Pre-Ride -
E
Air Filter - Pre-Ride - Inspect; replace as needed
E
Coolant Level - Daily -
Head Lamp / Tail Lamp - Daily -
Air Filter - Weekly - Inspect; replace as needed
E
Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically
Brake Pad Wear / Inspect
Parking Brake
Parking Brake Cable
Adjustment (INT’L)
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Front Gearcase Oil
(Demand Drive Plus)
Transmission - Main
(AGL Gearcase Lubricant)
EEngine Oil Change
(Break-In Period)
Pads (INT’L)
10 H Monthly 100 (160) Inspect periodically
25 H - - Inspect; adjust tension after first 25 hours
25 H Monthly 250 (400) Inspect level; change yearly
25 H Monthly 250 (400) Inspect level; change yearly
25 H 1 M 250 (400) Perform a break-in oil change at one month
(whichever comes first)
Miles
(KM)
Make adjustments as needed. See Pre-Ride Checklist on Page 2.10.
Check level daily, change coolant every 2
ars
ye
Check operation; apply die replacing
Remarks
lectric grease if
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
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MAINTENANCE
50 - 500 Hour Maintenance Interval
Maintenance Interval
Item
Throttle Cable / Throttle Pedal 50 H 6 M 300 (500) Inspect; adjust; lubricate; replace if necessary
E
Throttle Body Air Intake Ducts
E
General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
Steering 50 H 6 M 500 (800) Lubricate
Front Suspension 50 H 6 M 500 (800) Lubricate
Rear Suspension 50 H 6 M 500 (800) Lubricate
E
E
E
Radiator / Cooling Hoses 100 H 12 M 1000 (1600) Inspect; clean external surfaces
Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification
Wiring 100 H 12 M 1000 (1600)
Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
Shocks 100 H - - Visually inspect shock seals
Brake Fluid 200 H 24 M
 
E
Toe Adjustment -
nge
/ Fla
Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust
Cooling System 50 H 6 M 500 (800)
Fuel System 100 H 12 M 600 (1000)
Spark P lug 100 H 12 M 600 (1000) Inspect; replace as needed
Engine Oil & Filter Change 100 H 6 M 1000 (1600)
Parking Brake Cable Adjustment (INT’L)
Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed
Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect
Spark Arrestor 300 H 36 M 3000 (4800) Clean out
Shocks 500 H 12 M - Change shock oil and seals
Valve Clearance Check 500 H - 5000 (8050) Inspect / Adjust as needed
Headlight Aim - Adjust as needed
(whichever comes first)
Hours Calendar
50 H 6 M 300 (500) Inspect ducts for proper sealing / air leaks
100 H 6 M 1000 (1600) Inspect; adjust tension as needed
Miles
)
(KM
Inspect coolant strength seasonally; pressure
stem yearly
test sy
Check for leaks at fill cap, fuel line / rail, and fuel
Replace lines every two years.
pump.
Perform a break-in oil change at 25 hours or one
nth / always replace oil filter when changing
mo engine oil
Inspect for wear, routing, security; apply
ectric grease to connectors subjected to
diel water, mud, etc.
2000 (3200) Change every two years (DOT 4)
Inspect periodically; adjust when parts are
eplaced
r
Remarks
2
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
2.5
MAINTENANCE
Maintenance Quick Reference
III. # Item Lube Rec. Method Frequency*
Change after 1st month or first
hours of operation, 100 hours
25 thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation
1 Engine Oil
Polaris PS-4 Plus Per
formance Synthetic
4-Cycle Engine Oil
Add oil to proper level on
stick
dip
2 Engine Coolant Polaris 60/40 Coolant
3 Brake Fluid Polaris DOT 4 Brake Fluid
* More often under severe use, such as operated in water or under severe loads.
Maintain coolant level in
olant reservoir bottle
co
Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir
Check level daily, change coolant every 2 years
Check level during pre-ride inspection; change fluid every two years
2.6
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MAINTENANCE
Maintenance Quick Reference
III. # Item Lube Rec. Method Frequency*
4 Front Gearcase Polaris Demand Drive Plus
5 Transmission
* More often under severe use, such as operated in water or under severe loads.
Polaris AGL Plus Gearcase Lubricant
Add lubricant until it is visible at the fill
Add lubricant until it is visible at the fill
hole threads
hole threads
Check level every 25 hours; change fluid yearly
Check level every 25 hours; change lubricant yearly
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9923523 - RANGER RZR 570 Service Manual
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2.7
MAINTENANCE
Rear Stabilizer Bar
Prop Shaft
Front Suspension
Rear Suspension
Front Stabilizer Bar
Grease Lubrication Points
There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, 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)
A-arm Pivot Bushings
Stabilizer Bar Bushings
Polaris Premium U-Joint Grease
Grease fittings every 500 mi
les (800 km).
Grease before long periods of storage, and after thoroughly washing or submerging the vehicle.
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MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service Products
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244
2876245
2878068
2878069
2878070
2877922
PS-4 Plus Synthetic 4-Cycle Engine Oil
uart)
(Q
PS-4 Plus Synthetic 4-Cycle Engine Oil
Gallon)
(
Gearcase / Transmission Lubricants
AGL Plus Gearcase Lubricant (1 Qt.) (12 Count)
AGL Plus Gearcase Lubricant (1 Gal.) (4 Count)
AGL Plus Gearcase Lubricant (2.5 Gal.) (2 Count)
Demand Drive Plus (Quart)
NOTE: Each item c an b e pu rchased se parately at your local Polaris dealer.
Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
2871950
2871326
2870652 Fuel Stabilizer (16 oz.) (12 count)
2872189 DOT 4 Brake Fluid (12 count)
2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
NOTE: The nu mber co unt indicated by each part number units that are shipped with each order.
Loctite™ Threadlock 242 (6 ml.) (12 count)
Premium Carbon Clean (12 oz.) (12 count)
in th e table above ind icates t he numbe r of
2
2877923
2870465 Oil Pump for 1 Gallon Jug
2871312 Grease Gun Kit
2871322
2871423
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
Demand Drive Plus (2.5 Gallon)
Grease / Specialized Lubricants
Premium All Season Grease (3 oz. cartridge) (24 Count)
Premium All Season Grease (14 oz. cartridge) (10 Count)
Coolant
9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
2.9
MAINTENANCE
Shift Cable
Mount
Dust Boot
Clevis Pin
Shift Cable
Jam Nut (A)
Jam Nut (B)
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel tank - fill to proper level
• All brakes - check operation and adjustment
• Throttle - check for free operation and closing
• Headlights/Taillights/Brakelights - also check ope
ration of all indicator lights and switches
• Ignition switch - 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.
• Steering - check for free operation noting any unu
sual looseness in any area
Shift Cable Inspection / Adjustment
Shift c able a djustment m ay be ne cessary if sy mptoms include:
• No AWD or gear position display on instrument er
clust
• Ratcheting noise on deceleration
• Inability to engage into a
• Excessive gear clash (noise)
• Gear selector moving out of desired range
1. Locate th e shift ca ble in th e rear r ight-hand whe el w
ell area.
gear
• Loose parts - visually inspect vehicle for any dam
aged 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, Bolts, and Fasteners
Periodically inspect the tor que of all fasten ers in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.
2. Inspect shift cable, clevis pin, pivot bushings, and dust t. Replace if worn or damaged.
boo
3. If adjustment is required: Lo
cable out of the mount and rotate jam nut (B).
osen jam nut (A), pull the
2.10
9923523 - RANGER RZR 570 Service Manual
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MAINTENANCE
WA RN I N G
Fuel Line
4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) gear and PARK (P).
5. Thread jam nut (A) or (B) as required to obtain proper
ble adjustment.
ca
NOTE: This procedure may require a few attempts to
tain the proper adjustment.
ob
6. Once the p roper ad justment is obtained, place the
cable and jam nut (B) into the mount. Tighten jam
shift nut (A) against the mount.
7. Start engine and shift through all gears to ensure the
cable is properly adjusted. If transmission still
shift ratchets after cable adjustment, the transmission will require service.
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Line
1. Check the quick-connect fu el line from th e en gine fuel rail conn ection to th e fu el ta nk connection for signs of wear, de terioration, da mage or leakag e. Replace if necessary.
2
2. Be sure fuel line is routed and retained properly.
IMPORTANT: Make sure line is not kinked or pinched.
3. Replace fuel line every two years.
Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors or in
a well ventilated area.
Do not smoke or allow open flames or sparks in
r near the area where refueling is performed or
o
where gasoline is stored. Do not overfill the tank. Do not fill the tank If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on y immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed
ea. Engine exhaust fumes are poisonous and
ar
can result in loss of consciousness or
death in a short time.
Never drain the fuel when the engine is hot.
Severe burns
our skin or clothing,
may result.
neck.
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MAINTENANCE
Fuel Pump Asm
Fuel Line
Throttle Pedal
Fuel Pump / Fuel Filters
The RZR 57 0 engine uses a se rviceable, hi gh-volume, high-pressure, fuel pump that includes a preliminary filter and a n in ternal fine filter located be fore th e p ump regulator.
NOTE: Neither f ilter is se rvicable individua lly. Mu st
place the fuel pump as an assembly.
re
Vent Lines
1. Check 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: Ensure lines are not kinked or pinched.
Throttle Pedal Inspection
If the throttle pedal has excessive play due to cable stretch or cab le misadju stment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic.
NOTE: Refer to Chapter 4 for fuel pump replacement a
nd all other information related to the EFI System.
2.12
9923523 - RANGER RZR 570 Service Manual
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Check the throttle ped al play periodically in accor dance with the Per necessary.
iodic Maintenance Chart and adjust the play if
MAINTENANCE
Throttle Body
Boot
A
B
Press In Tabs
Pre-filter Cover
Pre-Filters
Throttle Freeplay Adjustment
Inspection
1. Place the transmission in the P (Park) position.
2. Start the engine, and warm it up thoroughly.
3. Measure the distance the throttle pedal moves before en gine be gins to increase in RPM . Freeplay
the should be 1/16” - 1/8” (1.5 - 3 mm).
Adjustment
1. Remove the cargo box a ccess panel to ac
throttle body area.
cess the
4. Re-tighten the jam nut after fina
5. Apply a small am ount of grease to the inside of the ot and slide it over the cable adjuster to its original
bo position.
6. Reinstall the cargo box access panel.
l adjustment is made.
Engine and PVT Intake Pre-Filter Service
It is r ecommended tha t the e ngine and PVT intake pre­filter b e in spected daily. T he filter sho uld be inspected using the following procedure:
NOTE: T just above the left-rear wheel fender.
1. Press “IN” on the intak e grill cover tabs and remove
he engine and PVT inta ke pre-filter is locate d
the pre-filter cover to access the pre-filters.
2
2. Locate thro ttle ca ble o n the le ft-hand side o f the throttle body. Slide back the cable adjuster boot.
3. Using an o pen-end wrench, lo osen the a djustment
m nut (A). Using another open-end wrench, move
ja the cable adjuster (B) until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the throttle pedal.
NOTE: While adj usting, li ght pedal in and out.
ly move th e t hrottle
2. Remove and insp ect the p re-filters. If ne cessary, an with soapy water and dry with compressed air.
cle
3. Reinstall the dry pre-filter s an
cover.
d inst all the pr e-filter
2.13
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MAINTENANCE
A
Remove Hose
A
Install Hose
Air Filter Service
It is recommended that the air filter be inspected as part of pre-ride inspection. In extremely dusty conditions, air filter replacement will be required more often.
The filter shou ld be inspected procedure:
Removal
using the following
4. Inspect the air filter element and replace if necessary. not attempt to clean the air filter.
Do
NOTE: If the filter has been soaked with fuel or oil it
st be replaced.
mu
NOTE: Service more frequently if vehicle is operated
cond itions o r at hig h th rottle ope ration f or
in wet extended periods.
Installation
1. Clean the air box and air box cover thoroughly.
2. Place the filter into the air box with the air filter pleats
cing UP, as shown.
fa
NOTE: The air box is located underneath the cargo box access panel.
1. Thoroughly clean the air box area to remove dirt and ebris.
d
2. Loosen hose clamp (A) and remove the intake hose
from the air box cover.
3. Unlatch the (6) clips and carefully remove the air box
cover. Be sure not air filter element during removal.
to let the air box cover contact the
3. Carefully install air box cover and secure with the (6) clips.
4. Reinstall the clea n intake h ose a nd tigh ten ho se c
lamp (A).
5. Reinstall the cargo box access cover.
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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
Intake Baffle Box
Remove Hose From Air Box
Cover for Filter Removal
MAINTENANCE
2
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2.15
MAINTENANCE
WA RN I N G
Maintain Oil Level In SAFE Range
DO NOT Overfill the Engine
ENGINE
Engine Oil Level
This single cylinder engine is a wet-sump engine, meaning the o il is co ntained in t he bo ttom of th e cr ankcase. To check the oil level follow the procedure listed below:
IMPORTANT: Thoroughly clean engine around the oil
ain plug, oil filte r and oil dip stick to prevent
dr contamination from entering the engine.
1. Position vehicle on a level surface.
2. Place the transmission in Park (P).
3. Be sure engine OFF has not been run for at lease 3 utes.
min
IMPORTANT: Do not run the machine and then immediat
4. Locate the engine oil dipstick:
ely check the oil level.
RZR 57 engine case; accessible through the right­hand rear wheel well area.
0 - Located on the right-hand side of the
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. D o not overfill (see N OTE below!).
NOTE: A rising oil level bet ween ch ecks in cool
ther driving can indicate contaminants suc h as
wea gas or moisture collecting in the crankcase. If the oil level is ov er t he f ull mar k, cha nge t he o il immediately.
9. Reinstall the dipstick and hand tighten.
Engine Oil and Filter Service
Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.
5. Thoroughly clean the engine around dipstick area.
6. Unscrew / remove dipstick and wipe dry with a clean cloth.
7. Reinstall the dipstick completely.
NOTE: Make certain the dipstick is thr eaded all the
into the engine case.
way
IMPORTANT: Thoroughly clean engine around the oil drain plug, oil f contamination from entering the engine.
Personal injury can occur when handling used
oil. Hot oil can cause burns or skin damage.
PS-4 Plus Synthetic 4-Cycle Engine Oil
1. Position vehicle on a level surface.
2. Place the transmission in PARK (P).
ilter an d oil dipst ick t o prev ent
Recommended Engine Oil:
(PN 2876244) (Quart)
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MAINTENANCE
CA U T I O N
Drain Plug
NOTE: Drain plug is accessed through the skid plate.
Oil Filter
= T
3. If needed, start the engine and allow it to idle for three minutes until warm. Stop the engine.
4. Place a d rain pa n b eneath e ngine cr ankcase a nd
emove the drain plug.
r
Oil may be hot. Do not allow hot oil to come into
contact with skin, as serious burns may result.
5. Allow oil to drain completely.
6. Replace sealing washer on drain plug.
NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.
7. Reinstall drain plug and torque to 12 ft. lbs. (16 Nm).
8. Place a drain pan under vehicle below the oil filter.
9. Place shop towels beneath oil filter. U sing Oil Filter Wrench (PU-50105) and a 3/8” extension, turn the oil filter counter-clockwise to remove it.
11. Lubricate O-ring on n ew filter with a film o f fre sh gine oil. Check to make sure the O-ring is in good
en condition.
12. Install new filter an d turn by hand u ntil filter gasket ntacts the sealing surface, then turn an ad ditional
co 1/2 turn.
13. Remove the engine o il dipstick (see “Eng ine Oil vel”).
Le
14. Using a long funnel, fill the sump with 2 qts. (1.9 l)
PS-4 Plus Synthetic Engine Oil (2876244).
Crankcase Drain Plug Torque:
12 ft. lbs. (16 Nm)
Oil Filter Torque:
Turn by hand until filter gasket contacts sealing
surface, then turn an additional 1/2 turn
Oil Filter Wrench:
PU-50105: 2.5” (64 mm)
15. Verify the transmission is still
16. Start the engine and let it idle for two minutes.
17. Stop the engine and inspect for leaks.
18. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the dipstick.
19. Dispose of used oil and oil filter properly.
positioned in PARK (P).
of
2
10. Using a clean dry cloth, clean filter sealing surface on the crankcase.
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2.17
MAINTENANCE
Breather
Hose
Engine Breather Hose Inspection
The engine is equipped with a breather hose. Inspect the breather hose fo r po ssible kinks or we ar. The hose is form fitted for a proper fit. Follow the breather hose from the engine cr ankcase to the a ir intake baffle box on the left-hand rear fender panel.
NOTE: Make sure line is not kinked or pinched.
Valve Clearance Inspection
IMPORTANT: Valve cl earance i nspection should be performed on a cold engine, at room temperature.
1. Remove the seats and disconn ect th e negative ( -) y cable.
batter
2. Remove the cargo box access panel.
3. Remove the spar k plug wire from the en gine an d
ove the spark plug. Place a clean shop towel into
rem the spark plug tube to prevent debris from entering the combustion chamber.
4. Remove the (3) T40 bolts retaining the valve cover.
5. Remove the valve cover fro m the engine out of the
t-hand rear wheel well area.
righ
Engine and Transmission Mounts
Periodically inspect engine and transmission mounts for cracks or damage.
Refer to Chapter 3 “Engine Assembly mounting fastener torque values.
and Installation” for
Compression Test Specification
NOTE: This 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.
Cylinder Compression:
80 - 120 psi (decompression)
6. Remove the outer PVT cover and drive belt as shown
in ch
apter 6.
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MAINTENANCE
7. Rotate th e drive clu tch co unter-clockwise until the cam chain sprocket timing marks are aligned with the gasket sur face as sho wn (see Ch apter 3 for mo re TDC setting procedures).
IMPORTANT: Intake ca m s procket sh ould ha ve “I”
ks aligned with ga sket surface a nd the ex haust
mar cam spr ocket shou ld have “E” ma rks aligned with gasket surface.
Image for Reference Only
I
8. Measure the valve clearance of each valve using thickness (feeler) gauge. Record the measurement if clearance is out of specification.
I
E
E
9. If the valve clearance is out o to “Valve Clearance Adjustment” (see Chapter 3).
f specification, proceed
= In. / mm.
Intake Valve Clearance (cold):
.005-.007 in. (0.125-0.175 mm)
= In. / mm.
Exhaust Valve Clearance (cold):
.008-.010 in. (0.152-0.254 mm)
10. Repeat steps 8- 9 u ntil all (4) valves h ave b een inspected.
11. Inspect the valve cover seal and replace if necessary.
12. Install the valve cover and spark plug as o utlined in
a
Chapter
13. Install d rive b elt an d o uter clu tch cover a nd ( 8) retaining screws (see Chapter 6)
3.
2
= T
Outer Clutch Cover Screws:
45-50 in. lbs. (5 Nm)
14. Connect the negative (-) battery cable to the battery.
15. Start the engine to ensure proper operation.
16. Reinstall the cargo box access panel and seats (see Chapter
5).
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2.19
MAINTENANCE
WA RN I N G
40 in. lbs.
(4.5 Nm)
18 ft. lbs.
(24.5 Nm)
Gaskets and Seals -
Replace Each Time Component is Removed
18 ft. lbs.
(24.5 Nm)
Exhaust - Spark Arrestor
Do not clean spark arrestor immediately after the
engine has been run, as the exhaust system
becomes very hot. Serious burns could result from
contact with the exhaust components. Allow
components to cool sufficiently before proceeding.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust
ntains poisonous carbon monoxide gas that can
co
cause loss of consciousness or death in a very
short time.
Periodically clean spark arrestor to remove accumulated carbon.
1. Allow engine and exhaust system to completely cool.
2. Remove the retaining screw, washer and spark arrestor from the end of the silencer.
3. Use a non-synthetic brush to clean the arrestor screen.
4. Inspect the screen for wear and damage. Replace if needed.
5. Reinstall the arrestor and torque the screw to 40 i
n. lbs. (4.5 Nm).
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MAINTENANCE
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TRANSMISSION AND FRONT GEARCASE
Specification Chart
Gearcase Lubricant Capacity Fill / Drain Plug Torque
Transmission AGL Plus Gearcase Lubricant 44 oz. (1300 ml) 10-14 ft. lbs. (14-19 Nm)
Transmission (INTL) AGL Plus Gearcase Lubricant 41 oz. (1200 ml) 10-14 ft. lbs. (14-19 Nm)
Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft. lbs. (11-14 Nm)
Transmission Lubrication
2
NOTE: It is important to f ollow t he t ransmission maintenance inte rvals de scribed in the Periodic Maintenance Chart . Regular lu bricant leve l inspections should be performed as well.
The transmission lubricant level shou ld be che cked and
nged in accordance with the maintenance schedule.
cha
• Be sur e ve hicle is po sitioned on a level su rface en checking or changing the lubricant.
wh
• Check vent hose to be sure it
and unobstructed.
Transmission Lubricant Level Check
The fill plug is located on the rear portion of the transmission gearcase. Access the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the lubricant level.
is routed properly
the fill plug at the rear of
3. If lubricant level is not even with the bottom threads, dd the recommended lubricant as needed. Do n ot
a overfill.
4. Reinstall the fill plug and torque
Fill / Drain Plug Torque:
10-14 ft. lbs. (14-19 Nm)
to specification.
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MAINTENANCE
=
= T
Transmission Lubricant Change
The drain plug is located on the gearcase. Access the drain plug through the drain hole in the skid plate.
1. Remove the fill plug (refer to “Transmission Level Check”).
2. Place a drain pan under the transmission drain plug.
3. Remove d rain p lug and allo w lub ricant to dr ain completely.
bottom of the transmission
Lubricant
6. Add the recommended amount of lubricant through the fill plug bottom of the fill plug hole w hen filling the transmission. Do not overfill.
Recommended Transmission Lubricant:
7. Reinstall fill plug with a ne specification.
hole. Maintain the lubricant level at the
AGL Plus Gearcase Lubricant
(PN 2878068) (Quart)
Capacity: 44 oz. (1300 ml)
Capacity (INTL): 41 oz. (1200 ml)
w O-r ing a nd tor que to
Fill / Drain Plug Torque:
10-14 ft. lbs. (14-19 Nm)
4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a ne
specification.
w O-ring and torque to
8. Check for leaks. Dispose of used lubricant properly.
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MAINTENANCE
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Front Gearcase Lubrication
NOTE: It is important to fo llow the fro nt gea rcase maintenance inte rvals de scribed in the Periodic Maintenance Chart . Regular fluid leve l ins pections should be performed as well.
The fron t gearcase fluid le vel should be checked and
nged in accordance with the maintenance schedule.
cha
• Be sur e ve hicle is po sitioned on a level su rface en checking or changing the fluid.
wh
• Check vent hose to be sure it
and unobstructed.
Front Gearcase Fluid Level Check
The fill plug is located on the bottom gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the fluid level.
is routed properly
right side of the front
4. Reinstall the fill plug and torque to
Fill / Drain Plug Torque:
8-10 ft. lbs. (11-14 Nm)
Front Gearcase Fluid Change:
The d rain pl ug is locate d on th e bo ttom of th e fro nt
rcase. Access the drain plug through the access hole
gea in the frame underneath the front gearcase.
1. Remove the fill plug (refer to “Front Gearcase Fluid Level Chec
2. Place a drain pan under the front gearcase drain plug.
3. Remove th e dr ain plug and allo w fl uid to drain completely
k”).
.
specification.
2
3. If fluid level is not even with the bottom threads, add the recommended fluid
as needed. Do not overfill.
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4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a new
specification.
O-ring and torque to
2.23
MAINTENANCE
=
= T
6. Add the recommended amount of fluid through the fill hole. Maintain the fluid le vel ev en wit h t he b ottom threads of the fill plug hole.
Recommended Front Gearcase Fluid:
Polaris Demand Drive Plus
(PN 2877922) (Quart)
Capacity: 6.
7. Reinstall fill plug with a ne specification.
Fill / Drain Plug Torque:
8-10 ft. lbs. (11-14 Nm)
8. Check for leaks. Dispose of used fluid properly.
75 oz. (200 ml)
w O- ring an d tor que to
2.24
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COOLING SYSTEM
Water Pump
Upper Engine Hose
Lower Engine
Hose
Bypass Hose
Radiator
Recovery
Bottle
Upper Radiator
Hose
Pressure Cap
Filler Neck
Hoses
Cooling Fan
Cooling System Exploded View
MAINTENANCE
2
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MAINTENANCE
Recovery Bottle
Pressure Cap
WA RN I N G
Cooling System Overview
The engine coolant level is controlled, or maintained, by the recovery system. The re covery system components are the recovery bo ttle, radiator filler neck, radiator pressure cap and connecting hose.
As coola nt op erating tem perature in creases, the
xpanding (heated) excess coola nt is for ced out of the
e 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 pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is
rmal as the system is purging itself of trapped air.
no Observe coolan t lev els of ten during the brea k-in period.
NOTE: Overheating of engine could oc cur if air is
t fully purged from system.
no
Polaris Premium 60/40 is already premixed and ready to
e. Do not dilute with water.
us
Coolant Level Inspection
The pressure cap and recovery bottle are located under the front hood of th e ve hicle. The coolant level must be maintained between the minimum and maximum levels indicated on the recovery bottle.
4. If the coolant level is below the MIN line, inspect the co
olant level in the radiator.
NOTE: If o verheating is e vident, allow system to cool comp letely and ch eck coolant leve l in th e radiator and inspe ct f or s igns of trapped a ir in system.
Never remove the pressure cap when the
engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool
before removing the pressure cap.
5. Remove the pr essure ca p. Using a funnel, ad d
oolant to the top of the filler neck.
c
6. Reinstall the pressure cap.
NOTE: Use of a non-standard pressure ca p will not allo
w the recovery system to function properly.
7. Remove recovery bottle cap and add coolant using a funnel.
8. Fill recov ery bottle to M AX level w ith Polaris 60/40 premix Anti Freeze/Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.
9. Reinstall the recovery bottle cap.
10. If co olant was re quired, sta rt eng ine an d check for leaks. Ma ke su re radiator fins ar e clea n to prevent overheating.
With the en gine at o perating temp level should be between the upper 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 the front cab.
3. View the coolant level in the recovery bottle.
erature, the coolant
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Cooling System Pressure Test
Refer to Ch apter 3 fo r co oling sy stem pressure tes t procedure.
MAINTENANCE
CA U T I O N
Antifreeze Hydrometer
WA RN I N G
Drain Here
Coolant Strength / Type
Test th e str ength of the co olant u sing a n an tifreeze hydrometer.
• A 50/50 or 60/40 mixture of antifre water will provide the optimum c ooling, corrosion protection, and antifreeze protection.
• Do n ot use t ap water , stra ight a ntifreeze, or straight water in th e system. T ap water co ntains minerals an d impu rities wh ich build up in the system.
• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
eze and distilled
Coolant Drain / Fill
Coolant Drain
1. Remove the hood from the front cab.
Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any cooling em pressure.
syst
3. Place a su itable drain pan underneath the rad iator
fitting on
4. Drain the coolant from the radiator by rem oving the
ower co olant ho se fro m the ra diator a s shown.
l Properly dispose of the coolant.
the front right-hand side of the vehicle.
2
Cooling System
1. Inspect all hoses fo r cracks, d eterioration, a brasion or leaks. Replace if necessary.
Do not over-tighten hose clamps at radiator,
or radiator fitting may distort, causing a
restriction to coolant flow.
Radiator hose clamp torque is 36 in. lbs. (4 Nm).
2. Check tightness of all hose clamps.
5. Allow coolant to completely drain.
6. Place a su itable d rain pan underneath t he lo wer ngine hose on the right-hand rear side of the vehicle.
e
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MAINTENANCE
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= T
7. Remove the h ose and completely dr ain th e en gine. Reinstall the lower coolant hose.
8. Properly dispose of the coolant.
9. Remove the pressure cap. Using a funnel, add the recommended c fill the recovery bottle to the MAX level.
10. Refer to Chapter 3 for the “Cooling System Bleeding
ocedure”.
Pr
oolant to the top of the filler neck and
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
FINAL DRIVE / WHEEL AND TIRE
Wheel and Hub Torque Table
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
Hub Retaining Nuts:
80 ft. lbs. (108 Nm)
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 ine.
eng
3. Loosen the wheel nuts slightly. If wheel hub removal
is required, remove the cotter pin and loosen the hub nut slightly.
4. Elevate the appropriate side of the vehicle by placing
suitable stand under the frame.
a
5. Remove the wheel nuts and remove the wheel.
6. If hub removal is re quired, remove the hub nut an d
shers.
wa
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MAINTENANCE
CA U T I O N
Wheel Nuts (4)
Hub Nut
Use a new
cotter pin
Note
Tire Rotation
Val ve ste m
facing outward
(RZR Only)
WA RN I N G
Tread Depth 1/8" (3 mm)
Wheel Installation
1. Verify the transmission is still in PARK (P).
2. Install th e wh eel hub, washe rs, an d hub n ut, if reviously removed.
p
3. Place the wheel in the correct position on the wheel ub. Be sure the valve stem is toward the outside and
h rotation arrows on the t ire point towa rd fo rward rotation.
4. Attach the wheel nuts and finger tighten them.
5. Carefully lower the vehicle to the ground.
6. Torque the whee l nuts and/or hub nut to the proper
que specification listed in th e torque table at the
tor beginning of this section.
7. If hub nut was removed, install a new cotter pin after
the hub nut has been tightened.
Tire Inspection
• Improper tire inflation may affect vehicle maneuverability.
• When replacing a tire always use original
uipment size and type.
eq
• The use of non-standard size or type tires may
ffect vehicle handling.
a
Operating with worn tires will increase the
possibility of the vehicle skidding easily with
possible loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth
easures 1/8", (.3 cm) or less.
m
Tire Tread Depth
Replace tires when tread depth is worn to 1/8" (3 mm) or
.
less
2
If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end
of nut goes into taper on wheel.
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MAINTENANCE
CA U T I O N
Front Boots
Rear Boots
WA RN I N G
WA RN I N G
Tire Pressure
Maintain proper tire pressure.
Refer to the warning tire pressure decal
applied to the vehicle.
Tire Pressure Inspection (Cold)
Front Rear
10 psi (55 kPa) 12 psi (55 kPa)
Drive Shaft Boot Inspection
Inspect the drive shaft boots for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Refer to Chapter 7 for drive shaft boot replacement.
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with c lean shop towels . Coat the terminals with dielectric grease or petroleum jelly.
CALIFORNIA PROPOSITION 65 WARNING:
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 harm.
WASH HANDS AFTER HANDLING.
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal:
Follow with milk of magnesia, beaten egg, or
Eyes: Flus
Ventilate when charging or using in an enclosed
NOTE: Batteries must be fully charged before use or
tery life will b e re duced by 10 -30% of fu ll
bat potential. Ch arge battery acc ording t o “Charging Procedure” provided in Cha pter 1 0. Do not use the vehicle’s stator/alternator to charge a new battery.
Drink large quantities of water or milk.
vegetable oil. Call physician immediately.
h with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases.
Keep sparks
space. Always shield eyes when
KEEP OUT OF REACH OF CHILDREN.
, flame, cigarettes, etc. away.
working near batteries.
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MAINTENANCE
CA U T I O N
Battery Removal
1. Remove the driver’s seat to access the battery.
2. Disconnect the (2) black (neg
3. Disconnect the (2) red (positive) battery cables.
4. Remove the ho ld-down strap and lift th e battery out the vehicle.
of
ative) battery cables.
Battery Installation
IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can a lso hinder v ehicle pe rformance. Follow the battery charging procedure in Chapter 10 “Electrical” before installing the battery.
1. Ensure the battery is fully charged.
2. Place the battery in the battery holder and secure with old-down strap.
h
3. Coat the terminals with dielectric grease or petroleum
elly.
j
4. Connect and tighten the (2) re
5. Connect a nd tighten the ( 2) black ( negative) cable
last.
d (positive) cables first.
2
To reduce the chance of sparks: Whenever
removing the battery, disconnect the black
(negative) cable first. When reinstalling the
battery, install the black (negative) cable last.
rify that cables are properly routed and reinstall the
6. Ve
driver’s seat.
Battery Off Season Storage
Refer to Chap ter 10 “Electrical” for o ff sea son stor age procedures.
2.31
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MAINTENANCE
WA RN I N G
Note for
reassembly
Inspect electrode for wear and buildup
Gap - .0276 - .0315" (0.7 - 0.8 mm)
Spark Plug Gap
Spark Plug Service
1. Remove the dr iver’s sea t a nd d isconnect th e ( -) negative battery cable from the battery.
2. Remove cargo box access panel.
A hot exhaust system and engine can cause
serious burns. Allow engine to cool or wear
protective gloves when removing the spark plugs.
3. Clean top of engine to remove all dirt and debris.
4. Remove the spark plug wire from the engine.
8. Measure gap with a wire gauge. Adjust gap if ecessary by carefully bending the side electrode.
n
9. If n ecessary, r eplace spa rk p lug with p roper type.
C
AUTION: Severe en gine damage may occur if the
incorrect spark plug is used.
10. Apply Anti-seize compound to the spark plug threads.
11. Install spark plugs and torque to specification.
Recommended Spark Plug:
Champion RG4YCX
Spark Plug Torque:
7 ft. lbs. (10 Nm) Apply Anti-seize
5. Remove spark plug.
6. Inspect electrodes for wear and carbon buildup. Look a sharp outer edge with no rounding or erosion of
for the electrodes.
7. Clean with electrical contact cleaner only.
12. Install spark plug wire into spark plug / engine.
13. Reinstall cargo box access panel.
14. Reinstall the (- ) negative b attery cab le and driver’s at.
se
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© Copyright 2011 Polaris Sales Inc.
MAINTENANCE
Engine
Ground Cable
Chassis
Ground Terminal
WA RN I N G
Engine To Frame Ground
Inspect ground cable connections. Be sure they are clean and tight.
The engine ground cable runs from the upper starter motor
unting bolt to the chassis ground terminal.
mo
The Chassis ground is located under the drivers seat, near
starter solenoid.
the
STEERING
Steering Inspection
The steering components should be checked periodically for lo ose fa steners, wor n tie ro d e nds, b all jo ints, and damage. Also ch eck to make sure all cotter pin s ar e in place. If cotte r p ins are re moved, they mu st not be re– used. Always use new cotter pins.
Replace any wor n or da maged steer ing com ponents.
teering should mo ve freely through th e entire range of
S travel without binding. Check routing of all cables, hoses, and wirin g to b e sur e the steer ing mech anism i s n ot restricted or limited.
NOTE: Whenever s teering c omponents are
ed, check front end alignment.
replac
Due to the critical nature of the procedures
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.
2
9923523 - RANGER RZR 570 Service Manual
2.33
© Copyright 2011 Polaris Sales Inc.
MAINTENANCE
Tie Rod
U-Joints
Gearbox
Tie Rod
Check for Loose Wheel or Hub
Steering Wheel Freeplay
Check t he st eering wh eel f or specified freeplay and operation.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is exce ssive fr eeplay or the stee ring feels rough, inspect the following components.
• Tie Rod Ends
• Steering Shaft U-Joints
• Steering Gearbox
Tie Rod End / Wheel Hub Inspection
• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.
• Replace any worn steering components. Steering
ld move freely through entire range of travel
shou without binding.
• Elevate fr ont end of mach ine so front wheels are off the ground. Che ck fo r a ny looseness in fr ont hub/wheel assembly by g rasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.
• If abnormal movement is detected, inspect the hub
d whe el assemb ly to deter mine the cau se
an (loose wheel nuts or loose front hub nut).
2.34
• Refer to Chap ter 7 “ Final Drive” for fro nt hu b service procedures.
9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
MAINTENANCE
= In. / mm.
CA U T I O N
Wheel Toe Alignment Inspection
1. Place ma chine o n a smooth le vel su rface and set steering wheel in a str aight ahead position. Secure the steering wheel in this position.
2. Place a chalk mark on the cente approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.
r line of the front tires
Wheel Toe Adjustment
If to e alig nment is inco rrect, mea sure th e dist ance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.
2
NOTE: It is impor tant t he h eight of b oth mark s be equally positioned to get an accurate measurement.
3. Measure the distance between the marks and record
measurement. Call this measurement “A”.
the
4. Rotate the tires 180 Position chalk marks facing rearward, even with the hub/axle center line.
5. Again measure the distance between the marks and
cord. Call t his m easurement “ B”. Su btract
re measurement “ B” from me asurement “ A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/ 8”, t o 1/4”, ( .3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement at the rear (B).
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
° by moving the vehicle forward.
Wheel Toe-Out:
NOTE: Be sure st eering wheel is st raight ahead
ore determining which tie rod needs adjustment.
bef
During tie rod adjustment, it is very important that
the following precautions be taken when
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not
pivot, and may break.
2.35
9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
MAINTENANCE
= T
WA RN I N G
Increase
Preload
Decrease
Preload
Cam
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as re
quired to achieve the pr oper toe settin g as
specified in “Wheel Toe Alignment”.
IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod e nd da mage and p remature wear. Dama ge may not be immed iately app arent if done incorrectly.
• After alignment is complete, torque jam nuts to
pecification.
s
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
SUSPENSION
Spring Preload Adjustment
The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and
serious injury or death. Always adjust both the left
and right spring preloads equally.
Suspension Spring Adjustment
1. Position the vehicle on a lev el surface and stop the ine.
eng
2. Raise and safely su pport th e fr ont or rear of th e
vehicle off the ground to allow the suspension to fully extend.
NOTE: The tires should not be touching the ground.
3. To adjust the suspension, rotate the
clockwise to incr ease spr ing ten sion or counter­clockwise to decrease spring tension.
Shock Spanner Wrench
(PN 2871095)
4. Each notch of the adjustment will add 6% - 8% more
load to the spring over the primary position.
pre
adjustment cam
2.36
9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
MAINTENANCE
Master Cylinder
Maximum
Minimum
Measure Pad Material
Service Limit:
.040" (1 mm)
Thickness
Measure Brake Disc Thickness
Service Limit:
.170" (4.32 mm)
Front
Disc
Rear
Disc
BRAKE SYSTEM
Brake Fluid Inspection
Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
uld also be chan ged anytime th e fluid becomes
sho contaminated, the fluid level is below the minimum level, or if th e type and br and of th e fluid in the reservoir is unknown.
The brake fluid master cylinder re through the left front wheel well.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK (P).
3. View the brake fluid level in the reservoir. The level uld be between the MAX and MIN level lines.
sho
4. If the fluid level is lower than
brake fluid until it reaches the MAX level line.
servoir can be accessed
the MIN level line, add
Brake Pad / Disc Inspection
1. Check the br ake pa ds for wear, dam age, or looseness.
2. Inspect th e br ake p ad we ar su rface for e xcessive wear.
3. Pads should be changed when the worn to .040” (1 mm).
4. Check surface condition of the brake discs.
friction material is
2
5. Install th e re servoir ca p and apply the br ake pe dal forcefully fo r a fe w se conds a nd ch eck for fluid leakage around the master cylind er fittings an d the brake caliper fittings.
5. Measure the th ickness of the front an d re ar bra ke s.
disc
6. The disc(s) should be replaced if thickness is less than
.170” (4.32 mm).
Brake Hose and Fitting Inspection
Check b rake system hoses and fitting s for cracks, deterioration, ab rasion, an d leaks. Tighten an y loo se fittings and replace any worn or damaged parts.
9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
2.37
MAINTENANCE
Inboard
Pad
Outboard
Pad
Outboard Pad Thickness
New 0.250” (6.35 mm) Limit: 0.190” (4.83 mm)
Inboard Pad Thickness
New 0.300” (7.62 mm) Limit: 0.240” (6.10 mm)
Parking Brake Cable Adjustment (INTL)
When the parking brake is fully engaged and “BRAKE” is displayed on the instrument clu ster, en gine spe ed is limited to 1500 RPM while in gear. If throttle is applied, this limiting fea ture pr events op eration, wh ich pr otects the parking brake pads from excessive wear.
NOTE: Inspect the parking brake cable tension after
he first 25 hours of operation a nd ev ery 100 hours
t of operation af terwards to ens ure prop er cab le tension.
Loss of tension in the p arking brake cable will caus illumination of the parking brake indicator and activation of the limiting feature. If this occurs, inspect an d a djust parking brake cable tension. If performing this service is difficult due to conditions o r location , temporarily disconnect the parking brake switch electrical connector. Reconnect th e co nnector as so on as practicable an d adjust the parking brake cable to proper tension.
1. Pull back on the parking brake lever (located in dash).
2. After 3 t o 4 clic ks “BRAKE ” should display on the nstrument cl uster a nd th e whe els of the vehicle
i should not rotate when tur ning b y hand. After 8 full clicks of lever travel, the vehicle should not roll while parked.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the pa rking brake cable wh ere th e ca ble
ttaches to the caliper mount / shift cable bracket. The
a mount bracket is located on the right-hand side of the transmission.
e
Parking Brake Pad Inspection (INTL)
Inspect t he p arking br ake ca liper br ake p ad thickness. Replace brake pads if damaged or worn beyond service limit. Replac e caliper ass embly if damage or excessive wear is found. Refer to the following image for brake pad specifications.
Adjustment Procedure: Refer to Chapter 9 “Brakes”
or complete adjustment procedure.
f
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9923523 - RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
ENGINE / COOLING SYSTEM
CHAPTER 3
ENGINE / COOLING SYSTEM
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE SPECIFICATIONS - 1204286 RZR570HO-11 . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . . . . . . . . 3.8
MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND 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 / IDLE
SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER . . . . . . . . . . . . . . . 3.12
PISTON / CRANKSHAFT / BALANCE SHAFT. . . . . . . . .
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM. . . . . . . . . 3.14
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . .
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
WATER PUMP COVER AND IMPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . 3.21
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . .
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . 3.41
CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . .
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
R GEARS / STATOR COVER. 3.11
. . . . . . . . . . . . . . . . . . . . . . . 3.13
. . . . . . . . . . . . . . . . . . . . . . . . 3.18
. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
. . . . . . . . . . . . . . . . . . . . . . . 3.45
3
9923523 - 2012 RANGER RZR 570 Service Manual
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3.1
ENGINE / COOLING SYSTEM
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.52
CLEANING THE CYLINDER AFTER HONING . . . . . . . . .
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . .
INTAKE VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
EXHAUST VALVE LASH - SHIM SELECTION MA
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
CAMSHAFT TIMING - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
TRIX . . . . . . . . . . . . . . . . . . . . . . . . 3.62
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71
STATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72
STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75
CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76
BALANCE SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.77
CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79
MAG SIDE CRANKCASE BEARING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.80
OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . 3.81
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
CRANKCASE ASSEMBLY - PTO SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.87
. . . . . . . . . . . . . . . . . . . . . . 3.52
. . . . . . . . . . . . . . . . . . . . 3.59
3.2
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ENGINE / COOLING SYSTEM
=
GENERAL INFORMATION
Special Tools
Tool Description Part Number
Bench Mount Engine Stand Adapter PW-47053
Clutch Center Distance Tool PU-50658
Crankshaft Removal / Installation Tool Kit PU-50784
Cylinder Holding & Camshaft Timing Plate PU-50563
Engine Stand (2” Bore) PU-50624
Engine Stand Adapter (Mounts To The Engine) 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 Gauge PV-43531
Oil Pressure Gauge Adapter PU-50569
Stator Cover Removal Handles PA-49317
Valve Spring Compressor PV-1253 or PV-4019 (Quick Release)
Valve Spring Compressor Adapter PV-43513-A
Water Pump Mechanical / Oil Seal
SPX Corporation - 1-800-328-6657 http://polaris.spx.com/
.
Installation Kit PU-50689
Engine Lubrication Specifications
3
Oil Capacity Approx. 2 Quarts (1.9 L)
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Oil Type
Oil Pressure
Minimum Spec
(using Polaris PS-4 Plus
at operating temperature)
ification
Polaris PS-4 Plus
Synthetic En
10 PSI @ 1200 RPM
(Minimum)
40 PSI @ 7000 RPM
(Minimum)
9923523 - 2012 RANGER RZR 570 Service Manual
gine Oil
© Copyright 2011 Polaris Sales Inc.
3.3
ENGINE / COOLING SYSTEM
PV-43531
PU-50569
A
Image for Reference Only
=
= T
Oil Pressure Test
1. Attach the Oil Pr essure Gauge Adapter (PU-50569)
to the Oil Pressure Gauge (PV-43531).
Oil Capacity Approx. 2 Quarts (1.9 L)
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Oil Pressure Gauge Adapter: PU-50569
Oil Pressure Gauge: PV-43531
2. Remove the seats and engine service panel.
3. Clean the area around th e m ain oil gallery plug ( A),
cated on the oil filter adapter housing.
lo
4. Remove the plu g ( A) and in sert the oil pressure
dapter.
a
Oil Type
Oil Pressure
mum Specification
Mini
(using Polaris PS-4 Plus
at operating temperature)
6. Upon assembly, torque the crankcase gallery plug to pecification.
s
Oil Gallery Plug:
11 ft. lbs. (15 Nm)
Polaris PS-4 Plus
Synthe
10 PSI @ 1200 RPM
40 PSI @ 7000 RPM
tic Engine Oil
imum)
(Min
imum)
(Min
5. Start engine an d a llow it to r each op erating temperature, monitoring gauge indication.
NOTE: Test results ar e bas ed on the us e of the
commended engine oil (Pola ris PS- 4 Plus) at
re operating temperature, and may vary considerably if any ot her oil is used or if engine is not up to temperature.
3.4
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Engine Oil Flow Chart
ENGINE / COOLING SYSTEM
3
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3.5
ENGINE / COOLING SYSTEM
ENGINE SERVICE SPECIFICATIONS
Engine Specifications - 1204286 RZR570HO-11
CAMSHAFT / CYLINDER HEAD / CYLINDER (IN. / MM)
Cam Lobe Height - Intake 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Cam Lobe Height - Exhaust 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
Camshaft Journal O.D. - All (Standard) 0.9029" - 0.9037 " (22.933 - 22.954 mm)
Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)
Camshaft
Cylinder Head
Valve Seat
Valve Guide Valve Guide Inner Diameter 0.2165" - 0.2171" (5.500 - 5.515 mm)
Valve
Valve Spring
Cylinder
Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)
Camshaft Oil Clearance (Standard) 0.0018" - 0.0034" (0.046 - 0.088 mm)
Camshaft Oil Clearance (Service Limit) 0.0047" (0.121 mm)
Camshaft End Play (Standard) 0.0069" - 0.0128" (0.175 - 0.325 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0024" (0.060 mm)
Cylinder Head - Standard Height 4.745" ± 0.0020" (120.53 ± 0.05 mm)
Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)
Valve Seat - Contacting Width - Intake (Service
t)
i
Lim
Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)
Valve Seat - Contacting Width - Exhaust (Service
i
t)
Lim
Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
Valve Lash (Cold) - Intake 0.005" - 0.007" (0.125 - 0.175 mm)
Valve Lash (Cold) - Exhaust 0.00
Valve Stem Diameter - Intake 0
Valve Stem Diameter - Exhaust 0.2147" - 0.2153" (5.455 - 5.470 mm)
Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)
Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
Valve Stem Overall Length - Exhaust 3.7964" (96.43 mm)
Valve Spring Free Length (Standard) 1.7263" (43.85 mm)
Valve Spring Free Length (Service Limit) 1.683" (42.75 mm)
Cylinder - Surface Warp Limit (mating with cylinder head)
Cylinder Bore - Standard 3.8976" ± 0.0003" (99.0 mm ± 0.008 mm)
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm)
0.0551" (1.4 mm)
0.0748" (1.9 mm)
6"
- 0.010" (0.152 - 0.254 mm)
.2155" - 0.2161" (5.475 - 5.490 mm)
0.00098" (0.025 mm)
3.6
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ENGINE / COOLING SYSTEM
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT (IN. / MM)
Piston - Standard O.D. - Measured 90 degrees to pin, 0.47 in. (12 mm) up from piston skirt. See text.
Piston
Piston Pin
Piston Ring
Connecting
Rod
Crankshaft
Balance Shaft Bearing Journal O.D. (Standard) 1.1798” - 1.1802" (29.969 - 29.979 mm)
Piston Pin Bore I.D. (Standard)
Piston Pin Bore I.D. (Service Limit)
Piston Pin O.D. (Standard) 0.8659" - 0.8661" (21.995 - 22.000 mm)
Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)
Top Ring (Standard) 0.0059" - 0.0122" (0.15 - 0.31 mm)
Top Ring (Service Limit) 0.0137" (0.35 mm)
Installed
p
Ga
Ring to
oove
Gr
Clearance
Connecting Rod Small End I.D. (Standard) 0.8665" - 0.8670" (22.010 - 22.023 mm)
Connecting Rod Small End I.D. (Service Limit) 0.8682" (22.053 mm)
Connecting Rod Big End I.D. See Service Procedure Listed In This Chapter
Main Journal O.D. (Service Limit) 1.6137" (40.990 mm)
Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter
Second Ring (Standard)
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)
Top Ring (Standard) 0.0011" - 0.0037" (0.030 - 0.095 mm)
Top Ring (Service Limit) 0.0042" (0.108 mm)
Second Ring (Standard) 0.0007" - 0.0029" (0.020 - 0.076 mm)
Second Ring (Service Limit) 0.0035" (0.089 mm)
0.8662” - 0.8665” (22.004 - 22.010 mm)
0.8677" (22.042 mm)
3.8957” - 3.8968” (98.953 - 98.980 mm)
94" - 0.0196" (0.24 - 0.50 mm)
0.00
3
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3.7
ENGINE / COOLING SYSTEM
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES
Main Engine Components - Torque Specification and Sequence
3.8
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ENGINE / COOLING SYSTEM
Replace Bolts if
Loosened or Removed
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
3
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3.9
ENGINE / COOLING SYSTEM
Replace Bolts if
Loosened or Removed
Apply Loctite® 272™
Cylinder / Oil Filter / Oil Pump / Breather
3.10
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ENGINE / COOLING SYSTEM
Replace Bolts if
Loosened or Removed
Apply Loctite® 272™
Loosened or Removed
Replace Gasket if
Loosened or Removed
Replace Nut if
Loosened or Removed
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
3
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3.11
ENGINE / COOLING SYSTEM
Apply Anti-seize
Replace Bolts if
Loosened or Removed
Spark Plugs / Starter / Throttle Body / Valve Cover
3.12
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Piston / Crankshaft / Balance Shaft
ENGINE / COOLING SYSTEM
3
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3.13
ENGINE / COOLING SYSTEM
Water Pump
Upper Engine Hose
Lower Engine
Hose
Bypass Hose
Radiator
Recovery
Bottle
Upper Radiator
Hose
Pressure Cap
Filler Neck
Hoses
Cooling Fan
ENGINE COOLING SYSTEM
Cooling System Exploded View and Coolant Flow Diagram
3.14
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ENGINE / COOLING SYSTEM
WA RN I N G
Tes t H ere
Cooling System Specifications
Condition Coolant Temperature °F (°C)
Room Temperature 68° F (20° C)
Thermostat Open 180° F (82° C)
Fan Off 192° F (89° C)
Fan On 198° F (92° C)
Thermostat Full Open Lif
t
Engine Temperature
rheat Indicator
Ove
Engine Protection Ignition Misfire
Engine Protection
down
Shut
Item Specification
Cooling System Capacity 4.25 qts. (4 l)
Pressure Cap Relief 13 PSI
203° F (95° C)
233° F (112° C)
236° F (113° C)
257° F (125° C)
Cooling System Pressure Test
1. Remove the hood from the front cab.
Never remove pressure cap when engine is
warm or hot. The cooling system is under
pressure and serious burns may result.
Allow the engine to cool before servicing.
2. Remove pressure cap a nd pressure test the cooling system using a commercially available pressure tester.
3
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
Recommended Coolant
Use only high quality antif re distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.
CAUTION: Using to a buildup of deposits which may restrict coolant flow and reduce he at dissip ation, r esulting in p ossible engine damage. Pola ris Pre mium 60 /40 An tifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
tap water in the cooling system will lead
eze/coolant m ixed with
3. The system must maintain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the filler neck, radiator, hoses, clamps and water pump weep hole for leakage.
3.15
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ENGINE / COOLING SYSTEM
A
CA U T I O N
A
Flush radiator fins
in this direction
Pressure Cap Test
1. Remove th e ho od fro m th e fro nt cab (see “WARNING” under “Cooling System Pressure Test”).
2. Remove pressure cap (A) and test using a pressure
tester (commercially available).
cap
3. The 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 radiator fins.
3. Remove any obstructions wit pressure water.
h compressed air or low
Washing the vehicle with a high-pressure
washer could damage the radiator fins and
impair the radiators effectiveness. Use of a high-
pressure washer is not recommended.
3.16
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ENGINE / COOLING SYSTEM
WA RN I N G
Drain Here
Recovery
Engine
T-Fitting
Radiator
Fan Motor Asm.
Screws
Grommets
Inserts
Hose
Outlet Hose
Engine
Inlet Hose
Coolant Drain / Radiator Removal
Coolant Drain
1. Remove the hood from the front cab.
Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any cooling tem pressure.
sys
3. Place a suitab le drain p an underneath the r adiator
g on the front right-hand side of the vehicle.
fittin
4. Drain the coolant from the radiator by removing the
wer coo lant hose from the r adiator as sho wn.
lo Properly dispose of the coolant.
Radiator Removal
1. Remove the front bumper (see Chapter 5).
2. Remove the upp er engine outlet hose and reco very ose from the top of the radiator.
h
3. Remove the (2) upper radiator retaining bolts and the
4) bolts retaining the lo wer radiator mount bracket.
( Remove the bracket from the frame.
4. Disconnect th e fa n mo tor an d re move the radiator
m the vehicle. Take care not to damage the cooling
fro fins.
3
5. Allow coolant to completely drain.
6. Place a s uitable drain p an u nderneath th e lower engine hose on the right-hand rear side of the vehicle.
5. Reverse procedure for installation.
7. Remove the hose and completely drain the engine.
9923523 - 2012 RANGER RZR 570 Service Manual
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3.17
ENGINE / COOLING SYSTEM
WA RN I N G
= T
X
WA RN I N G
CA U T I O N
CA U T I O N
B
A
MAX Line
Thermostat Replacement
1. Remove the hood from the front cab.
The cooling system is under pressure and
serious burns may result.
Allow the engine to cool before servicing.
2. Remove the pr essure cap to reliev e any sys tem pressure (see “Pressure Cap Test”).
3. Drain coolant to a level below the thermostat housing.
4. Remove the cargo box access panel.
5. Remove the spark plug wire from the engine.
6. Remove th e (2 ) bo lts (X) retai ning the th ermostat cover.
Cooling System Bleeding Procedure
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death.
Use caution when performing these procedures.
Coolant may be hot and may cause
severe injury or burns.
NOTE: If the coolant level is LOW in the radiator, or if there are lea ks in th e system, the coolant system will not draw coolant from the reservoir tank.
NOTE: It may be ne cessary to safely raise the front
the vehicle 1 2” ( 30 c m) to blee d the c ooling
of system.
1. Allow engine and cooling system to completely cool.
7. Lift the co ver from th e en gine a nd r emove the
rmostat.
the
8. Reverse th is p rocedure for in stallation. Re place
rmostat seal if wor n or da maged. T orque
the thermostat cover bolts to specification.
Thermostat Cover Bolts:
9. Be sure to properly fill and bleed cool outlined in this chapter.
7.5 ft. lbs. (10 Nm)
ing system as
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 hot and
could cause severe injury or burns.
2. Remove the hood.
3. Remove the recovery to the MAX line.
bottle cap (A) and fill the bottle
3.18
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ENGINE / COOLING SYSTEM
= T
C
= T
4. Remove the pressure cap (B) and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.
5. Remove the cargo box access to th e coola nt bleed screw that is on top of the thermostat housing.
6. Open the bleed screw (C) to allow any trapped air to
cape.
es
7. Fill the radiator until a steady stream of coolant begins to drain out of the bleed screw (C).
cover to gain access
13. Tighten the b leed scr ew to coolant and properly install the pressure cap.
Coolant Bleed Screw:
6 ft. lbs. (8 Nm)
14. Fill the recovery bottle to the MAX line.
15. Reinstall the hood.
16. Reinstall cargo box access cover.
sp ecification, to p off
3
8. Tighten the b leed scr ew to sp ecification, to p o ff lant and properly install the pressure cap.
coo
Coolant Bleed Screw:
6 ft. lbs. (8 Nm)
9. Start the en gine and allow it to idle until the coolant
fan has cycled.
10. Allow en gine and cooling sys
down (see CAUTION).
11. Remove the pressure cap. Add the necessary amount
of P olaris Premium Antifree ze to the radiator filler neck.
12. Open th e ble ed scre w to allo w any tr apped air to
scape. Close the bleed screw once a steady stream
e of coolant begins to drain out.
tem to completely cool
3.19
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ENGINE / COOLING SYSTEM
CA U T I O N
= T
A
B
C
D
Finger Tighten
(Reverse Threads)
9 ft. lbs.
(12 Nm)
9 ft. lbs.
(12 Nm)
WATER PUMP SERVICE
Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
NOTE: The wate r pu mp cov er, ga sket and impe ller can be serviced with the stator cover installed on the engine.
1. Allow engine and cooling system to completely cool.
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 hot and
could cause severe injury or burns.
2. Remove both seats and the engine service panel.
3. Disconnect the (-) negative battery cable.
4. Remove all debris and thoroughly clean water pump rea and right-hand side of engine block.
a
5. Remove the hood.
11. Using an 8 mm socket, r emove th e water pum p impeller (D).
NOTE: The wa ter pump impe ller (D) use s rev erse (LH) threads.
12. Inspect the water pum p co ver an d impe ller for
amage. Replace as necessary.
d
13. Follow this pro cedure in reverse to asse mble th e
ter pump impeller and cover. Always u se a new
wa water p ump co ver g asket. To rque a ll fa steners in sequence to specification.
6. Remove the pressure c
7. Completely dr ain co oling syste m and engine as outlined in this chapter.
8. Raise and sa fely su pport the ve hicle. Rem ove the
ight-hand rear wheel.
r
9. Remove th e (8 ) b olts (A) attaching th e wa ter pu mp
to the stator cover.
cover
10. Remove the water pump cover (B) and water p ump
ver gasket (C). Discard the water pump gasket (C).
co
ap from the filler neck.
Water Pump Cover Fastener Torque:
9 ft. lbs. (12 Nm)
14. Fill and bleed cooling s ystem as outlined in this apter.
ch
3.20
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ENGINE / COOLING SYSTEM
CA U T I O N
A
B
C
D
Water Pump Mechanical Seal / Oil Seal Replacement
NOTE: The s tator cov er must be re moved f rom t he engine t o s ervice the wa ter pump drive sh aft, oil seal, mechanical seal and bearing.
1. Allow engine and cooling sys
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 hot and
could cause severe injury or burns.
2. Remove both seats and the engine service panel.
3. Disconnect the (-) negative battery cable.
4. Remove all debris and thoroughly clean water pump rea and right-hand side of engine block.
a
5. Remove the hood.
6. Remove the pressure cap from the
tem to completely cool.
filler neck.
10. Remove the CPS sensor from the stator cover on the ight-hand side of the engine. Inspect CPS O-ring and
r replace if needed.
11. Remove the oil dipstick.
12. Remove the ( 8) bolts (A) retaining the water pump
er to the stator cover.
cov
13. Remove the water pump cover (B) and water pump
cover gasket (C). Discard the water pump gasket (C).
3
7. Completely drain c ooling syst em and engine as outlined in this chapter.
8. Raise an d s afely support the right-hand rear wheel.
9. Disconnect the stator wire connector and cut the tie
ap s ecuring th e w iring t o t he fr ont e ngine mount
str bracket.
vehicle. Rem ove the
14. Remove the water pump impeller (D).
NOTE: The water pump impeller (D) uses reverse
H) threads.
(L
3.21
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ENGINE / COOLING SYSTEM
CA U T I O N
CA U T I O N
PA-49317
E
F
G
15. Remove the (13) 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 bolt holes to aid
( in stator cover removal.
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.
18. Bring the sta tor cover assemb ly to a clea n work ch.
ben
19. Using a b rass dr ift, re move th e water pum p dr ive
aft. Be sur e not to da mage the thr eads. Inspe ct
sh shaft for wear or damage, replace if necessary.
20. Extract th e mechanical seal (E) and th e o il seal (F)
om the stator cover.
fr
17. Remove and discard the stator cover gasket.
Be sure engine coolant does not contaminate the
engine oil during stator cover service.
21. Press out the water pump drive shaft bearing (G) from
e stator cover. Disca rd bearing an d r eplace with
th new.
3.22
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Water Pump Assembly
CA U T I O N
G
H
PU-50869
Item #1 Item #2
Item #3
PU-50869
Item #1
PU-50869
Item #1
1. Thoroughly clean the stator cover.
ENGINE / COOLING SYSTEM
2. Press in a ne
until it is fully seated in the cover.
Be sure bearing is fully seated in cover or severe
3. Clean and de-grease the water pump drive shaft (H).
4. Press in th e wa ter pu mp dr ive shaft (H) into the earing using PU-50869 Item #1.
b
w water pump drive sha ft b earing ( G)
engine damage may result.
5. Install the water pump drive shaft ho lding tool ( Item #1) in kit PU-50869. the as sembly u p-side-down so the special tool PU­50869 is supporting the assembly.
Hold the tool in position and flip
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3.23
ENGINE / COOLING SYSTEM
CA U T I O N
I
PU-50869
Item #2
J
PU-50869
Item #3
A
Water Pump Alignment Detail View
Crankshaft
Oil Seal
Mechanical
Impeller
Seal
Drive Shaft
6. Lubricate the new wa ter p ump oil se al w ith c lean
engine oil.
7. Use the water pump oil seal installation
tool in kit
PU-50869 to fully install the new water pump oil seal (I).
Be sure the oil seal is fully seated in cover or
severe engine damage may result
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 w.
belo
12. Apply a small amount of crankcase sealant to the area
indicated below (A).
8. Use the water pump mechanical seal installation tool in kit PU-50869
to fully install the new water pump
mechanical seal (J) until it is fully seated in the cover.
9. Install a new stator
cover gasket onto the engine.
13. If needed, install the stator cover removal handles tool PA-
49317 to the water cover bolt holes to aid in stator
cover installation.
3.24
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14. While installing the stator cover to the engine, slightly
CA U T I O N
CA U T I O N
PA-49317
9 ft. lbs.
(12 Nm)
= T
= In. / mm.
Water Pump Drive Shaft
Mechanical Seal
Stator Cover
K
Finger Tighten
(Reverse Threads)
rotate the water pump impeller 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.
The flywheel contains powerful magnets. Use
caution when installing the stator cover.
DO NOT place fingers between cover and
crankcase at any time during the removal and
installation process or injury could result.
ENGINE / COOLING SYSTEM
Stator Cover and Water Pump Cover
9 ft. lbs. (12 Nm)
16. Measure the installe d height of the new mechanical
seal a s sh own b elow. If not within sp ecification, remove and discard the mechanical seal and properly install new mechanical s eal as outlined in this chapter.
3
If the water pump drive shaft blade and slot in the
crank shaft are not in alignment during the
installation process, severe engine damage may
result.
15. Install and to rque the stator cover fa steners in sequenc
e to specification.
Mechanical Water Pump Seal Installed Height:
0.280” - 0.287” (7.2 +/- 0.1 mm)
17. Install the water pu mp imp
only.
NOTE: The water pump impeller (K) uses reverse
H) threads.
(L
18. Install a ne
w water pump cover gasket.
eller (K). Finger tighten
3.25
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ENGINE / COOLING SYSTEM
= T
9 ft. lbs.
(12 Nm)
19. Install th e water pu mp co ver to the stator cover. Torque all fasteners in sequence to specification.
20. Install the oil dipstick.
21. Install the coolant hose to the water pump cover and
ten hose clamp.
tigh
22. Connect the stator wir e connector and install a new
p securing the wiring to the front engine mount
tie stra bracket.
23. Install the CPS sensor into the stator cover. Inspect
O-ring and replace if needed.
CPS
24. Install the right-hand rear wheel and torque the wheel
uts to specification. Safely lower vehicle.
n
ENGINE SERVICE
Accessible Engine Components
The following components can be serviced or re moved with the engine installed:
• Camshaft
• Camshaft Sprockets
• Cylinder Head and Gaskets
• Cylinder and Gaskets
• Piston and Rings
• Flywheel
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
•Water Pump
• Camshaft Timing Chain and Guides
• Crankshaft Seal (PTO)
• Oil Pump / Oil Pump Sprocket or Chain
The following c omponents require e ngine re moval for se
rvice:
• Counterbalance Shaft and Bearings
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
25. Install both seats and the engine service panel.
26. Connect the (-) negative battery cable.
27. If the engine oil was contaminated during this service procedure, perform an engine oil change as outlined in Chapter 2. DO NOT run the engine until coolant has been added to the cooling system.
28. Fill cooling system with rec the system of air as outlined in this chapter.
29. Check for leaks.
ommend coolant and bleed
3.26
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• Crankshaft and Bearings
• Crankcase
• Oil Pressure Regulator
• Oil Pump Pickup Assembly
Top-End Service (Engine in Chassis)
ALL of the top-end engine components can be serviced while the engine is mounted in the chassis.
ENGINE / COOLING SYSTEM
CA U T I O N
WA RN I N G
Spring Style
Clamp
Engine Removal
IMPORTANT: Some engine repair procedures can be performed with out removing the engine as sembly from th e ve hicle. Re fer to “Acc essible Engine Components” for further information.
NOTE: The use of an overhead or port able engine
ist is the only recommended method for removing
ho and installing the engine.
NOTE: Have an a ssistant help gu ide the eng ine in
nd out of the vehicle while using an engine hoist to
a prevent pe rsonal injur y or dama ge to vehicle components.
Correct Drive Clutch Puller P/N PA-48595
3. Drain the engine oil and engine coolant prior to engine emoval (see Chapter 2).
r
4. Remove the sea ts an d en gine service pan el (see
apter 5).
Ch
5. Disconnect th e ( -) neg ative ba
battery.
6. Remove th e r ear bu mper and cargo b ox as a n
assembly (see Chapter 5).
ttery ca ble fr om the
3
Always wear safety glasses and proper shop
clothing when performing the procedures in
this Service Manual.
Failing to do so may lead to possible injury.
1. If vehicle was recently operated, allow it to cool down before
2. Thoroughly clean the engine and chassis.
attempting to perform any work.
7. Loosen the (3) clam ps se curing th e int ake ba ffle ssembly to the air box lid, inn er clutch cover and
a engine crankcase vent. Remove the air intake baffle / intake ho ses / engine cran kcase 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.
3.27
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ENGINE / COOLING SYSTEM
A
B
C
E
D
9. Remove the outer clutch cover, drive belt, drive clutch, driven clutch and inner clutch cover (see Chapter 6). Make note of hose and wire routings for reassembly.
IMPORTANT: Be sure to use the correct Drive Clutch
(PA-48595) to prevent damage to crankshaft.
Puller
10. Disconnect the stator wire connector and cut the tie
p secur ing the wir ing to th e front eng ine mou nt
stra bracket. Replace tie strap for engine installation.
11. Remove the CPS sensor from the stator cover on the
ight-hand side of the engine. Plug CPS h ole with
r clean shop towel. Inspect CPS O-ring and replace if needed.
12. Disconnect the IAC valve (A), TPS (B), T-MAP sensor (C), har
13. Disconnect the fuel injector harness lead (D) from the fuel injector.
14. Properly relieve fuel pressure from the fuel rail.
15. Place a shop to beneath the fuel line quick connector to from the fuel rail by pressing in on the quick connector tabs.
16. Move fue l line to th e left-h and sid e of th e en gine co installation.
ness leads from the throttle body.
catch any excess fuel. Disconnect the fuel line (E)
mpartment. Make note of line routing for
3.28
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17. Disconnect the ignition coil har ness co nnector an d
ove the spark plug wire from the engine.
rem
ENGINE / COOLING SYSTEM
F
G
H
J
I
18. Remove t he ( 8) fa steners securing t he ( 2) b olt in braces to the veh icle main fra me. Ma neuver the braces for engine removal clearance. Note the routing of the transmission breather hose and wire harness.
19. Remove (+) positive cable from the starter motor.
20. If desired, remov e the re maining s and remove the starter motor from the engine.
21. Remove (-) negative cable from the starter mounting
lt.
bo
tarter motor bolt
22. Loosen the hose clamp (F) securing the throttle body the air box. L ift air box up and rea rward a s an
to assembly to disengage it from the throttle body.
23. Loosen the hose clamp (G) securing the throttle body the engine intake boot. Remove throttle body from
to the engine and wrap it with a clean shop towel. Place throttle body on the left-hand side frame rail area.
IMPORTANT: Be sure dirt and debris do not enter the
ngine, a ir box or t hrottle bod y. Use clean sho p
e towels to plug engine and air box intake holes.
3
24. Disconnect the upper en gine coo lant h ose ( H),
ass hose (I) and ECT (J) harness connector.
byp
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© Copyright 2011 Polaris Sales Inc.
3.29
ENGINE / COOLING SYSTEM
L
K
L
Discard
N
O
M
PU- 50824
Bolts From The Center Outward
25. Remove the (3 ) he x bolts (K) secur ing th e exha ust head pipe to the eng ine. Remo ve th e (3 ) r ubber exhaust hangers (L) securing the exhaust system to the main frame. Discard the exhaust seal and replace with new for reassembly.
26. Maneuver the exhaust system towards the right-hand
of the vehicle to gain engine removal clearance.
side Removal of the exhaust system from the chassis is not needed.
27. Place a s upport in -between th e main fra me and
nsmission case. Do not pinch brake line.
tra
30. Remove the ( 8) b olts (N) securing th e cou pler ckets to the engine and transmission.
bra
31. Loosen the (2) bolts and nuts (O) so the engine mount cket can be slightly tilted away from engine.
bra
32. With the h elp of an assista nt an d the en gine hoist,
the engine vertically out of the vehicle frame.
raise
NOTE: Have a n ass istant help guide t he e ngine in and out prevent per sonal injury or dama ge t o th e ve hicle components.
of the vehicle while using an engine hoist to
28. Use an overhead or portable engine hoist and suitable gine s traps t o s ecure the engine in its cu rrent
en position.
29. Remove the (4) bolts and nuts (M) securing the engine
to the front
3.30
motor mount bracket.
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© Copyright 2011 Polaris Sales Inc.
33. Install the engine stand adapter (PU-50824) onto the ine PTO side mounting ears as shown below.
eng
34. Select th e pr oper eng ine stan d slee ve ada pter an d
ll it onto the engine stand adapter.
insta
• 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 (PU- 50624) for rvice.
se
ENGINE / COOLING SYSTEM
A
B
C
Drive Clutch Bolt Installed
PU-50658
Tool Fully Seated Inward
Engine Installation
Use the following pr ocedure to re install th e eng ine assembly.
1. Attach en gine with suit a overhead or portable engine hoist.
2. Remove the engine stand adapter plate.
3. Use the ove rhead or p ortable engine ho ist a nd
le e ngine straps to lower the en gine in to the
suitab vehicle frame.
NOTE: Have an a ssistant help gu ide the eng ine in
nd out of the vehicle while using an engine hoist to
a prevent pe rsonal injur y or dama ge to vehicle components.
4. By hand, install the (4) front engine mount bolts and
(A). Do not tighten at this time.
nuts
5. Instal the (4) engine to tran and instal the ( 8) bo lts and washe rs ( C). Do no t tighten fasteners at this time.
ble lift ing str aps t o a n
smission coupler plates (B)
6. Install the Clutch Ce nter Distance To onto th e cr ankshaft and tr ansmission in put shaft t o properly position the clutch center distance.
The pictures below show the to installed.
ol (PU-50658) properly
ol (PU-50658)
3
IMPORTANT: DO NOT torque f
asteners at this time.
3.31
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ENGINE / COOLING SYSTEM
= T
= T
= T
55 ft. lbs
(74.5 Nm)
40 ft. lbs.
(54 Nm)
40 ft. lbs.
(54 Nm)
= T
= T
New
18 ft. lbs.
(24.5 Nm)
7. In sequence, to rque the (8 ) e ngine cou pler br acket fasteners to specification.
Rear Engine Coupler Fastener (In Sequence):
55 ft. lbs. (74.5 Nm)
8. In a criss-cross pattern, to mount fasteners to specification.
rque the (4 ) fro nt eng ine
10. Remove the lifting str aps a nd over head or po rtable engine hoist an d r emove th e sup port pr eviously installed under the tra nsmission case du ring th e engine removal process.
11. Reposition th e e xhaust system a nd insta ll the (3)
ber exhaust hangers, new exhaust seal and the (3)
rub head p ipe bo lts. To rque he ad pipe b olts to specification.
Front Engine Mount Fasteners:
40 ft. lbs. (54 Nm)
9. Torque th e (2) front center iso lator bolts to ification.
spec
Isolator Center Bolt:
40 ft. lbs. (54 Nm)
Exhaust Head Pipe Bolts:
18 ft. lbs. (24.5 Nm)
12. Install the (3) coolant hoses onto the engine.
13. Install the throttle body and air box. Tighten the hose mps that secure the throttle body to the intake boot
cla and air box.
14. Install the lower stater motor
starter motor mounting boss.
15. Instal the starter motor onto the engine.
16. Install the starter motor and ba
in Chapter 10.
Starter Motor Fastener:
7 ft. lbs. (10 Nm)
bolt through the lower
ttery cables as outlined
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ENGINE / COOLING SYSTEM
D
E
F
H
G
= T
= T
17 ft. lbs.
(23 Nm)
40 ft. lbs.
(54 Nm)
17. Connect the harness leads to the IAC valve (D), TPS (E), T-MAP sensor (F). Verify routing is correct.
18. Connect the fuel injector harness lead (G) to the fuel injector.
19. Connect the fuel line (H) to the fuel rail.
20. Install the (8) fasteners securing the (2) bolt in braces to th e ve hicle m ain frame. Torque fas teners to specification. Be sure the routing of the transmission breather hose and wire harness is correct.
3
Rear Bolt in Brace Fastener Torque:
17 ft. lbs. (23 Nm)
Front Bolt in Brace Fastener Torque:
40 ft. lbs. (54 Nm)
21. Connect the ignition coil harness connector and install
e spark plug wire.
th
22. Install the CPS and mounting bolt into the stator cover
d torque to specification.
an
CPS Fastener Torque:
9 ft. lbs. (12 Nm)
23. Connect th e st ator wire connector and install a ne w
strap to secure the wiring to the front engine mount
tie bracket.
24. Install the inner clutch cover as outlined in chapter 6.
25. Install the dr ive clutch, driven clutch, belt an d outer
ch cover as outlined in Chapter 6. Be sure all hose
clut and wire routings are correct. Torque all fasteners to specification as outlined in Chapter 6.
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
26. Install the in take ba ffle as sembly. Se cure the 3
mps that attach the a ssembly to the crankc ase
cla vent, air box lid and inner clutch cover.
3.33
ENGINE / COOLING SYSTEM
= T
CA U T I ON
27. Install th e re ar bumper and cargo box assembly as outlined in Chapter 5.
28. Install the left-hand rear wheel and torque wheel nuts to specification.
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
29. Remove the pressure cap and fill the through the filler neck with properly mixed anti-freeze / coolant.
30. If the e ngine o il wa s com pletely d rained, a dd
roximately 2 quarts (1.9 L) of Polaris PS-4 Plus
app Synthetic Engine Oil into the crankcase.
31. Install a new oil filter. Lubricate the seal with engine
rior to installation (see Chapter 2 “Maintenance”).
oil p
32. Connect the (-) negative battery cable to the battery.
33. Install the engine service panel and seats.
34. Follow the “Cooling System Bleeding Procedure” as
ed in this chapter.
outlin
35. Start engine and check for any oil or coolant leaks.
36. Check the engine oil level (see Chapter 2).
37. Refer customer to “En gine Bre ak-In Peri od” up on
urning vehicle to customer.
ret
cooling system
Engine 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 components will result in more efficient performance and longer life for these components.
Use only Polaris PS-4 PLUS
Synthetic Engine Oil.
Never substitute or mix oil brands.
Serious engine damage and voiding of
w a r r a n t y c a n r e s u l t .
Do not operate at full throttle or high speeds for
extended periods during the first three hours of
use. Excessive heat can build up and cause
damage to close fitted engine parts.
1. Fill fuel tank with unleaded fuel which has a minimum ump octane number of 87 = (R+ M)/2.
p
2. Refer to Chapter 2, “Engine Oil
indicated on oil tank dipstick. Add oil if necessary.
3. Drive slowly at first to gradually bring engine up to
erating temperature.
op
4. Vary throttle po sitions. Do no t operate at su stained
le or sustained high speed.
id
5. Perform regular checks on fluid le vels, con trols and ll important bolt torques.
a
6. Change oil an d oil filter a fter br eak-in pe riod at 25
urs.
ho
Level”. Check oil level
3.34
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Engine Mounting and Torque Values
=
Front Engine Mount
Isolator Mount
Exhaust System
25 ft. lbs.
(34 Nm)
18 ft. lbs.
(24.5 Nm)
40 ft. lbs. (54 Nm)
25 ft. lbs.
(34 Nm)
40 ft. lbs. (54 Nm)
55 ft. lbs. (74.5 Nm)
Coupler Brackets
40 in. lbs.
(4.5 Nm)
Gasket
Seal
See Torque Sequence
See Engine Installation For
Critical Torque Procedure
40 ft. lbs. (54 Nm)
40 ft. lbs. (54 Nm)
ENGINE / COOLING SYSTEM
3
Engine Lubrication Specifications
Oil Capacity Approx. 2 Quarts (1.9 L)
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Oil Type
Oil Pressure
Minimum Specification
(using Polaris
operating temperature)
PS-4 Plus at
Polaris PS-4 Plus
Synthetic Engine Oil
10 PSI @ 1200 RPM
(Minimum)
40 PSI @ 7000 RPM
(Minimum)
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
3.35
ENGINE / COOLING SYSTEM
PU-50563
I
I
E
E
Image for Reference Only
1/4” Drive Extension
Alignment Hole
SETTING TDC (TOP-DEAD-CENTER)
There ar e thre e ways to en sure the pisto n is at TDC. Remove the outer clutch cover to access the drive clutch to aid in engine ro tation (m anually tu rn the drive clu tch counter clockwise).
1. With the CPS sensor removed, rotate the engine until “V” mar ked o n the flywhee l is a ligned with the
the CPS mounting ho le. This will se t TDC, but not
necessarily TDC o f t he compression st roke.
View the timing marks on the camshaft sprockets to ensure the e ngine is at TDC o f the co mpression stroke.
2. With t he v alve cover a nd thermostat h ousing
emoved, ro tate th e en gine so the cam lobe s a re
r 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 compression stroke.
IMPORTANT: Intake c am spr ocket shou ld h ave “I”
rks aligned wit h g asket su rface and t he e xhaust
ma cam s procket sh ould ha ve “E” mark s a ligned wit h gasket surface.
3. With the stator cover and flywh engine and position the piston at TDC by aligning the timing ho le in cra nk case with a timing hole in th e crankshaft.
Insert a 1 /4” dr ive socket exte nsion through th e
ankcase and into the crankshaft locating hole. This
cr
will s et TDC, but n ot necessarily TDC of the compression stroke. View the timing marks on the
cam shaft sprockets to ensure the en gine is at TD C of the compression stroke.
eel removed, rotate the
3.36
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ENGINE / COOLING SYSTEM
A
B
D
C
Lobes should face out
E
F
ENGINE DISASSEMBLY / INSPECTION -
Valve Cover Removal
NOTE: The valve cover, camshafts, cy linder hea d, cylinder and piston can be se rviced with the engine installed in the chassis.
1. If needed, rem ove th e sp ark plu g wir e fr om the ngine.
e
2. Remove dirt and debris from valve cover area.
3. Remove the ( 3) valve cover shou lder bolts (A) a nd
lators (B) using a T40 driver.
iso
4. Carefully lift valve cover from the engine and remove
it out of
the right-hand rear wheel well area.
TOP END
Camshaft Removal
NOTE: The c amshafts c an be removed wit h the engine installed in the chassis.
1. Rotate the engine so the piston is at Top Dead Center on the compression stroke.
(TDC)
NOTE: To verify TD C, see the “S ETTING TDC” section in this chapter.
3
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
shop towel to prevent anything from falling into the
a combustion chamber (if further engine disassembly is required).
2. Remove the hydraulic cam chain tensioner (E) from e cylinder. Repla ce the se aling washer (F) u pon
th reassembly.
9923523 - 2012 RANGER RZR 570 Service Manual
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3.37
ENGINE / COOLING SYSTEM
G H
I
J
3. Remove the (2 ) bo lts r etaining th e fixed cam chain guide (G) and remove the assembly from the engine. Inspect the guide for wear and replace if necessary.
4. Remove th e re maining (6 ) b olts t hat r etain th e camshaft carrier (H) and carefully lift the carrier off the camshafts.
6. Mark the intake ( I) an d exha ust (J) camsh afts to e proper assembly.
ensur
7. Lift up ward on the intake ca mshaft wh ile r otating it
ounter-clockwise. Walk the timing chain off of th e
c sprocket. Carefully remove the intake camshaft from the engine.
8. Remove the cam chain fro m the exha ust ca mshaft
rocket (J) and remove the exhaust camshaft from
sp the engine.
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 revent it from dropping down into the engine.
p
3.38
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ENGINE / COOLING SYSTEM
= T
Inspect
Sprocket Teeth
Replace if
Worn or Damaged
= In. / mm.
Camshaft Sprocket Inspection
NOTE: Camshaft sprocket removal is n ot necessary unless the replacement of the sprockets is required.
Inspect cam sprocket teeth for wear timing chain and sprockets as a set if worn or damaged.
IMPORTANT: Replace camshaft sprocket bolts if they are loosened or removed.
or damage. Replace
Camshaft / Camshaft Bore Inspection
Inspect a ll main journals a nd cam lo bes as de scribed below and compare to specifications. 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 lobe from the base cle to highest point on the lobe using a micrometer.
cir Compare to specification.
NOTE: Replace camshafts if damaged or if any part
worn past the service limit.
is
3
Camshaft Sprocket Bolts:
15 ft. lbs. (20 Nm)
Camshaft Lobe Height:
Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
3. Visually insp ect each camsha ft journal for sco ring,
wear or damage.
4. Measure the diameter of the camshaft journals using
micrometer. Compare to specification.
a
3.39
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ENGINE / COOLING SYSTEM
= In. / mm.
= T
= In. / mm.
= In. / mm.
NOTE: Replace camshafts if damaged or if any part is worn past the service limit.
Camshaft Journal O.D. Standard:
0.9029” - 0.9037” (22.933 - 22.954 mm)
Service Limit:
0.9025” (22.923 mm)
5. Temporarily install the camshaft carriers to measure camsha ft b ore. To rque b olts in sequence to
the specification.
6. If the camshaft journal bo re is found to be ou t of ecification, re placement o f th e cylin der head
sp assembly is required.
NOTE: Replace cy linder he ad if camshaft jour nal
s are damaged or if worn past the service limit.
bore
Camshaft Journal Bore I.D. Standard:
0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft Carrier Bolts:
7.5 ft. lbs. (10 Nm)
Service Limit: 0.9072" (23.044 mm)
7. Calculate o il cle arance by su btracting ca mshaft
journal O.D.s fro m camshaft car rier bor e I.D.s. Compare to specification.
Calculated Camshaft Oil Clearance:
0.0018" - 0.0034" (.046 - .088 mm)
Service Limit: .0047" (.121 mm)
3.40
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ENGINE / COOLING SYSTEM
Return Spring
Retaining Ring
Pivot
Decomp. Cam and Pin
= T
9 ft. lbs
(12 Nm)
Exhaust Camshaft Decompression Mechanism
NOTE: Removal of t he d ecompression mec hanism is not necessary unless replacement is required.
1. Thoroughly cle an an d inspe ct the de compression chanism located on the exhaust camshaft.
me
2. Replace th e decom pression assemb ly if any
cessive wear or binding is evident.
ex
Cam Chain and Guide Service
NOTE: The cra nkcase has a remov able lowe r cam 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 cam
hain tensioner ca n b e re placed wit h t he eng ine
c installed in the vehicle.
1. If no t a lready pe rformed, re move th e va lve cov er, cover , flywhe el, cam chain tensioner, cam
stator carrier and camshafts as outlined in this chapter.
2. Remove the (2) fasteners that secure the cam chain
guides to
3. Remove the (2) fasteners that secure the lower cam
chain guide
4. Inspect all cam chain guides and replace if excessive
we
5. Upon installation, torque all
and reassemble engine and vehicle as outlined in this chapter.
the crankcase.
to the crankcase.
ar is evident.
fasteners to specification
3
3. Be sure th e de compression me chanism fu nctions thly and easily returns under spring pressure to
smoo the resting position against gravity.
Tension Blade and Guides:
9 ft. lbs. (12 Nm)
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3.41
© Copyright 2011 Polaris Sales Inc.
ENGINE / COOLING SYSTEM
A
C
B
D
WA RN I N G
F
G
PV-43513-A
Cylinder Head Removal
NOTE: The cy linder hea d ca n be se rviced with the engine installed in the chassis.
IMPORTANT: Do not rotate hea d assembly up side-
wn until the valve buck ets and shims hav e been
do removed.
1. Remove and discard the (2) outer M6 bolts (A) tha t etain the cylinder head (B) and the cylinder.
r
2. Loosen the (4) cylinder head bolts (C) evenly 1/8 turn 60 degrees) at a time until all are loose.
(
3. Remove an d d iscard the cylin der h ead bo lts ( C).
Replace with new upon assembly.
4. Tap cylinder he ad lightly with a so ft faced hammer
til loose. Tap only in re inforced areas or on th ick
un parts of the cylinder head casting.
5. Remove the cylinder head (B) and head gasket (D).
Cylinder Head Disassembly
Wear eye protection during cylinder head
disassembly and reassembly or when working
with the valve springs.
IMPORTANT: Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes. It is important to install cylinder head components b ack in the same lo cation. M ark each component or place them in an organized rack as you remove them.
1. Remove the valve bu cket ( F) an d a djustment shim G) from the cylinder head.
(
2. Compress the valve spring by hand using valve spring
mpressor adapter (PV-43513-A).
co
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ENGINE / COOLING SYSTEM
H
I
J
L
K
M
= In. / mm.
To p
Bottom
3. Push down on the spring and remove the split keepers (H).
9. Measure the free length of each valve spr ing with a Vernier caliper and compare to specification.
3
Valve Spring Free Length:
Standard: 1.7263" (43.85 mm)
Service Limit: 1.6830" (42.75 mm)
4. Slowly release valve spring pressure and remove the ressor adapter.
comp
5. Remove the valve retainer (I), valve spring (J), valve
stem se valve seal.
NOTE: Replace valve seals wh enever cylinder head is disa will cause excessive oil consumption.
6. Lift up the cylinder head and push the valve (M) out,
ke guide.
7. Repeat the pr evious steps to re
valves.
8. Clean the co mbustion ch amber and he ad g asket
surf
al (K) and valve spring seat (L). Discard the
ssembled. Harde ned, cr acked or worn s eals
eping it in order for reassembly in the same valve
ace.
move the re maining
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ENGINE / COOLING SYSTEM
CA U T I ON
= In. / mm.
E
Cylinder Head Inspection
Thoroughly clea n cylinde r h ead sur face to r emove a ll traces of gasket material and carbon.
Use care not to damage gasket sealing surface. All gasket surfaces must be clean, dry and free
of any oil or grease upon assembly. Clean
sealing surfaces with rubbing alcohol or
electrical contact cleaner. Do not touch sealing
surfaces of the new head gasket.
Cylinder Head Warp Inspection
1. Lay a s traight ed ge ( E) ac ross the s urface of th e cylinder head at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel or brush.
2. Check valve face fo r exce s burnt spots.
3. To chec k for bent v alve st em blocks and measure with a dial indicator.
sive runout, pit ting, a nd
s, mo unt va lve in “V ”
4. Check the end of the valve stem for flaring, pitti ng, wear or damage.
Cylinder Head Warp Limit:
.0024" (0.06 mm)
5. Inspect split keeper groove for wear or flaring in th e keeper seat area.
NOTE: The valves can be re-faced or end ground, if
essary. T hey mu st be re placed if e xtensively
nec worn, burnt, bent or damaged.
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ENGINE / COOLING SYSTEM
= In. / mm.
= In. / mm.
WA RN I N G
Combustion Area
6. Measure diameter of valve stem with a micrometer in three places, then rotate 90° and measure again (take six measurements total). Compare to specifications.
Valve Stem Diameter:
Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)
Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)
7. Measure valve guide inside dia and end of the guide using a small hole gauge and a micrometer. Measure in two directions.
meter at the top middle
Combustion Chamber Cleaning
Wear eye protection during combustion
chamber cleaning.
1. Clean a ll accumulated car bon dep osits fro m combustion chambers and valve seat area.
NOTE: Carbon Clean Fu el Tre atment (2 871326) can
e used to help remove carbon deposits.
b
3
Valve Guide I.D.:
0.2165" - 0.2171" (5.500 - 5.515 mm)
8. Be su re to mea sure each guide a nd valve combination indiv
NOTE: The valve guides cannot be replaced.
idually.
IMPORTANT: Do not u se a met al scr aper, a co arse
brush or abrasive cleaners to clean the cylinder
wire head. Damage may result.
2. Visually inspe ct cylinde r head g asket su rface and bustion chamber for cracks or damage. Pay close
com attention to the ar eas a round sp ark p lug and va lve seats.
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ENGINE / COOLING SYSTEM
WA RN I N G
A
Valve Seat Reconditioning
Valve se at reconditioning should be pe rformed by a technician pr oficient in cylinder hea d reco nditioning techniques. Reconditioning techniques vary, so follow the instructions pr ovided by the valve reco nditioning equipment m anufacturer. D o not grind seats more t han necessary t o provide p roper seat su rface, w idth, and contact point on valve face.
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt spots,
oughness, a nd u neven sur face. If a ny of the a bove
r conditions exist, the valve seat must be reconditioned. If
the valve seat is cracked the cylinder head must be replaced.
Valve seat width and point of contact on the valve face is
y important for proper sealing. The valve must contact
ver the valve seat over the entire c ircumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too n arrow, heat tr ansfer from va lve to seat is r educed. The valve may over heat an d warp , r esulting in burnt valves.
* If the contact area is less than 75% of the circumference
seat, rotate the pilot 180° and make another light cut.
of the
* If the cutter now contacts the uncut portion of the sea t, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.
* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation.
* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident.
NOTE: Remove on ly t he a mount o f material
essary to repair the seat surface.
nec
5. To ch eck the con tact area of the seat on the valve ce, apply a thin coating of Prussian Blue paste to the
fa valve seat. If using an interference angle (46°) apply black p
6. Insert valve into guide and tap v
a few times.
ermanent marker to the entire valve face (A).
alve lightly into place
Renewing Valve Seats
1. Install pilot into valve guide.
2. Apply cutting oil to valve seat and cutter.
3. Place 46° cutter on the pilot and make a light cut.
4. Inspect the cut area of the seat:
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7. Remove valve an d check where the Pru ssian Blu e
indicate seat should co ntact th e middle of th e valve face or slightly above, and must be the proper width.
* If the indicated seat contact is at the face and contacts the margin area (B) it is too high on the
valve face. Use the 30° cutter to lower the valve seat.
* If too lo w, use the 60° cutter to raise th e seat. When contact area is centered on the valve face, measure seat width.
* If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.
* If the seat is too narrow, widen using the 45° cutter and
check contact p oint on the valve face and seat width
re­after each cut.
s seat contact o n the valve face . The valve
top edge of the valve
ENGINE / COOLING SYSTEM
B
A
Proper Seat Contact
on Valve Face
INTAKE
Seat Width
.039” (1.00 mm)
60°
45°
30°
= In. / mm.
EXHAUST
Seat Width
.059” (1.50 mm)
60°
45°
30°
NOTE: When us ing a n int erference a ngle, t he seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A).
Intake Seat Cutter Diameter: 1.567 in. (39.80 mm)
Exhaust Seat Cutter Diameter: 1.364 in. (34.65 mm)
3
Valve Seat Width:
Intake: .0393" (1.00 mm)
Service Limit: .0551" (1.4 mm)
8. Clean all filings from the area with hot s oapy water. Rinse and dry with compressed air.
9. Lubricate valve guides with clean engine oil and apply oil or water based lapping compound to the face of the valve.
NOTE: Lapping is no t req uired if an interference
ngle reconditioning method is used.
a
10. Insert the valve into its respective guide and lap using
lapping tool or a section of fuel line connected to the
a valve stem.
11. Rotate th e va lve rapidly ba ck and fo rth un til th e cu t
unds smooth. Lift the valve slightly off of the seat,
so rotate 1/4 turn, and repeat the lapping process. Do this four to f ive times until t he valve is fully seated, and repeat process for the other valves.
12. Thoroughly clean cylinder head and valves.
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
Exhaust: .0
Service Limit: .0758" (1.9 mm)
590” (1.50 mm)
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ENGINE / COOLING SYSTEM
1/2” Down From Top of Cylinder
1/2” Up From Bottom
X
X
X
Y
Y
Y
Cylinder Removal
1. Remove and discard the head gasket.
2. Position the cam chain and guides vertically.
3. Tap cylin der lig htly with a p lastic h ammer in th e reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from the
ankcase, supporting piston and connecting rod.
cr
5. Remove the cylinder from the engine.
Cylinder Inspection
1. Remove all gasket material from the cylinder sealing surfaces.
2. Inspect the top of the cylinder for war page using a
ight edge and feeler gauge.
stra
Cylinder Warpage:
.00098” (.025 mm)
6. Remove and discard cylinder base gasket.
3. Inspect cylinder for wear, s
4. Inspect cylinder for ta per an d ou t o f r ound with a te
lescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1 /2" down from top, in the middle, and 1/2” up from bottom).
cratches, or damage.
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9923523 - 2012 RANGER RZR 570 Service Manual
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