Polaris RZR 570 (2013) Service manual

Page 1

2013-2016 RZR 570

Service Manual

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 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 procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop 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 have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

FOREWORD

technicians in a properly

Publication Printed March 2016 (PN 9926813 R04)

© Copyright 2016 Polaris Industries 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. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. 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.

Page 2

UNDERSTANDING SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE

NOTE provides key information by clarifying instructions.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

Page 3

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 Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

REVISION INDEX

REV DATE

R01 10/01/2015

R02 12/15/2015

R03 12/30/2015

2/29/2016

R04

3/22/2016

CHANGES

Initial release

Updated Spark Plug spec information

• Revised cylinder head bolt torque to be based on bolt color instead of model year

• Reworded Oil Change procedure

Clarified CAN system testing

• Clarified wheel lug nut torque differences

• Updated EBS and non-EBS Driven Clutch procedures

Page 4

Page 5

2013-2016 RZR 570

Service Manual

Chapter Summary

CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: MAINTENANCE

CHAPTER 3: ENGINE / COOLING SYSTEM

CHAPTER 4: FUEL SYSTEM

CHAPTER 5: PVT SYSTEM

CHAPTER 6: TRANSMISSION

CHAPTER 7: FINAL DRIVE

CHAPTER 8: STEERING / SUSPENSION

CHAPTER 9: BRAKE SYSTEM

CHAPTER 10: BODY / FRAME

CHAPTER 11: ELECTRICAL

Page 6

Page 7

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL SPECIFICATIONS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

2013 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

2013 RANGER RZR 570 LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

2013 RANGER RZR 570 INTL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

2014 RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

2014 RZR 570 LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

2015 RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16

2015 RZR 570 LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

2016 RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20

2016 RZR 570 LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24

MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24

CONVERSION TABLE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.27

STANDARD BOLT TORQUE SPECIFICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28

METRIC BOLT TORQUE SPECIFICATION... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.29

DECIMAL EQUIVALENTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.1

Page 8

GENERAL INFORMATION

VEHICLE IDENTIFICATION

MODEL NUMBER DESIGNATION

Beginning with the 2014 model year, all RZR model numbers begin with “Z”. 2014 Example: Z14VH57AD

GROUP

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th

Z 1 4 V H 5 7 A D

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

MODEL

YEAR

CHASSIS

DRIVE-

LINE

ENGINE /

MOTOR CODE

CATEGORY OPTION REGION

MODEL NUMBER DESIGNATION (2015 +)

Example: R15RUE57AC

GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**

R 1

R U E

A C

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

Example: 4XAJT87A0C3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

WORLD MFG. ID

CHASSIS

DRIVELINE

ENGINE SIZE

ENGINE MODIFIER

CATEGORY

CHECK DIGIT

MODEL YEAR *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A J T 8 7 A 0 C 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014

1.2

INDIVIDUAL SERIAL NO.

MFG. LOCATION

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 9

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

Example: 4XARUE573FG000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

GENERAL INFORMATION

WORLD MFG. ID

CHASSIS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R U E 5 7 3 F G 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016

CHASSIS

DRIVELINE

MODIFIER

ENGINE SIZE

CHECK DIGIT

MODEL YEAR *

ENGINE MODIFIER

MFG. LOCATION

INDIVIDUAL SERIAL NO.

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.3

Page 10

GENERAL INFORMATION

VEHICLE INFORMATION

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. (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’S MANUAL PARTS MANUAL

2013 RZR 570 R13VH57AD

2013 RZR 570 LE R13VH6EAK

2013 RZR 570 International R13VH57FX 9924198

2014 RZR 570 Z14VH57AD

2014 RZR 570 LE Z14VH6EAI

2015 RZR 570 Z15VHA57AJ

2015 RZR 570 EPS

2015 RZR 570 EU Z15VHA57FJ 9925856

2016 RZR 570 Z16VHA57A2

2016 RZR 570 EPS Z16VHE57AK

2016 RZR 570 EU Z16VHA57FJ 9926383

Z15VHE57AK Z15VHE57AS

9924102

9924710 9924711

9925470

9926398

NOTE

Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.

9924103

9925683

9926399

1.4

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 11

GENERAL INFORMATION

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.

Bosch Automotive Service Solutions 1-800-328-6657 or www.polaris.service-solutions.com

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.5

Page 12

GENERAL INFORMATION

GENERAL SPECIFICATIONS

2013 RANGER RZR 570

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 962 lbs. / 436 kg

Front Storage Capacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

N/A

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.6

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 13

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 460 Watts @ 3000 RPM

Headlights 2 - Halogen: Single Beam 55W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.25 gal. (27.4 liters) 87 Octane (minimum)

Electric Start

ECU Controlled RG6YC / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

EFI: 30 Amp Chassis: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

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

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 ml)

Polaris AGL 44 oz. (1300 ml)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

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

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.7

Page 14

GENERAL INFORMATION

2013 RANGER RZR 570 LE

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 999 lbs. / 453 kg

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.8

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 15

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 460 Watts @ 3000 RPM

Headlights 2 - Halogen: Single Beam 55W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.25 gal. (27.4 liters) 87 Octane (minimum)

Electric Start

ECU Controlled RG6YC / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

EFI: 30 Amp Chassis: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

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

CLUTCH SETTINGS Altitude

Meters (Feet)

1800-3700

(6000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 41 oz. (1200 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

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

Shift Weight Drive Spring

0-1800

(0-6000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.9

Page 16

GENERAL INFORMATION

2013 RANGER RZR 570 INTL

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 1001 lbs. / 454 kg

Front Storage Capacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

N/A

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.10

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 17

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 460 Watts @ 3000 RPM

Headlights (INTL)

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

INTL Features

Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.25 gal. (27.4 liters) 87 Octane (minimum)

2 - Halogen: 55W Low / 60W High

Turn Signals, Rear Diff. Control, Horn, Lic. Plate Light

Electric Start

ECU Controlled RG6YC / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

EFI: 30 Amp Chassis: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

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

CLUTCH SETTINGS Altitude

0-1500

Meters (Feet)

(0-5000)

1500-3700 (5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 41 oz. (1200 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (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

Shift Weight Drive Spring

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.11

Page 18

GENERAL INFORMATION

2014 RZR 570

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 962 lbs. / 436 kg

Gross Vehicle Weight 1719 lbs. (780 kg)

Test GVW - Rollover Protection System (ROPS)

Front Storage Capacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

1745 lbs. (791.5 kg) per OSHA 29 CFR 1928.53

N/A

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.12

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 19

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 650 Watts @ 7000 RPM

Headlights 2 - Halogen: Single Beam 55W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.0 gal. (26.5 liters) 87 Octane (minimum)

Electric Start

ECU Controlled RG6YC / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

Engine Control: 30 Amp Chassis: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

Toe Out

WHEELS / BRAKES

Front Wheel Size Front Tire Type / Size

Rear Wheel Size Rear Tire Type / Size

Tire Pressure ONE RIDER

Tire Pressure TWO RIDERS

Brake - Front / Rear

Brake Fluid DOT 4

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 44 oz. (1300 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

12 x 6 / Steel Ancla / 25 x 8 R12

12 x 8 / Steel Ancla / 25 x 10 R12

Front: 7 psi (48 kPa) Rear: 9 psi (62 kPa)

Front: 8 psi (55 KPa) Rear: 10 psi (69 KPa)

Foot Actuated - 4 Wheel Hydraulic Disc

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.13

Page 20

GENERAL INFORMATION

2014 RZR 570 LE

CATEGORY DIMENSION / CAPACITY

Length

Width 50″/ 127 cm Height

Wheel Base 77″ / 196 cm Ground Clearance 10″ / 25.4 cm Dry Weight 999 lbs. (453 kg)

Gross Vehicle Weight 1719 lbs. (780 kg)

Test GVW - Rollover Protection System (ROPS)

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

1745 lbs. (791.5 kg) per OSHA 29 CFR 1928.53

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.14

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 21

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 650 Watts @ 7000 RPM

Headlights

Tail / Brake

Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.0 gal. (26.5 liters) 87 Octane (minimum)

2 dual beam, 6-LED cluster, 40w High / 27w Low

2 single beam, 6W / 2 single beam, 27W

Electric Start

ECU Controlled RG6YC / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

Engine Control: 30 Amp Chassis: 30 Amp EPS: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

Toe Out

WHEELS / BRAKES

Front Wheel Size Front Tire Type / Size

Rear Wheel Size Rear Tire Type / Size

Tire Pressure ONE RIDER

Tire Pressure TWO RIDERS

Brake - Front / Rear

Brake Fluid DOT 4

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 41 oz. (1200 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

12 x 6 / Steel Ancla / 25 x 8 R12

12 x 8 / Steel Ancla / 25 x 10 R12

Front: 7 psi (48 kPa) Rear: 9 psi (62 kPa)

Front: 8 psi (55 KPa) Rear: 10 psi (69 KPa)

Foot Actuated - 4 Wheel Hydraulic Disc

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.15

Page 22

GENERAL INFORMATION

2015 RZR 570

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 962 lbs. / 436 kg

Gross Vehicle Weight 1719 lbs. (780 kg)

Test GVW - Rollover Protection System (ROPS)

Front Storage Capacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

1745 lbs. (791.5 kg) per OSHA 29 CFR 1928.53

N/A

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.16

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 23

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 650 Watts @ 7000 RPM

Headlights 2 - Halogen: Single Beam 55W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.0 gal. (26.5 liters) 87 Octane (minimum)

Electric Start

ECU Controlled NGK MR7F / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

Engine Control: 30 Amp Chassis: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

Toe Out

WHEELS / BRAKES

Front Wheel Size Front Tire Type / Size

Rear Wheel Size Rear Tire Type / Size

Tire Pressure ONE RIDER

Tire Pressure TWO RIDERS

Brake - Front / Rear

Brake Fluid DOT 4

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 44 oz. (1300 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

12 x 6 / Steel Ancla / 25 x 8 R12

12 x 8 / Steel Ancla / 25 x 10 R12

Front: 7 psi (48 kPa) Rear: 9 psi (62 kPa)

Front: 8 psi (55 KPa) Rear: 10 psi (69 KPa)

Foot Actuated - 4 Wheel Hydraulic Disc

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.17

Page 24

GENERAL INFORMATION

2015 RZR 570 LE

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 999 lbs. (453 kg)

Gross Vehicle Weight 1719 lbs. (780 kg)

Test GVW - Rollover Protection System (ROPS)

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

1745 lbs. (791.5 kg) per OSHA 29 CFR 1928.53

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.18

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 25

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 650 Watts @ 7000 RPM

Headlights

Tail / Brake

Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.0 gal. (26.5 liters) 87 Octane (minimum)

2 dual beam, 6-LED cluster, 40w High / 27w Low

2 single beam, 6W / 2 single beam, 27W

Electric Start

ECU Controlled NGK MR7F / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

Engine Control: 30 Amp Chassis: 30 Amp EPS: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

Toe Out

WHEELS / BRAKES

Front Wheel Size Front Tire Type / Size

Rear Wheel Size Rear Tire Type / Size

Tire Pressure ONE RIDER

Tire Pressure TWO RIDERS

Brake - Front / Rear

Brake Fluid DOT 4

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 41 oz. (1200 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

12 x 6 / Steel Ancla / 25 x 8 R12

12 x 8 / Steel Ancla / 25 x 10 R12

Front: 7 psi (48 kPa) Rear: 9 psi (62 kPa)

Front: 8 psi (55 KPa) Rear: 10 psi (69 KPa)

Foot Actuated - 4 Wheel Hydraulic Disc

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.19

Page 26

GENERAL INFORMATION

2016 RZR 570

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 962 lbs. / 436 kg

Gross Vehicle Weight 1719 lbs. (780 kg)

Test GVW - Rollover Protection System (ROPS)

Front Storage Capacity

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

1745 lbs. (791.5 kg) per OSHA 29 CFR 1928.53

N/A

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 336.4 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.20

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 27

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 650 Watts @ 7000 RPM

Headlights 2 - Halogen: Single Beam 55W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.0 gal. (26.5 liters) 87 Octane (minimum)

Electric Start

ECU Controlled NGK MR7F / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

Engine Control: 30 Amp Chassis: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

Toe Out

WHEELS / BRAKES

Front Wheel Size Front Tire Type / Size

Rear Wheel Size Rear Tire Type / Size

Tire Pressure ONE RIDER

Tire Pressure TWO RIDERS

Brake - Front / Rear

Brake Fluid DOT 4

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 44 oz. (1300 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

12 x 6 / Steel Ancla / 25 x 8 R12

12 x 8 / Steel Ancla / 25 x 10 R12

Front: 7 psi (48 kPa) Rear: 9 psi (62 kPa)

Front: 8 psi (55 KPa) Rear: 10 psi (69 KPa)

Foot Actuated - 4 Wheel Hydraulic Disc

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.21

Page 28

GENERAL INFORMATION

2016 RZR 570 LE

CATEGORY DIMENSION / CAPACITY

Length

Width 50″ / 127 cm

Height

Wheel Base 77″ / 196 cm

Ground Clearance 10″ / 25.4 cm

Dry Weight 999 lbs. (453 kg)

Gross Vehicle Weight 1719 lbs. (780 kg)

Test GVW - Rollover Protection System (ROPS)

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension (LxWxH)

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

107.5″ / 273.05 cm

69″ / 175.26 cm

1745 lbs. (791.5 kg) per OSHA 29 CFR 1928.53

20 x 40 x 9" (51 x 102 x 23 cm)

740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight)

1.22

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 29

GENERAL INFORMATION

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression 80 - 120 psi (decompression)

Engine Idle Speed

Engine Max RPM

Lubrication Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.25 qts. (4 L)

Exhaust System Single Headpipe / Single Silencer

FUEL SYSTEM

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure Fuel Filters In tank Fuel Capacity /

Requirement

ELECTRICAL

Alternator Output 650 Watts @ 7000 RPM

Headlights

Tail / Brake

Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing

Spark plug / Gap

Battery (RZR)

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fuses (Fuse/Relay

Box)

Fuses (Power Fuse Holder)

Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC

567cc

99 x 73.6 mm

10:1

1250 ± 100 RPM

7750 RPM Pressurized Wet Sump

Bosch M17 EFI

58 ± 2 psi (400 ± 14 kPa)

7.0 gal. (26.5 liters) 87 Octane (minimum)

2 dual beam, 6-LED cluster, 40w High / 27w Low

2 single beam, 6W / 2 single beam, 27W

Electric Start

ECU Controlled NGK MR7F / .0276 - .0315″

(.7 - .8 mm)

Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt

EFI / Chassis / Fan / Fuel Pump / Headlight

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp

Engine Control: 30 Amp Chassis: 30 Amp EPS: 30 Amp

DRIVETRAIN

Transmission Type

Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

STEERING / SUSPENSION

Front Suspension

Front Travel 9″ / 23 cm

Rear Suspension

Rear Travel 9.5″ / 24 cm Shock Preload

Adjustment

Toe Out

WHEELS / BRAKES

Front Wheel Size Front Tire Type / Size

Rear Wheel Size Rear Tire Type / Size

Tire Pressure ONE RIDER

Tire Pressure TWO RIDERS

Brake - Front / Rear

Brake Fluid DOT 4

CLUTCH SETTINGS Altitude

Meters (Feet)

1500-3700

(5000 - 12000)

Polaris Automatic PVT

In Line Shift - H / L / N / R / P

Polaris Demand Drive

6.75 oz. (200 mL)

Polaris AGL 41 oz. (1200 mL)

Independent Dual A-arm w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4″ (3 - 6.4 mm)

12 x 6 / Steel Ancla / 25 x 8 R12

12 x 8 / Steel Ancla / 25 x 10 R12

Front: 7 psi (48 kPa) Rear: 9 psi (62 kPa)

Front: 8 psi (55 KPa) Rear: 10 psi (69 KPa)

Foot Actuated - 4 Wheel Hydraulic Disc

Shift Weight Drive Spring

0-1500

(0-5000)

(5632409)

(5633217)

25-52

25-48

Black

(7043594)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.23

Page 30

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

MASTER TORQUE TABLE

ITEM

A-Arm Bolt

Ball Joint Pinch Bolts

(Front)

Bearing Carrier Nuts

(Rear)

Bearing Retaining Plate

Screws

Bell Crank Nut

Brake Disc Mounting Bolts

(Front)

Brake Disc Mounting Bolts

(Rear)

Brake Bleed Screws

Brake Caliper Mounting

Bolts (Front)

Brake Caliper Mounting

Bolts (Rear)

Brake Line Junction Block

Mounting Screws

Brake Line Banjo Bolts

(Master Cylinder and

Caliper Attachment)

Brake Line Flare Fittings 14 ft-lbs (19 Nm)

Brake Pedal Mount

Bracket Bolts

Brake Rotor Bolts

Brake Switch

Cab Frame Bolts

Cam Chain Tensioner

Camshaft Carrier Bolts

Camshaft Sprocket Bolts 14 ft-lb (19 Nm)

Clutch Cover (outer)

Screws

Clutch Spring Retaining

Ring Bolts

Coolant Bleed Screw

Coolant Temperature

Sensor

CPS Retaining Bolt 9 ft-lb (12 Nm)

Cylinder Head Bolts -

Black

TORQUE

39 ft-lb (53 Nm)

23 ft-lb (31 Nm)

40 ft-lb (54 Nm)

8 ft-lbs (11 Nm)

15 ft-lbs (20 Nm)

18 ft-lbs (24 Nm)

28 ft-lbs (38 Nm)

47 in-lbs (5 Nm)

30 ft-lbs (41 Nm)

44 ft-lbs (60 Nm)

36 in-lbs (4 Nm)

15 ft-lbs (20 Nm)

17 ft-lbs (23 Nm)

30 ft-lbs (41 Nm)

14 ft-lbs (19 Nm)

28 ft-lb (38 Nm)

30 ft-lb (40 Nm)

7.5 ft-lb (10 Nm)

100 in-lbs (12 Nm)

11 ft-lbs (15 Nm)

6 ft-lbs (8 Nm)

17 ft-lb (23 Nm)

Torque in sequence for all

steps

Step 1: 21 ft-lbs (28 Nm)

Step 2: 26 ft-lb (35 Nm)

ITEM

Cylinder Head Bolts -

Silver

Differential Cover Screws

Drive Clutch Retaining Bolt 47 ft-lbs (64 Nm)

Drive Clutch Cover Plate

Exhaust Head Pipe Bolts 18 ft-lb (25 Nm)

Front Gearcase Drain/Fill

(INTL)

Screw

Drive Clutch Spider

Driven Clutch Retaining

Bolt

Driven Clutch Cover

Screws

ECU Mounting Screws 10 in-lb (1 Nm)

Engine Mount (front) 40 ft-lbs (54 Nm)

Engine Oil Plug 12 ft-lbs (16 Nm)

Engine to Transmission

Coupler Bolts

Floor Screws

Flywheel Retaining Nut 133 ft-lbs (180 Nm)

Front Bumper / Fender

Screws

Front Gearcase Cover

Plate Screws

Plugs

(Apply 0.4 mL Loctite® 7088

Primer and 0.4 mL Loctite®

TORQUE

Step 3: Additional 135°

Torque The Outer M6 Head

Bolts 89 ± 9 in-lbs (10 ± 1

Nm)

Torque in Sequence for all

steps Step 1: 18 ft-lbs (25 Nm) Step 2: 30 ft-lbs (40 Nm)

Step 3: Loosen all

fasteners until they are

unseated Step 4: 15 ft-lbs (20 Nm) Step 5: 26 ft-lbs (35 Nm)

Step 6: Additional 180° Step 7: Additional 180°

Torque The Outer M6 Head

Bolts 89 ± 9 in-lbs (10 ± 1

Nm)

21 ft-lb (28 Nm)

100 in-lb (12 Nm)

225 ft-lb (305 Nm)

620™)

36 ft-lbs (49 Nm)

10 ft-lb (14 Nm)

55 ft-lbs (75 Nm) *see

procedure for illustration

5 ft-lb (7 Nm)

8 ft-ln (11 Nm)

9 ft-lbs (12 Nm)

10 ft-lbs (14 Nm)

1.24

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 31

GENERAL INFORMATION

ITEM

Front Gearcase Mounting

Bolts

Fuel Pump PFA Nut 70 ft-lbs (95 Nm)

Fuel Rail Mounting Screws 7 ft-lbs (10 Nm)

Fuel Tank Mounting

Screws

Gear Sector Cover

Hip Bolster Bolts 8 ft-lb (11 Nm)

Hose Clamp 36 in-lb (4 Nm)

IAC Mounting Screw 18 in-lbs (2 Nm)

Master Cylinder Mount

Bolts

Oil Filter

Oil Filter Adapter

Fasteners

Oil Pump Cover Bolts 7 ft-lbs (10 Nm)

Oil Pump Sprocket Bolts 9 ft-lbs (12 Nm)

Parking Brake Assembly

Bolts

Parking Brake Disc

Mounting Bolts

Parking Brake Disc

Mounting Bolts (INTL)

Park Flange Screws 8 ft-lbs (11 Nm)

Parking Brake Lever

Mounting Bolts

Parking Brake Mount

Bracket to Transmission

Bolts

Power Steering Bracket to

Frame Nuts

Power Steering Unit to

Mount Bracket

Prop Shaft Support

Bearing Fasteners

PVT Inner Cover Bolts

PVT Outer Cover Bolt

Seat Base to Seat Frame

Fasteners

Seat Base to Frame (front) 40 ft-lb (54 Nm)

Seat Base to Frame (rear) 40 ft-lb (54 Nm)

Seat Belt Mounting

Fasteners

Seat Belt to Seat Base

Shift Cable Bracket Bolts

Shock Mount Bolts

TORQUE

30 ft-lbs (41 Nm)

17 ft-lbs (23 Nm)

11 ft-lbs (15 Nm)

17 ft-lbs (23 Nm)

6 ft-lbs (8 Nm)

20 ft-lbs (28 Nm)

37 ft-lbs (50 Nm)

21 ft-lbs (28 Nm)

8 ft-lbs (11 Nm)

16 ft-lbs (22 Nm)

37 ft-lbs (50 Nm)

14 ft-lb (19 Nm)

30 ft-lb (42 Nm)

30-36 ft-lbs (41-49 Nm)

12 ft-lbs (16 Nm)

50 in-lbs (5 Nm)

40 ft-lbs (54 Nm)

17 ft-lbs (23 Nm)

37 ft-lb (50 Nm)

ITEM

Skid Plate Fasteners

Snorkel Tube

Snorkel Tube Locking

Screw

Spark Arrestor Fasteners 8 ft-lbs (11 Nm)

Spark Plug 9 ft-lbs (12 Nm)

Speed Sensor Screw 8ft-lbs (11 Nm)

Stabilizer Bushing

Retaining Nut

Stabilizer Bar Linkage

(rear)

Stabilizer Bar Mounting

Bracket Bolts (rear)

Starter Mounting Bolts 7 ft-lb (10 Nm)

Starter One-Way Clutch

Screws

Stator Cover Screws

Stator Wire Routing Bolts

Steering Tilt Shock

Fastener (Lower)

Steering Tilt Shock

Fastener (Upper)

Steering Pivot Tube

Fasteners

Steering Rack Mounting

Bolts

Steering Shaft to EPS Unit 16 ft-lbs (22 Nm)

Steering Shaft to Steering

Rack

Steering Wheel Nut 65 ft-lbs (88 Nm)

Thermostat Cover Bolts

Throttle Pedal Mounting

Fasteners

Tie Rod End Jam Nuts

Tie Rod End Fastener

T-MAP Retaining Bolt 24 in-lbs (2.8 Nm)

TPS Mounting Screws 18 in-lbs (2 Nm)

Transmission Bell Crank

Nut

Transmission Case Bolts

Transmission Drain / Fill

Plugs

Transmission Isolator

Bolts (Rear)

TORQUE

8 ft-lbs (11 Nm)

Refer to “Snorkel Gear

Backlash Procedure”

8 ft-lbs (11 Nm)

37 ft-lbs (50 Nm)

18 ft-lb (24 Nm)

9 ft-lbs (12 Nm)

Apply Loctite® 272™

9 ft-lb (12 Nm)

6 ft-lbs (9 Nm)

Apply Loctite® 242™

12 ft-lb (16 Nm)

7 ft-lbs (10 Nm)

23 ft-lb (31 Nm)

16 ft-lbs (22 Nm)

36 ft-lb (48 Nm)

7 ft-lbs (10 Nm)

8 ft-lb (11 Nm)

13 ft-lbs (18 Nm)

43 ft-lb (58 Nm)

15 ft-lb (20 Nm)

17 ft-lbs (23 Nm)

12 ft-lbs (16 Nm)

40 ft-lbs (54 Nm)

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.25

Page 32

GENERAL INFORMATION

ITEM

Transmission Rear Mount

Bracket Fasteners

Transmission Park Flange

Screws

Transmission Sector Gear

Cover

Transmission Shift Fork

Screws

Transmission Snorkel

Tube Locking Screw

Valve Cover Bolts

Voltage Regulator

Fasteners

Water Pump Cover Bolts

Wheel Hub Castle Nuts

(Front)

Wheel Hub Castle Nuts

(Rear)

Wheel Lug Nuts

TORQUE

17 ft-lb (23 Nm)

8 ft-lb (11 Nm)

11 ft-lb (15 Nm)

8 ft-lb (11 Nm)

9 ft-lbs (12 Nm)

75 in-lb (6 Nm)

9 ft-lb (12 Nm)

(Apply Loctite® 204™ to bolt

threads)

80 ft-lb (108 Nm)

110 ft-lbs (149 Nm)

Steel Rims: 27 ft-lbs (37

Nm)

Aluminum Rims: 30 ft-lbs

(41 Nm) + 90°

1.26

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 33

GENERAL INFORMATION

CONVERSION TABLE

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs

in-lbs x 0.0833 = ft-lbs

ft-lbs

in-lbs x 0.0115 = kg-m

Nm x 0.7376 = ft-lbs

kg-m x 7.233

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi)

km x 0.6214 = mile

ounces (oz)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

grams (g)

pounds (lb) x 0.454 = kg

kilogram (kg)

cubic inches (cu in)

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

liters (L)

US gallons x 3.785 = liters (L)

liters (L)

PSI

kilopascals (kPa) x 0.145 PSI

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x 12 = in-lbs

x 1.356 = Nm

= ft-lbs

= mm

x 0.03937 = inch

= cm

x 1.6 = km

x 28.35

x .03381

x 0.035

x 2.2046 = lbs

x 16.387

x 0.946

x 1.057

x 0.264

x 6.895

= grams (g)

= fluid ounces

= ounces

= cc

= liters (L)

= US quarts

= US gallons

= kilopascals (kPa)

= cylinder volume

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.27

Page 34

GENERAL INFORMATION

STANDARD BOLT TORQUE SPECIFICATION

BOLT SIZE

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

GRADE 2

FT-LB (NM)

5 (7) 8 (11) 12 (16)

6 (8) 10 (14) 14 (19)

11 (15) 17 (23) 25 (35)

12 (16) 19 (26) 29 (40)

20 (27) 30 (40) 45 (62)

23 (32) 35 (48) 50 (69)

30 (40) 50 (69) 70 (97)

35 (48) 55 (76) 80 (110)

50 (69) 75 (104) 110 (152)

55 (76) 90 (124) 120 (166)

METRIC BOLT TORQUE SPECIFICATION

BOLT

SIZE

M10

M12

M14

M16

M18

4.6 4.8 8.8 / 8.9 10.9 12.9

0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)

0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

26 (35) 33 (45) 63 (85) 97 (130) 111 (150)

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

GRADE 5

FT-LB (NM)

GRADE

FT-LB (NM) DRY THREADS

GRADE 8

FT-LB (NM)

1.28

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 35

GENERAL INFORMATION

SAE TAP / DRILL SIZES

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64 50 5/8–11 17/32

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

#8–32

#8–36

#10–24

#10–32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

7/16–20 25/64

F 2–12

U 3–4

THREAD

SIZE DRILL SIZE

1/2–20 29/64

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

7/8–14 13/16

1 1/8–7 63/64

1 1/8–12 1 3/64

1 1/4–7 1 7/64

1 1/4–12 1 11/64

1 1/2–6 1 11/32

1 3/4–12 1 43/64

2–4 1/2 1 25/32

2 1/4–4 1/2 2 1/32

1 59/64

2 3/4

METRIC TAP / DRILL SIZES

DECIMAL

TAP SIZE DRILL SIZE

3 x .50 #39 0.0995 3/32 3 x .60 4 x .70 4 x .75 5 x .80

5 x .90 #20 0.161 5/32 6 x 1.00 7 x 1.00 8 x 1.00 J 0.277 8 x 1.25 9 x 1.00 5/16 0.3125 5/16 9 x 1.25

10 x 1.25 11/32 0.3437 11/32 10 x 1.50 R 0.339 11 x 1.50 3/8 0.375 3/8 12 x 1.50 12 x 1.75

3/32

#30

1/8 0.125 1/8

#19

16/64

17/64

5/16

13/32 13/32

EQUIVA-

LENT

0.0937

0.1285

0.166

0.196

0.234

0.265

0.3125

0.406

NEAREST

FRACTION

3/32

1/8

11/64

13/64 15/64

9/32

17/64

5/16

11/32

13/32 13/32

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1.29

Page 36

GENERAL INFORMATION

DECIMAL EQUIVALENTS

FRACTION DECIMAL MM TO INCHES

1/64 1/32 3/64 1/16 0.0625″ 5/64 3/32 0.0938″ 7/64

1/8 0.1250″ 9/64 5/32 0.1563″ 4 mm = 0.1575″

11/64

3/16

13/64 0.2031″

7/32

15/64 0.2344″ 6 mm = 0.2362″

1/4

17/64 0.2656″ 7 mm = 0.2756″

9/32

19/64

5/16

21/64 11/32 23/64

3/8 0.375″

25/64 13/32 0.4063″ 27/64

7/16 0.4375″

29/64 15/32 31/64

1/2

33/64 0.5156″ 17/32 35/64 0.5469″ 14 mm = 0.5512″

9/16

37/64 19/32 0.5938″ 39/64

5/8 0.625″ 16 mm = 0.6299″

41/64 21/32 0.6563″ 17 mm = 0.6693″ 43/64 11/16 45/64 23/32

0.0156″

0.0312″ 1 mm = 0.0394″

0.0469″

0.0781″ 2 mm = 0.0787″

0.1094″ 3 mm = 0.1181″

0.1406″

0.1719″

0.1875″ 5 mm = 0.1969″

0.2188″

0.25″

0.2813″

0.2969″

0.3125″ 8 mm = 0.3150″

0.3281″

0.3438″ 9 mm = 0.3543″

0.3594″

0.3906″ 10 mm = 0.3937″

0.4219″ 11 mm = 0.4331″

0.4531″

0.4688″ 12 mm = 0.4724″

0.4844″

0.500″ 13 mm = 0.5118″

0.5313″

0.5625″

0.5781″ 15 mm = 0.5906″

0.6094″

0.6406″

0.6719″

0.6875″

0.7031″ 18 mm = 0.7087″

0.7188″

FRACTION DECIMAL MM TO INCHES

47/64

3/4 49/64 25/32 0.7813″ 20 mm = 0.7874″ 51/64 13/16 0.8125″ 21 mm = 0.8268″ 53/64 27/32 55/64

7/8 57/64 0.8906″ 23 mm = 0.9055″ 29/32 59/64 0.9219″ 15/16 61/64 0.9531″ 31/32 63/64 0.9844″

1 1.000″

0.7344″ 19 mm = 0.7480″

0.750″

0.7656″

0.7969″

0.8281″

0.8438″

0.8594″ 22 mm = 0.8661″

0.875″

0.9063″

0.9375″ 24 mm = 0.9449″

0.9688″ 25 mm = 0.9843″

1.30

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 37

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

BREAK-IN PERIOD.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

MAINTENANCE CHART KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

GREASE LUBRICATION POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

LUBRICANTS / SERVICE PRODUCTS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

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

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

ENGINE OIL AND FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

ENGINE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

ENGINE AND TRANSMISSION MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

COMPRESSION TEST SPECIFICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

COOLING SYSTEM .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

COOLING SYSTEM OVERVIEW... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

COOLING SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

COOLANT LEVEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

COOLING SYSTEM PRESSURE TEST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COOLANT STRENGTH / TYPE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

COOLANT DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

FUEL LINE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

THROTTLE PEDAL INSPECTION .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

ENGINE AND PVT INTAKE PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

AIR FILTER SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

PVT / FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

WHEEL INSTALLATION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.1

Page 38

MAINTENANCE

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

TRANSMISSION AND FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

SPECIFICATION CHART .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

TRANSMISSION LUBRICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

FRONT GEARCASE LUBRICATION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

STEERING INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

WHEEL TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

BRAKE SYSTEM ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

BRAKE PAD / DISC INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

PARKING BRAKE CABLE ADJUSTMENT (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

PARKING BRAKE PAD INSPECTION (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

SPARK PLUG SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36

2.2

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 39

PERIODIC MAINTENANCE CHART

MAINTENANCE

PERIODIC MAINTENANCE OVERVIEW

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.

NOTE

Service and adjustments are critical. If you’re not

familiar with safe service and adjustment procedures,

have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

MAINTENANCE 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 performed by an 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.

WARNING

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.

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.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• 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.

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.3

Page 40

MAINTENANCE

MAINTENANCE INTERVALS

MAINTENANCE INTERVAL

ITEM

Steering

■

Front Suspension

▶

Rear Suspension

▶

Tires

▶

Brake Fluid Level

▶

Brake Pedal Travel Brake Systems

Wheels / Fasteners Frame Fasteners

▶

Engine Oil Level

▶

Air Filter

Coolant Level

Head Lamp / Tail Lamp

▶

Air Filter

▶

Brake Pad Wear 10 H

■ Brake Pad Wear / Inspect

▶

Parking Brake Pads (INT’L)

■

Parking Brake Cable

▶

Adjustment (INT’L)

■

Battery

Front Gearcase Oil

▶

(Demand Drive)

Transmission - Main

▶

(AGL Gearcase Lubricant)

Engine Oil Change

▶

(Break-In Period)

■ Throttle Cable / Throttle Pedal 50 H 6 M

Throttle Body Air Intake Ducts

/ Flange

▶

General Lubrication 50 H 3 M

Shift Linkage

Steering

■

Front Suspension

▶

Rear Suspension

▶

Cooling System

■

Fuel System

■

Spark Plug

(WHICHEVER COMES FIRST)

HOURS CALENDAR

10 H

25 H

25 H 1 M

50 H 6 M

100 H 12 M

MILES

(KM)

Pre-Ride

Pre-Ride Pre-Ride Pre-Ride

Pre-Ride

Pre-Ride Pre-Ride

Pre-Ride

Daily

Weekly

Monthly 100 (160) Inspect periodically

- -

Monthly 250 (400)

Monthly 250 (400) Inspect level; change yearly

250 (400) Perform a break-in oil change at one month

300 (500) Inspect; adjust; lubricate; replace if necessary

300 (500) Inspect ducts for proper sealing / air leaks

500 (800) Lubricate all fittings, pivots, cables, etc.

500 (800) Inspect, lubricate, adjust

500 (800)

600 (1000)

600 (1000) Inspect; replace as needed

REMARKS

Make adjustments as needed. See Pre-Ride Checklist in this chapter.

Inspect; replace as needed

Check level daily, change coolant every 2 years

Check operation; apply dielectric grease if replacing

Inspect; replace as needed

Inspect; adjust tension after first 25 hours

Check terminals; clean; test

Lubricate

Inspect coolant strength seasonally; pressure test system yearly

Check for leaks at fill cap, fuel line / rail, and fuel pump. Replace lines every two years.

2.4

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 41

MAINTENANCE INTERVAL

ITEM

▶

Engine Oil & Filter Change

Parking Brake Cable

▶

Adjustment (INT’L)

■

Drive Belt 100 H 12 M

Radiator / Cooling Hoses

▶

Engine Assembly Mounts

▶

Exhaust Muffler / Pipe

Wiring

▶

Clutches (Drive and Driven)

■

Front Wheel Bearings

■

▶

Shocks 100 H

■

Brake Fluid 200 H 24 M

Spark Arrestor

▶

Shocks 500 H 12 M

■

■ Valve Clearance Check 500 H

Toe Adjustment

■

Headlight Aim

(WHICHEVER COMES FIRST)

HOURS CALENDAR

100 H 6 M

100 H 12 M

300 H 36 M

MILES

(KM)

1000 (1600)

1000 (1600) Inspect; adjust tension as needed

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect, torque to specification

1000 (1600) Inspect

1000 (1600)

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

-X

2000 (3200) Change every two years (DOT 4)

3000 (4800)

5000 (8050) Inspect / Adjust as needed

▶ 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.

MAINTENANCE

REMARKS

Perform a break-in oil change at 25 hours or one month / always replace oil filter when changing engine oil

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Visually inspect shock seals

Clean out

Change shock oil and seals

Inspect periodically; adjust when parts are replaced

Adjust as needed

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.5

Page 42

MAINTENANCE

MAINTENANCE QUICK REFERENCE

# ITEM LUBE REC. METHOD

Engine Oil

Engine Coolant

3 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Polaris PS-4 Performance Synthetic 4-Cycle Engine Oil

Polaris 50/50 Extended Life Coolant

Add oil to proper level on dipstick

Maintain coolant level in coolant reservoir bottle

Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir

FREQUENCY*

Change after 1st month or first 25 hours of operation, 100 hours thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation

Check level daily, change coolant every 2 years

Check level during pre-ride inspection; change fluid every two years

2.6

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 43

MAINTENANCE

# ITEM LUBE REC. METHOD

4 Front Gearcase Polaris Demand Drive

5 Transmission

* More often under severe use, such as operated in water or under severe loads.

Polaris AGL Gearcase Lubricant

Add lubricant until it is visible at the fill hole threads

FREQUENCY*

Check level every 25 hours; change fluid yearly

Check level every 25 hours; change lubricant yearly

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.7

Page 44

MAINTENANCE

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

Front Propshaft Yoke(s)

A-arm Pivot Bushings

Stabilizer Bar Bushings

Polaris Premium U-Joint Grease

Grease fittings every 500 miles (800 km).

FREQUENCY

Grease before long periods of storage, and after thoroughly washing or submerging the vehicle.

2.8

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 45

LUBRICANTS / SERVICE PRODUCTS

MAINTENANCE

PRODUCT SIZE (QUANTITY)

1 qt (12)

2 qt (8)

PS-4

PS-4 Extreme Duty

AGL

Demand Drive

Gas Shock Oil

Antifreeze / Coolant

Chain Lube

Fogging Oil

All Season Grease

U-Joint Grease

Carbon Clean

Fuel Stabilizer

1 gal (4)

16 gal keg 2876247

55 gal drum 2876246

1 qt (12) 2878920

2 qt (8)

1 gal (4) 2878919

16 gal keg 2879003

55 gal drum 2879002

330 gal tote 2879001

1 qt (12)

1 gal (4) 2878069

2.5 gal (2)

1 qt (12) 2877922

2.5 gal (2)

1 qt (6) 2870995

2.5 gal (2)

1 qt (12) 2880514

1 gal (6)

55 gal drum 2880512

16 oz aerosol (12) 2872348

12 oz aerosol (12)

1 qt (12) 2871517

Four 3 oz packs (6)

14 oz cartridge 2871423

3 oz tube (24) 2871515

14 oz cartridge 2871551

12 oz bottle (12)

16 oz (12) 2870652

2.5 gal (2)

PART NUMBER

2876244

2877490

2876245

2878922

2878068

2878070

2877923

2872279

2880513

2870791

2871322

2871326

2872280

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.9

Page 46

MAINTENANCE

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 operation 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 unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

• Check all front and rear suspension components for wear or damage.

FRAME, NUTS, BOLTS, AND FASTENERS

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

2.10

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 47

ENGINE

MAINTENANCE

ENGINE OIL LEVEL

This single cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below:

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 minutes.

NOTE

Do not run the machine and then immediately check the

4. Locate the engine oil dipstick

• Located on the right-hand side of the engine case;

accessible through the right-hand rear wheel well area.

5. Thoroughly clean the engine around dipstick area.

6. Unscrew / remove dipstick and wipe dry with a clean cloth.

7. Reinstall the dipstick completely.

oil level.

NOTE

Make certain the dipstick is threaded all the way into the

engine case.

8. Unscrew and remove dipstick and verify the oil level is in the SAFE (XX) range. Add oil as indicated by the level on the dipstick. Do not overfill (see NOTE below!).

NOTE

A rising oil level between checks in cool weather driving

can indicate contaminants such as gas or moisture

collecting in the crankcase. If the oil level is over the full

mark, change the oil 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.

NOTE

Thoroughly clean engine around the oil drain plug , oil

filter and oil dipstick to prevent contamination from

entering the engine.

WARNING

Personal injury can occur when handling used oil. Hot

oil can cause burns or skin damage.

Recommended Engine Oil:

PS-4 Synthetic 4-Cycle Engine Oil

2876244 - Quart

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

1. Position vehicle on a level surface.

2. Place the transmission in PARK (P).

3. If needed, start the engine and allow it to idle for three minutes until warm. Stop the engine.

2.11

Page 48

MAINTENANCE

4. Place a drain pan beneath engine crankcase and remove the drain plugw.

CAUTION

Oil may be hot. Do not allow hot oil to come into contact

5. Allow oil to drain completely.

6. Replace sealing washer on drain plug.

with skin, as serious burns may result.

NOTE

The sealing surface on the drain plug should be clean

7. Reinstall drain plug and torque to specification.

and free of burrs, nicks or scratches.

TORQUE

Crankcase Drain Plug:

12 ft-lbs (16 Nm)

8. Place a drain pan under vehicle below the oil filter

9. Place shop towels beneath oil filter. Using Oil Filter Wrench (PU-50105) and a 3/8” extension, turn the oil filter counter-clockwise to remove it.

Oil Filter Wrench:

PU-50105: 2.5″ (64 mm)

10. Using a clean dry cloth, clean filter sealing surface on the crankcase.

11. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.

12. Install new filter and tighten to specification.

TORQUE

Oil Filter:Turn by hand until filter gasket contacts

sealing surface, then turn an additional 3/4 turn.

13. Remove the engine oil dipstick

14. Add oil as necessary to bring the oil level to the

upper mark on the dipstick. Do not over fill the engine, the maximum oil capacity is 2 qts(1.9 l).

2.12

NOTE

The dipstick must be screwed completely in to ensure

15. Reinstall the upper fill cap (if removed) and tighten the dipstick.

16. Verify the transmission is still positioned in PARK (P).

17. Start the engine and let it idle for two minutes.

18. Stop the engine and inspect for leaks.

accurate measurement.

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 49

MAINTENANCE

19. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

20. Dispose of used oil and oil filter properly.

ENGINE BREATHER HOSE INSPECTION

The engine is equipped with a breather hoseq. Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the engine crankcase to the air intake baffle box on the left-hand rear fender panel.

ENGINE AND TRANSMISSION MOUNTS

Periodically inspect engine and transmission mounts for cracks or damage.

Refer to Chapter 3 “Engine Assembly and Installation” for mounting fastener torque values.

COMPRESSION TEST SPECIFICATION

NOTE

This engine has 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)

A leakdown test is a more accurate way to check for engine wear. Even with compression in the acceptable range, the engine may still have a worn cylinder/rings.

Cylinder Leakdown:

Less than 20%

NOTE

Make sure line is not kinked or pinched.

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.13

Page 50

MAINTENANCE

VALVE CLEARANCE INSPECTION

NOTE

Valve clearance inspection should be performed on a

cold engine, at room temperature.

1. Remove the seats and disconnect the negative (-) battery cable.

2. Remove the cargo box access panel.

3. Remove the spark plug wire from the engine and remove the spark plug. Place a clean shop towel into the spark plug tube to prevent debris from entering the combustion chamber.

4. Remove the three T40 bolts retaining the valve cover.

5. Remove the valve cover from the engine out of the right-hand rear wheel well area.

7. Rotate the drive clutch counter-clockwise until the cam chain sprocket timing marks are aligned with the gasket surface as shown (see Chapter 3 for more TDC setting procedures).

NOTE

Intake cam sprocket should have “I” marks aligned with

gasket surface and the exhaust cam sprocket should

have “E” marks aligned with gasket surface.

8. Measure the valve clearance of each valve using a thickness (feeler) gauge. Record the measurement if clearance is out of specification.

6. Remove the outer PVT cover and drive belt as shown in chapter 6.

2.14

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 51

MAINTENANCE

9. If the valve clearance is out of specification, proceed to Chapter 3 – Valve Clearance Check / Adjustment, page 3.63.

MEASUREMENT

Intake Valve Clearance (cold):

.006 ± .002″ (0.152 ± .050 mm)

MEASUREMENT

Exhaust Valve Clearance (cold):

.008 ± .002″ (0.203 ± .050 mm)

10. Repeat steps 8-9 until all four valves have been inspected.

11. Inspect the valve cover seal and replace if necessary.

12. Install the valve cover and spark plug as outlined in Chapter 3.

13. Install drive belt and outer clutch cover and eight retaining screws (see Chapter 6 – Belt Installation, page 5.12). Torque to specification.

TORQUE

Outer Clutch Cover Screws:

100 in-lbs (12 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 10) .

EXHAUST - SPARK ARRESTOR

WARNING

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

contains poisonous carbon monoxide gas that can

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 specification.

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

Spark Arrestor Fastener

8 ft-lbs (11 Nm)

Head Pipe Fasteners

18 ft-lb (25 Nm)

2.15

Page 52

MAINTENANCE

COOLING SYSTEM

COOLING SYSTEM OVERVIEW

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE

Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant

Overheating of engine could occur if air is not fully purged from system.

Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

COOLING SYSTEM EXPLODED VIEW

levels often during the break-in period.

2.16

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 53

MAINTENANCE

COOLANT LEVEL INSPECTION

The pressure capqand recovery bottleware located under the front hood of the vehicle. The coolant level must be maintained between the minimum and maximum levels indicated on the recovery bottle.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle. If not, perform the following 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.

4. If the coolant level is below the MIN line, inspect the coolant level in the radiator.

NOTE

If overheating is evident, allow system to cool

completely and check coolant level in the radiator and

inspect for signs of trapped air in system.

8. Fill recovery bottle to MAX level with Polaris 50/50 Extended Life Anti Freeze/Coolant as required for freeze protection in your area.

9. Reinstall the recovery bottle cap.

10. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating.

COOLING SYSTEM PRESSURE TEST

Refer to Chapter 3 for cooling system pressure test procedure.

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze hydrometer.

• A 50/50 mixture of antifreeze and distilled water will

provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight

water in the system. Tap water contains minerals and impurities which 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

WARNING

Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure

5. Remove the pressure cap. Using a funnel, add coolant to the top of the filler neck.

6. Reinstall the pressure cap.

cap.

NOTE

Use of a non-standard pressure cap will not allow the

recovery system to function properly.

7. Remove recovery bottle cap and add coolant using a funnel.

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

2.17

Page 54

MAINTENANCE

COOLING SYSTEM

1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

CAUTION

Do not over-tighten hose clamps at radiator, or radiator

fitting may distort, causing a restriction to coolant flow.

TORQUE

Radiator Hose Clamps:

36 in-lb (4 Nm)

2. Check tightness of all hose clamps.

COOLANT DRAIN

1. Remove the hood from the front cab.

WARNING

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 system pressure.

3. Place a suitable drain pan underneath the radiator fitting on the front right-hand side of the vehicle.

4. Drain the coolant from the radiator by removing the lower coolant hoseqfrom the radiator as shown. Properly dispose of the coolant.

6. Place a suitable drain pan underneath the lower engine hose vehicle.

7. Remove the hose and completely drain the engine. Reinstall the lower coolant hose.

8. Properly dispose of the coolant.

9. Remove the pressure cap. Using a funnel, add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level.

10. Refer to Chapter 3 for the “Cooling System Bleeding Procedure”.

on the right-hand rear side of the

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

5. Allow coolant to completely drain.

2.18

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 55

FUEL SYSTEM AND AIR INTAKE

MAINTENANCE

FUEL SYSTEM

WARNING

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 or near

the area where refueling is performed or where

gasoline is stored.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow

gasoline, seek medical attention immediately.

If you spill gasoline on your skin or clothing,

immediately wash it off with soap and water and

change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result in

loss of consciousness or death in a short time.

Never drain the fuel when the engine is hot. Severe

burns may result.

FUEL LINE

1. Check the quick-connect fuel lineqfrom the engine fuel rail connection to the fuel tank connection for signs of wear, deterioration, damage or leakage. Replace if necessary.

FUEL PUMP / FUEL FILTERS

The RZR 570 engine uses a serviceable, high-volume, high-pressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator.

NOTE

Neither filter is servicable individually. Must replace the

fuel pump as an assembly.

2. Be sure fuel line is routed and retained properly.

NOTE

Make sure line is not kinked or pinched.

3. Replace fuel line every two years.

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

Refer to Chapter 4 for fuel pump replacement and all

other information related to the EFI System.

2.19

Page 56

MAINTENANCE

VENT LINES

1. Check fuel tank, front transfer case and 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.

NOTE

Ensure lines are not kinked or pinched.

THROTTLE PEDAL INSPECTION

This vehicle is equipped with a Throttle Release Switch (TRS) used to detect when the throttle pedal has returned to the rest position.

NOTE

The throttle pedal lever is designed to have a few

degrees of freeplay prior to engaging the throttle arm

that pulls the throttle cable .

Always check that the throttle pedal moves independently of the cable pull lever at the start of throttle pedal travel and that the throttle pedal returns normally before starting the engine.

There should be minimal freeplay between the throttle cable and the cable pull lever. If there is excessive play due to cable stretch or incorrect adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle cable has no freeplay, the throttle may be hard to control, and the idle speed may be erratic.

THROTTLE FREEPLAY ADJUSTMENT

Inspection

1. Place the transmission in PARK.

2. Start the engine, and warm it up thoroughly.

3. Measure the distance the throttle arm (A) moves before the engine begins to pick up speed. Throttle cable freeplay should be 1/16 - 1/8″ (1.5 - 3 mm).

NOTE

The throttle pedal lever (B) is designed to have a few degrees of freeplay prior to engaging the throttle arm

(A) that pulls the throttle cable.

Adjustment

4. Remove the cargo box access panel to access the throttle body area.

Check throttle pedal freeplay periodically in accordance with the Periodic Maintenance Chart. Adjust the freeplay if necessary (see Chapter 2 – Throttle Freeplay Adjustment, page 2.20).

2.20

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 57

MAINTENANCE

5. Locate throttle cable on the left-hand side of the throttle body. Slide back the cable adjuster boot.

6. Using an open-end wrench, loosen the adjustment jam nut (A) . Using another open-end wrench, move the cable adjuster (B) until 1/16 to 1/8″ (1.5 - 3 mm) of free play is achieved at the throttle pedal.

NOTE

While adjusting, lightly move the throttle pedal in and

7. Re-tighten the jam nut after final adjustment is made.

8. Apply a small amount of grease to the inside of the boot original position.

9. Reinstall the cargo box access panel.

and slide it over the cable adjuster to its

out.

ENGINE AND PVT INTAKE PRE-FILTER SERVICE

It is recommended that the engine and PVT intake prefilter be inspected daily. The filter should be inspected using the following procedure:

NOTE

The engine and PVT intake pre-filter is located just

1. Press “IN” on the intake grill cover tabs remove the pre-filter cover.

2. Remove and inspect the pre-filtersw. If necessary, clean with soapy water and dry with compressed air.

above the left-rear wheel fender.

and

9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

3. Reinstall the dry pre-filters and install the pre-filter cover.

2.21

Page 58

MAINTENANCE

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 should be inspected using the following procedure:

Removal

NOTE

The air box is located underneath the cargo box access

panel.

4. Inspect the air filter element and replace if necessary. Do not attempt to clean the air filter.

NOTE

If the filter has been soaked with fuel or oil it must be

replaced.

Service more frequently if vehicle is operated in wet

conditions or at high throttle operation for extended

periods.

Installation

5. Clean the air box and air box cover thoroughly.

6. Place the filter into the air box with the air filter pleats facing UP, as shown.

1. Thoroughly clean the air box area to remove dirt and debris.

2. Loosen hose clamp (A) and remove the intake hose from the air box cover.

3. Unlatch the six clips and carefully remove the air box cover. Be sure not to let the air box cover contact the air filter element during removal.

7. Carefully install air box cover and secure with the six clips .

8. Reinstall the clean intake hose and tighten hose clamp (A).

9. Reinstall the cargo box access cover .

2.22

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 59

PVT / FINAL DRIVE / WHEEL AND TIRE

MAINTENANCE

WHEEL AND HUB TORQUE TABLE

TORQUE

Wheel Nuts:

Steel Rims: 27 ft-lbs (37 Nm)

Aluminum Rims: 30 ft-lbs (41 Nm) + 90°

TORQUE

Hub Castle Nuts:

Front:80 ft-lb (108 Nm)

Rear:110 ft-lbs (149 Nm)

NOTE

Do not lubricate the stud or the lug nut.

WHEEL REMOVAL

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P) and stop the engine.

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 a suitable stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and washers.

WHEEL INSTALLATION

1. Verify the transmission is still in PARK (P).

2. Install the wheel hub if previously removed.

3. Place the wheel wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

4. Attach the wheel nuts

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section.

7. If hub nut was removed, install a new cotter pin after the hub nut has been tightened and install dust capu.

, washersw, and hub nute,

in the correct position on the

and finger tighten them.

CAUTION

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.

2.23

Page 60

MAINTENANCE

TIRE INSPECTION

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect vehicle handling.

WARNING

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 measures 1/

8" (3 mm) or less.

Tire Tread Depth

Replace tires when tread depth is worn to 1/8" (3 mm) or less.

TIRE PRESSURE

CAUTION

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 front and rear drive shaft boots (Item 1) for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Check to see the boot clamps (Item 2) are properly positioned. Refer to for drive shaft boot replacement.

2.24

BELT INSPECTION

1. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt.

2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary.

3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes.

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 61

TRANSMISSION AND FRONT GEARCASE

SPECIFICATION CHART

MAINTENANCE

GEARCASE LUBRICANT CAPACITY

Transmission AGL Gearcase Lubricant

Transmission LE / INTL AGL Gearcase Lubricant

Front Gearcase Demand Drive

TRANSMISSION LUBRICATION

44 oz. (1300 ml) 12 ft-lbs (16 Nm)

41 oz. (1200 ml) 12 ft-lbs (16 Nm)

6.75 oz. (200 ml) 10 ft-lbs (14 Nm)

4. Reinstall the fill plug and torque to specification.

NOTE

It is important to follow the transmission maintenance

intervals described in the Periodic Maintenance Chart.

Regular lubricant level inspections should be performed

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the lubricant.

• Check vent hose to be sure it is routed properly and unobstructed.

Transmission Lubricant Level Check

The fill plug is located on the rear portion of the transmission gearcase. Access the fill plug at the rear of the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug

as well.

and check the lubricant level.

Transmission Lubricant Change

The drain plug transmission gearcase. Access the drain plug through the drain hole in the skid plate.

5. Remove the fill plug.

6. Place a drain pan under the transmission drain plug.

7. Remove drain plug and allow lubricant to drain completely.

8. Clean the drain plug magnetic surface.

9. Reinstall drain plug with a new O-ring and torque to specification.

10. Add the recommended amount of lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

FILL / DRAIN PLUG TORQUE

TORQUE

Fill / Drain Plug:

12 ft-lbs (16 Nm)

is located on the bottom of the

FLUID CAPACITY

Recommended Transmission Lubricant:

AGL Gearcase Lubricant

2878068 (Quart)

Capacity: 44 oz. (1300 ml)

Capacity: LE / INTL: 41 oz. (1200 ml)

3. If lubricant level is not even with the bottom threads, add the recommended lubricant as needed. Do not overfill.

11. Reinstall fill plug with a new O-ring and torque to specification.

TORQUE

Fill / Drain Plug:

12 ft-lbs (16 Nm)

12. Check for leaks. Dispose of used lubricant properly.

2.25

Page 62

MAINTENANCE

SHIFT CABLE INSPECTION / ADJUSTMENT

Shift cable adjustment may be necessary if symptoms include:

• No AWD or gear position display on instrument cluster

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear clash (noise)

• Gear selector moving out of desired range

1. Locate the shift cable area.

2. Inspect shift cable, clevis pinw, pivot bushings, and dust boote. Replace if worn or damaged.

3. If adjustment is required: Loosen outer jam nut and inner jam nuttso there is slack in the cable and neither jam nut touches the shift cable mount.

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 as required to obtain proper cable adjustment.

in the rear right wheel well

FRONT GEARCASE LUBRICATION

NOTE

It is important to follow the front gearcase maintenance

intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as

The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Front Gearcase Fluid Level Check

The fill plug is located on the bottom right side of the front 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

well.

and check the fluid level.

NOTE

This procedure may require a few attempts to obtain

the proper adjustment.

6. Once the proper adjustment is obtained, place the shift cable and inner jam nut into the mount. Tighten the outer jam nut against the mount.

7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service.

2.26

3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill.

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 63

MAINTENANCE

4. Reinstall the fill plug and torque to specification.

TORQUE

Fill / Drain Plug:

10 ft-lbs (14 Nm)

Front Gearcase Fluid Change:

The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase.

5. Remove the fill plug (refer to “Front Gearcase Fluid Level Check”).

6. Place a drain pan under the front gearcase drain plug.

7. Remove the drain plug and allow fluid to drain completely.

11. Reinstall fill plug with a new O-ring and torque to specification.

TORQUE

Fill / Drain Plug:

10 ft-lbs (14 Nm)

12. Check for leaks. Dispose of used fluid properly.

8. Clean the drain plug magnetic surface.

9. Reinstall drain plug with a new O-ring and torque to specification.

10. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.

FLUID CAPACITY

Recommended Front Gearcase Fluid:

Polaris Demand Drive

2877922 (Quart)

Capacity: 6.75 oz. (200 ml)

2.27

Page 64

MAINTENANCE

STEERING

STEERING INSPECTION

The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re– used. Always use new cotter pins.

Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

WARNING

Whenever steering components are replaced, check

front end alignment.

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.

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 should move freely through entire range of travel without binding.

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub/ wheel assembly by grasping 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.

2.28

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).

• Refer to Chapter 7 “Final Drive” for front hub service procedures.

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 65

MAINTENANCE

WHEEL TOE ALIGNMENT INSPECTION

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

NOTE

It is important the height of both marks be equally

positioned to get an accurate measurement.

WHEEL TOE ADJUSTMENT

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

3. Measure the distance between the marks and record the measurement. Call this measurement “A”.

4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8 to 1/4″ (3 to 6 mm) toe out. This means the measurement at the front of the tire (A) is 1/8 to 1/4″ (3 to 6 mm) wider than the measurement at the rear (B).

MEASUREMENT

Wheel Toe-Out:

(A) - (B) = 1/8 - 1/4" (3 to 6 mm)

NOTE

Be sure steering wheel is straight ahead before

determining which tie rod needs adjustment.

CAUTION

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.

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 required to achieve the proper toe setting as specified in “Wheel Toe Alignment”.

2.29

Page 66

MAINTENANCE

• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

• After alignment is complete, torque jam nuts to specification.

TORQUE

Tie Rod Jam Nut:

13 ft-lbs (18 Nm)

2.30

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 67

SUSPENSION

SPRING PRELOAD ADJUSTMENT

The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.

WARNING

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 level surface and stop the engine.

2. Raise and safely support the front or rear of the 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 adjustment cam clockwise to increase spring tension or counterclockwise to decrease spring tension.

Shock Spanner Wrench

2871095

MAINTENANCE

4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position.

2.31

Page 68

MAINTENANCE

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 should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed 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 should be between the MAX and MIN level lines

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches the MAX level line.

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

BRAKE PAD / DISC INSPECTION

1. Check the brake pads for wear, damage, or loosenessq.

2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material

is worn to .040″ (1 mm).

MEASUREMENT

Brake Pad Thickness

Service Limit: .040″ (1 mm)

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

6. The disc (s) should be replaced if thickness is less than .170″ (4.32 mm).

2.32

MEASUREMENT

Brake Disc Thickness

Service Limit: .170″ (4.32 mm)

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 69

MAINTENANCE

BRAKE HOSE AND FITTING INSPECTION

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

PARKING BRAKE CABLE ADJUSTMENT (INTL)

When the parking brake is fully engaged and “BRAKE” is displayed on the instrument cluster, engine speed is limited to 1500 RPM while in gear. If throttle is applied, this limiting feature prevents operation, which protects the parking brake pads from excessive wear.

NOTE

Inspect the parking brake cable tension after the first 25

hours of operation and every 100 hours of operation

afterwards to ensure proper cable tension.

Loss of tension in the parking brake cable will cause illumination of the parking brake indicator and activation of the limiting feature. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, temporarily disconnect the parking brake switch electrical connector. Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension.

1. Pull back on the parking brake lever (located in dash).

2. After 3 to 4 clicks “BRAKE” should display on the instrument cluster and the wheels of the vehicle should not rotate when turning by 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 parking brake cable where the cable attaches to the caliper mount / shift cable bracket. The mount bracket is located on the right-hand side of the transmission.

Adjustment Procedure: Refer to Chapter 9 “Brakes” for complete adjustment procedure.

PARKING BRAKE PAD INSPECTION (INTL)

Inspect the parking brake caliper brake pad thickness. Replace brake pads if damaged or worn beyond service limit. Replace caliper assembly if damage or excessive wear is found. Refer to the following image for brake pad specifications.

2.33

Page 70

MAINTENANCE

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 clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

WARNING

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.

WARNING

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: Drink large quantities of water or milk. Follow

with milk of magnesia, beaten egg, or vegetable oil. Call

physician immediately.

Eyes: Flush with water for 15 minutes and get prompt

medical attention.

Batteries produce explosive gases. Keep sparks, flame,

cigarettes, etc. away. Ventilate when charging or using

in an enclosed space. Always shield eyes when

working near batteries.

KEEP OUT OF REACH OF CHILDREN.

NOTE

Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery according to “Charging Procedure” provided in

Chapter 10. Do not use the vehicle’s stator/alternator to

charge a new battery.

BATTERY REMOVAL

1. Remove the driver’s seat to access the battery.

CAUTION

The battery in the 2014 vehicle is rotated 180°. This

results in the terminals being in different locations than

2. Disconnect the two black cables.

3. Disconnect the two red

4. Remove the hold-down strap and lift the battery out of the vehicle.

the image shown above.

(negative) battery

(positive) battery cables.

CAUTION

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.

2.34

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 71

MAINTENANCE

BATTERY INSTALLATION

NOTE

Using a new battery that has not been fully charged can

damage the battery and result in a shorter life. It can

also hinder vehicle performance. Follow the battery

charging procedure in Chapter 10 “Electrical” before

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with hold-down strap.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Connect and tighten the two red first.

5. Connect and tighten the two black cable last.

installing the battery.

(positive) cables

(negative)

BATTERY OFF SEASON STORAGE

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE

Battery charge can be maintained by using a Polaris

battery tender charger or by charging once a month to

make up for normal self-discharge. Battery tenders can

be left connected during the storage period, and will

automatically charge the battery if the voltage drops

below a pre-determined point.

SPARK PLUG SERVICE

1. Remove the driver’s seat and disconnect the (-) negative battery cable from the battery.

2. Remove cargo box access panel.

WARNING

A hot exhaust system and engine can cause serious

burns. Allow engine to cool or wear protective gloves

3. Clean top of engine to remove all dirt and debris.

4. Remove the spark plug wire

when removing the spark plugs.

from the engine.

CAUTION

The battery in some vehicles may be rotated 180°. This

results in the terminals being in different locations than

6. Verify that cables are properly routed and reinstall the driver’s seat.

the image shown above.

5. Remove spark plug.

2.35

Page 72

MAINTENANCE

6. Inspect electrodeswfor wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

7. Clean with electrical contact cleaner only.

8. Measure gap with a wire gauge. Adjust gap necessary by carefully bending the side electrode.

9. If necessary, replace spark plug with proper type.

CAUTION

Severe engine damage may occur if the incorrect spark

10. Install spark plugs and torque to specification.

plug is used.

ENGINE TO FRAME GROUND

Inspect ground cable connections. Be sure they are clean and tight.

The engine ground cableqruns from the upper starter motor mounting bolt to the chassis ground terminal.

The Chassis groundwis located under the drivers seat, near the starter solenoid.

Recommended Spark Plug:

2013-2014: Champion XG4YCX

2015 and later: NGK MR7F

TORQUE

Spark Plug:

9 ft-lbs (12 Nm)

11. Install spark plug wire into spark plug / engine.

12. Reinstall cargo box access panel.

13. Reinstall the (-) negative battery cable and driver’s seat.

2.36

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 73

ENGINE / COOLING SYSTEM

CHAPTER 3

ENGINE / COOLING SYSTEM

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

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

OIL PRESSURE TEST... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

ENGINE OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

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

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

TORQUE SEQUENCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

CYLINDER / OIL FILTER / OIL PUMP / BREATHER .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER - BLACK HEAD BOLTS . . . . . . . . . . . . 3.11

CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

PISTON / CRANKSHAFT / BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

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

AIR BOX / AIR FILTER EXPLODED VIEW.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

EXHAUST SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

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

COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

COOLING SYSTEM SPECIFICATIONS ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

COOLING SYSTEM PRESSURE TEST .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

PRESSURE CAP TEST... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

THERMOSTAT REPLACEMENT... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

WATER PUMP COVER AND IMPELLER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

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

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33

ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

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

VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39

CAMSHAFT / CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39

CAMSHAFT SPROCKET INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40

CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

EXHAUST CAMSHAFT DECOMPRESSION MECHANISM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

3.1

Page 74

ENGINE / COOLING SYSTEM

CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44

VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

COMBUSTION CHAMBER CLEANING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48

CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

PISTON REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49

PISTON / ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51

HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51

CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52

CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52

CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52

CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55

VALVE COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56

ENGINE ASSEMBLY - TOP END .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57

PISTON RING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57

PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58

CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60

CYLINDER HEAD INSTALLATION - BLACK BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61

CYLINDER HEAD INSTALLATION - SILVER BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62

VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63

INTAKE VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66

EXHAUST VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67

ENGINE DISASSEMBLY / INSPECTION - BOTTOM END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68

CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68

STATOR COVER REMOVAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68

STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68

STATOR REMOVAL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.70

OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71

OIL PUMP ASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73

CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74

CRANKCASE SEPARATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74

BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75

CRANKSHAFT REMOVAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76

CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76

PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77

MAG SIDE CRANKCASE BEARING SERVICE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.78

OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79

OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79

3.2

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 75

ENGINE / COOLING SYSTEM

CRANKCASE INSPECTION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79

ENGINE ASSEMBLY - BOTTOM END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80

CRANKCASE ASSEMBLY – PTO SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80

BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.82

FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.82

STARTER ONE-WAY CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84

FLYWHEEL INSTALLATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84

STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

SPARK PLUG FOULING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

ENGINE TURNS OVER BUT FAILS TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

ENGINE DOES NOT TURN OVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

ENGINE RUNS BUT WILL NOT IDLE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

ENGINE IDLES BUT WILL NOT ACCELERATE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.87

ENGINE HAS LOW POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

PISTON FAILURE - SCORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

EXCESSIVE SMOKE AND CARBON BUILDUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

PISTON FAILURE - SCORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

SLOW ENGINE CRANKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

EXCESSIVE SMOKE AND CARBON BUILDUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

LOW COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

BACKFIRING... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.88

OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.88

TEMPERATURE TOO LOW.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88

LEAK AT WATER PUMP WEEP HOLE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.88

3.3

Page 76

ENGINE / COOLING SYSTEM

GENERAL INFORMATION

SPECIAL TOOLS

PART

NUMBER

PW-47053

PU-50658 Clutch Center Distance Tool

PU-50784

PU-50563

PU-50624

PU-50824

PU-50625

PW-47054

PA-49316

PU-50105 Oil Filter Wrench

PV-43531

PU-50569

PA-49317 Stator Cover Removal Handles

PV-1253

PV-43513-A

PU-50689

Bosch Automotive Service Solutions : 1-800-3286657 or http://polaris.service-solutions.com/

TOOL DESCRIPTION

Bench Mount Engine Stand Adapter

Crankshaft Removal / Installation Tool Kit

Cylinder Holding & Camshaft Timing Plate

Engine Stand (2” Bore)

Engine Stand Adapter (Mounts To The Engine)

Engine Stand Sleeve Adapter (Use With 2” Bore Stand)

Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)

Flywheel Puller

Oil Pressure Gauge

Oil Pressure Gauge Adapter

Valve Spring Compressor

Valve Spring Compressor Adapter

Water Pump Mechanical / Oil Seal Installation Kit

ENGINE LUBRICATION SPECIFICATIONS

FLUID CAPACITY

Oil Capacity: 2 Quarts (1.9 L)

Oil Filter Wrench: PU-50105 or 2.5″ (64 mm)

Oil Type: Polaris PS-4 Synthetic Engine Oil

Oil Pressure:

(using Polaris PS-4 at operating temperature)

10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum)

OIL PRESSURE TEST

1. Attach the Oil Pressure Gauge Adapter to the Oil Pressure Gauge.

Oil Pressure Gauge Adapter: PU-50569

Oil Pressure Gauge: PV-43531

2. Remove the seats and engine service panel.

3. Clean the area around the main oil gallery plug (A), located on the oil filter adapter housing.

4. Remove the plug and insert the oil pressure adapter.

5. Start engine and allow it to reach operating temperature, monitoring gauge indication.

NOTE

Test results are based on the use of the recommended

engine oil (Polaris PS-4) at operating temperature, and

may vary considerably if any other oil is used or if

engine is not up to temperature.

6. Upon assembly, torque the crankcase gallery plug to specification.

TORQUE

Oil Gallery Plug:

12 ft-lbs (16 Nm)

3.4

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 77

ENGINE OIL FLOW CHART

ENGINE / COOLING SYSTEM

3.5

Page 78

ENGINE / COOLING SYSTEM

ENGINE SERVICE SPECIFICATIONS

ENGINE SPECIFICATIONS

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

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 Limit) 0.0551" (1.4 mm)

Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)

Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)

Valve Seat Angles

Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.152 ± 0.050 mm)

Valve Lash (Cold) - Exhaust 0.008" ± 0.002" (0.203 ± 0.050 mm)

Valve Stem Diameter - Intake

Valve Stem Diameter - Exhaust

Valve Stem Oil Clearance - Intake

Valve Stem Oil Clearance - Exhaust

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)

30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°

0.2165" - 0.2171" (5.500 - 5.515 mm)

0.2155" - 0.2161" (5.475 - 5.490 mm)

0.2147" - 0.2153" (5.455 - 5.470 mm)

0.0003" - 0.0015" (0.010 - 0.040 mm)

0.0011" - 0.0023" (0.030 - 0.060 mm)

0.00098" (0.025 mm)

3.6

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 79

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

Piston Pin Bore I.D. (Standard)

Piston Pin Bore I.D. (Service Limit) 0.8677" (22.042 mm)

Piston Pin O.D. (Standard)

Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)

Top Ring (Standard)

Top Ring (Service Limit) 0.0137" (0.35 mm)

Installed Gap

Ring to Groove Clearance

Connecting Rod Small End I.D. (Standard)

Connecting Rod Small End I.D. (Service Limit) 0.8682" (22.053 mm)

Connecting Rod Big End I.D.

Main Journal O.D. (Service Limit) 1.6137" (40.990 mm)

Crankshaft Runout Limit (PTO and MAG)

Bearing Journal O.D. (Standard)

Second Ring (Standard)

Second Ring (Service Limit) 0.0220" (0.56 mm)

Oil Control Rails (Standard)

Oil Control Rails (Service Limit)

Top Ring (Standard)

Top Ring (Service Limit) 0.0042" (0.108 mm)

Second Ring (Standard)

Second Ring (Service Limit) 0.0035" (0.089 mm)

ENGINE / COOLING SYSTEM

3.8957” - 3.8968” (98.953 -

98.980 mm)

0.8662” - 0.8665” (22.004 -

22.010 mm)

0.8659" - 0.8661" (21.995 -

22.000 mm)

0.0059" - 0.0122" (0.15 - 0.31 mm)

0.0094" - 0.0196" (0.24 - 0.50

mm)

0.0098" - 0.0401" (0.25 - 1.02 mm)

0.0480" (1.22 mm)

0.0011" - 0.0037" (0.030 -

0.095 mm)

0.0007" - 0.0029" (0.020 -

0.076 mm)

0.8665" - 0.8670" (22.010 -

22.023 mm)

See Service Procedure Listed In This Chapter

1.1798” - 1.1802" (29.969 -

29.979 mm)

3.7

Page 80

ENGINE / COOLING SYSTEM

TORQUE SEQUENCE

3.8

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 81

ENGINE / COOLING SYSTEM

CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE

3.9

Page 82

ENGINE / COOLING SYSTEM

CYLINDER / OIL FILTER / OIL PUMP / BREATHER

3.10

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 83

ENGINE / COOLING SYSTEM

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

Apply a drop of Loctite 641 (Yellow) to the crankshaft taper before assembly. Loctite 603 (Green) can be used if 641

is not available.

3.11

Page 84

ENGINE / COOLING SYSTEM

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

3.12

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 85

SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER

ENGINE / COOLING SYSTEM

3.13

Page 86

ENGINE / COOLING SYSTEM

PISTON / CRANKSHAFT / BALANCE SHAFT

3.14

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 87

INTAKE / EXHAUST SYSTEM

AIR BOX / AIR FILTER EXPLODED VIEW

ENGINE / COOLING SYSTEM

ASM., AIRBOX, MAIN

BOOT, AIRBOX

BASE, AIRBOX

CLAMP, AIRBOX

CLIP, AIRBOX

BRACKET, MOUNT, BLACK

GROMMET

HOSE, INTAKE

LID, AIRBOX

CLAMP, NARROW BAND

CLAMP, HOSE

FILTER, AIRBOX, MAIN

DECAL, FILTER MAINTENANCE

BOX, INTAKE

FILTER, ENGINE IN

FILTER, CLUTCH IN

SCREW

CAP, DRAIN

CLAMP, HOSE

SCREW

NUT, U

SCREW

3.15

Page 88

ENGINE / COOLING SYSTEM

EXHAUST SYSTEM ASSEMBLY VIEW

Muffler

Spark Arrestor

Isolator Mount

Silencer Screw

8 ft-lbs (11 Nm)

Nut

3.16

Exhaust Seal

Spring

Exhaust Pipe

Exhaust Gasket

Exhaust Flange Bolts

18 ft-lb (25 Nm)

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 89

ENGINE / COOLING SYSTEM

ENGINE COOLING SYSTEM

COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM

3.17

Page 90

ENGINE / COOLING SYSTEM

COOLING SYSTEM SPECIFICATIONS

CONDITION

Room Temperature 68° F (20° C)

Thermostat Open 180° F (82° C)

Fan Off

Fan On

Thermostat Full Open Lift

Engine Temperature Overheat Indicator

Engine Protection Ignition Misfire

Engine Protection Shutdown

ITEM SPECIFICATION

Cooling System Capacity 4.25 qts. (4 l)

Pressure Cap Relief

Polaris Premium Antifreeze:

COOLANT TEMPERATURE

°F (°C)

192° F (89° C)

198° F (92° C)

203° F (95° C)

233° F (112° C)

236° F (113° C)

257° F (125° C)

13 PSI

2871534 - Quart

2871323 - Gallon

COOLING SYSTEM PRESSURE TEST

1. Remove the hood from the front cab.

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and serious

burns may result. Allow the engine to cool before

servicing.

2. Remove pressure cap and pressure test the cooling system using a commercially available pressure tester.

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 ratio, depending on freeze protection required in your area.

CAUTION

Using tap water in the cooling system will lead to a

buildup of deposits which may restrict coolant flow and

reduce heat dissipation, resulting in possible engine

damage. Polaris Premium 50/50 Antifreeze/Coolant is

recommended for use in all cooling systems and comes

pre-mixed, ready to use.

3.18

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.

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 91

ENGINE / COOLING SYSTEM

PRESSURE CAP TEST

1. Remove the hood from the front cab (see “WARNING” under Cooling System Pressure Test, page 3.18).

2. Remove pressure cap (A) and test using a pressure cap tester (commercially available).

3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

RADIATOR

1. Check radiator air passages (A) for restrictions or damage.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low pressure water.

CAUTION

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.

3.19

Page 92

ENGINE / COOLING SYSTEM

COOLANT DRAIN / RADIATOR REMOVAL

Coolant Drain

1. Remove the hood from the front cab.

WARNING

Never drain the coolant when the engine and radiator

are warm or hot. Hot coolant can cause severe burns.

2. Slowly remove the pressure cap to relieve any

3. Place a suitable drain pan underneath the radiator

4. Drain the coolant from the radiator by removing the

Allow engine and radiator to cool.

cooling system pressure.

fitting on the front right-hand side of the vehicle.

lower coolant hose Properly dispose of the coolant.

from the radiator as shown.

8. Remove the front bumper (see Chapter 10 – Front Bumper, page 10.14).

9. Remove the upper engine outlet hose and recovery hose from the top of the radiator.

10. Remove the two upper radiator retaining bolts and the four bolts retaining the lower radiator mount bracket. Remove the bracket from the frame.

11. Disconnect the fan motor and remove the radiator from the vehicle. Take care not to damage the cooling fins.

12. Reverse procedure for installation.

5. Allow coolant to completely drain.

6. Place a suitable drain pan underneath the lower engine hosewon the right-hand rear side of the vehicle.

7. Remove the hose and completely drain the engine.

Radiator Removal

3.20

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 93

ENGINE / COOLING SYSTEM

THERMOSTAT REPLACEMENT

1. Remove the hood from the front cab.

WARNING

The cooling system is under pressure and serious

burns may result. Allow the engine to cool before

2. Remove the pressure cap to relieve any system pressure (see Chapter 3 – Pressure Cap Test, page

3.19).

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 the two bolts cover.

servicing.

retaining the thermostat

WATER PUMP COVER AND IMPELLER SERVICE

NOTE

The water pump cover, gasket and impeller can be

serviced with the stator cover installed on the engine.

1. Allow engine and cooling system to completely cool.

CAUTION

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be hot and could cause severe

2. Remove both seats and the engine service panel.

3. Disconnect the (-) negative battery cable.

4. Remove all debris and thoroughly clean water pump area and right-hand side of engine block.

5. Remove the hood.

6. Remove the pressure cap from the filler neck.

7. Completely drain cooling system and engine as outlined in this chapter.

8. Raise and safely support the vehicle. Remove the right-hand rear wheel.

9. Remove the eight bolts cover to the stator cover.

injury or burns.

attaching the water pump

7. Lift the cover from the engine and remove the thermostat.

8. Reverse this procedure for installation. Replace thermostat seal if worn or damaged. Torque thermostat cover bolts to specification.

TORQUE

Thermostat Cover Bolts:

7 ft-lbs (10 Nm)

9. Be sure to properly fill and bleed cooling system as outlined in this chapter.

10. Remove the water pump coverwand water pump cover gasket

11. Using an 8mm socket, remove the water pump impeller

. Discard the water pump gasket .

NOTE

The water pump impeller uses reverse (LH) threads.

12. Inspect the water pump cover and impeller for damage. Replace as necessary.

3.21

Page 94

ENGINE / COOLING SYSTEM

13. Follow this procedure in reverse to assemble the water pump impeller and cover. Always use a new water pump cover gasket. Torque all fasteners in sequence to specification.

TORQUE

Water Pump Cover Fastener:

9 ft-lb (12 Nm)(Apply Loctite® 204™ to bolt threads)

14. Fill and bleed cooling system as outlined in this chapter.

WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT

NOTE

The stator cover must be removed from the engine to

service the water pump drive shaft, oil seal, mechanical

seal and bearing.

1. Allow engine and cooling system to completely cool.

CAUTION

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be 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 area and right-hand side of engine block.

5. Remove the hood.

6. Remove the pressure cap from the filler neck.

7. Completely drain cooling system and engine as outlined in this chapter.

8. Raise and safely support the vehicle. Remove the right-hand rear wheel.

9. Disconnect the stator wire connector and cut the tie strap securing the wiring to the front engine mount bracket.

3.22

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 95

ENGINE / COOLING SYSTEM

10. Remove the CPS sensor from the stator cover on the right-hand side of the engine. Inspect CPS O-ring and replace if needed.

11. Remove the oil dipstick.

12. Remove the eight boltsqretaining the water pump cover to the stator cover.

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.

CAUTION

The flywheel contains powerful magnets. Use caution

when removing the stator cover.

DO NOT place fingers between cover and crankcase at

any time during the removal process or injury could

result.

17. Remove and discard the stator cover gasket.

13. Remove the water pump coverwand water pump cover gasket

14. Remove the water pump impeller

. Discard the water pump gasket.

NOTE

The water pump impeller uses reverse (LH) threads.

15. Remove the thirteen bolts securing the stator cover to the engine.

CAUTION

Be sure engine coolant does not contaminate the

engine oil during stator cover service.

18. Bring the stator cover assembly to a clean work bench.

3.23

Page 96

ENGINE / COOLING SYSTEM

19. Using a brass drift, remove the water pump drive shaft. Be sure not to damage the threads. Inspect shaft for wear or damage, replace if necessary.

20. Extract the mechanical sealtand the oil seal from the stator cover.

22. Thoroughly clean the stator cover.

23. Press in a new water pump drive shaft bearing until it is fully seated in the cover.

CAUTION

Be sure bearing is fully seated in cover or severe

24. Clean and de-grease the water pump drive shaft

25. Press in the water pump drive shaft into the bearing using PU-50869 Item #1.

engine damage may result.

21. Press out the water pump drive shaft bearingufrom the stator cover. Discard bearing and replace with new.

Water Pump Assembly

3.24

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 97

ENGINE / COOLING SYSTEM

26. Install the water pump drive shaft holding tool (Item #1) in kit PU-50869. Hold the tool in position and flip the assembly up-side-down so the special tool PU50869 is supporting the assembly.

29. PU-50869 to fully install the new water pump oil seal (I).

CAUTION

Be sure the oil seal is fully seated in cover or severe

engine damage may result

30. 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.

27. Lubricate the new water pump oil seal with clean engine oil.

28. Use the water pump oil seal installation tool in kit

31. Install a new stator cover gasket onto the engine.

3.25

Page 98

ENGINE / COOLING SYSTEM

32. Align the water pump drive slot as shown below.

33. Align the water pump drive shaft blade as shown below.

34. Apply a small amount of crankcase sealant to the area indicated below.

36. While installing the stator cover to the engine, slightly rotate the water pump impeller to verify the crankshaft slot and the water pump drive shaft blade are properly engaged. Verify the stator cover is laying flat on the engine case.

CAUTION

The flywheel contains powerful magnets. Use caution

when installing the stator cover.

DO NOT place fingers between cover and crankcase at

any time during the removal and installation process or

injury could result.

CAUTION

If the water pump drive shaft blade and slot in the crank

shaft are not in alignment during the installation

process, severe engine damage may result.

35. If needed, install the stator cover removal handles tool PA-49317 to the water cover bolt holes to aid in stator cover installation.

3.26

37. Install and torque the stator cover fasteners in sequence to specification.

TORQUE

Stator Cover and Water Pump Cover:

9 ft-lb (12 Nm)

9926813 R04 - 2013-2016 RZR 570 Service Manual

Page 99

ENGINE / COOLING SYSTEM

38. Measure the installed height of the new mechanical seal as shown below. If not within specification, remove and discard the mechanical seal and properly install new mechanical seal as outlined in this chapter.

MEASUREMENT

Mechanical Water Pump Seal Installed Height:

0.280 - 0.287″ (7.2 +/- 0.1 mm)

39. Install the water pump impeller (K). Finger tighten only.

NOTE

The water pump impeller uses reverse (LH) threads.

41. Install the water pump cover to the stator cover. Torque all fasteners in sequence to specification.

42. Install the oil dipstick.

43. Install the coolant hose to the water pump cover and tighten hose clamp.

44. Connect the stator wire connector and install a new tie strap securing the wiring to the front engine mount bracket.

45. Install the CPS sensor into the stator cover. Inspect CPS O-ring and replace if needed.

46. Install the right-hand rear wheel and torque the wheel nuts to specification. Safely lower vehicle.

TORQUE

Wheel Nuts:

Steel Rims: 27 ft-lbs (37 Nm)

Aluminum Rims: 30 ft-lbs (41 Nm) + 90°

40. Install a new water pump cover gasket.

47. Install both seats and the engine service panel.

48. Connect the (-) negative battery cable.

49. 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.

50. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter.

51. Check for leaks.

3.27

Page 100

ENGINE / COOLING SYSTEM

COOLING SYSTEM BLEEDING PROCEDURE

WARNING

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.

CAUTION

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

leaks in the system, the coolant system will not draw

It may be necessary to safely raise the front of the

vehicle 12” (30 cm) to bleed the cooling system.

1. Allow engine and cooling system to completely cool.

coolant from the reservoir tank.

CAUTION

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be hot and could cause severe

2. Remove the hood.

3. Remove the recovery bottle cap to the MAX line.

injury or burns.

and fill the bottle

6. Open the bleed screw escape.

7. Fill the radiator until a steady stream of coolant begins to drain out of the bleed screw

8. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

to allow any trapped air to

TORQUE

Coolant Bleed Screw:

6 ft-lbs (8 Nm)

9. Start the engine and allow it to idle until the coolant fan has cycled.

10. Allow engine and cooling system to completely cool down (see CAUTION).

11. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

12. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

13. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

4. Remove the pressure capqand add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

5. Remove the cargo box access cover to gain access to the coolant bleed screw that is on top of the thermostat housing.

3.28

TORQUE

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.

9926813 R04 - 2013-2016 RZR 570 Service Manual