Polaris Sportsman 570 EF (2014) Service manual

Page 1

2014 Polaris Sportsman® 570 EFI

Service Manual

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer 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.

Publication Printed August 2013 (PN 9924871 R03)

© Copyright 2013 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. 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.

technicians in a properly

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.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCT(S) 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.

Page 3

GENERAL INFORMATION

MAINTENANCE

ENGINE

FUEL SYSTEM - GENERAL

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

Page 4

Page 5

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

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

VEHICLE AND ENGINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

TRANSMISSION I.D. LOCATION . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 1.4

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 1.5

PUBLICATION PART NUMBERS . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 1.5

REPLACEMENT KEYS. . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

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

VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 1.6

2014 SPORTSMAN 570 EFI / EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. 1.6

2014 SPORTSMAN FOREST 570 EFI / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 1.7

2014 SPORTSMAN TOURING 570 EFI. . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 1.8

2014 SPORTSMAN TOURING 570 EFI (INTL.) . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

CLUTCHING SPECIFICATIONS . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.10

CLUTCHING CHART. . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 1.10

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 1.11

CONVERSION TABLE .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .1.12

METRIC BOLT TORQUE SPECIFICATION ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .1.12

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . .1.13

METRIC TAP / DRILL SIZES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .1.14

DECIMAL EQUIVALENTS.. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 1.15

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Number Designation

Example: A14KA09AD

GROUP

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

A 1 4 K A 0 9 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

Vehicle Identification Number (VIN) Designation

Example: 4XAKA09A0E3000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

WORLD MFG. ID

CHASSIS

DRIVELINE

ENGINE SIZE

ENGINE

MODIFIER

CATEGORY

CHECK DIGIT

MODEL YEAR *

MFG. LOCATION

1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17

4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0

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

INDIVIDUAL SERIAL NO.

1.2

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GENERAL INFORMATION

Vehicle and Engine Serial Numbers

The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (1).

The vehicle serial number is stamped on the frame on all models (2).

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Page 8

GENERAL INFORMATION

Transmission I.D. Location

The Transmission I. D. number is located on the RH side of the transmission case; visible from the RH side of the vehicle.

1.4

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VEHICLE INFORMATION

Publication Part Numbers

GENERAL INFORMATION

OWNER'S

YEAR

2014

2014 Sportsman 570 EPS A14MH5EAA, AC, AJ 9924113 9924640

2014

2014 Sportsman 570 EPS Forest A14MH5EFJ 9924299 9924642

2014

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. Should both keys become lost, ignition switch replacement is required.

MODEL MODEL NO.

Sportsman 570 A14MH57AA, AC, AD, FA

Sportsman 570 Forest

Sportsman Touring 570

Sportsman 570 HD INT’L

Sportsman Touring 570 INT’L

A14MH57FA, FJ 9924299 9924638

A14DH57AA, AJ 9924134 9924605

A14MH57TD 9924113 9924639

A14DH57FJ 9924134 9924607

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 Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-328-6657 or on-line at http://polaris. service-solutions.com /.

MANUAL PN

9924113 9924637

PARTS MANUAL PN

Series # Part Number

20 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

4010278

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GENERAL INFORMATION

VEHICLE SPECIFICATIONS

2014 Sportsman 570 EFI / EPS

MODEL NUMBER: A14MH57AA, AC, AD, TD A14MH5EAA, AC, AJ

SPORTSMAN 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Gross Vehicle Weight 1200 lbs. (544 kg)

Maximum Weight Capacity

Dry Weight

Fuel Capacity 4.5 gal. (17 l)

Engine Oil Capacity 2 qts. (1.9 l)

Transmission Oil Capacity 32 oz. (948 ml)

Demand Drive Fluid Capacity

Coolant Capacity 2.7 qts. (2.5 l)

Front Rack/Box Capacity 90 lbs. (40.8 kg)

Rear Rack/Box Capacity 180 lbs. (81.6 kg)

Receiver Hitch Tongue Capacity

Hitch Towing Rating 1225 lbs. (555.7 kg)

Unbraked Trailer Towing Capacity*

Overall Length/Width/ Height

Wheelbase

Ground Clearance

Minimum Turning Radius 65 in. (165 cm) unloaded

Engine

Displacement

485 lbs. (220 kg) (operator, cargo, accessories)

702 lbs. (318.4 kg) (570 EFI) 713 lbs. (323.4 kg) (570 EPS)

9 oz. (265 ml)

120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg

1786 lbs. (810 kg)

83 in. (211 cm) / 48 in. (122 cm) / 48 in. (122 cm)

50.5 in. (128.3 cm)

11 in. (28 cm)

Dual overhead cam, 4 valve 4 stroke single cylinder

567 cc

SPORTSMAN 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM

Idle RPM 1200 ± 100 Compression Ratio

Starting System

Fuel System Electronic Fuel Injection

Ignition System

Spark Plug / Gap RG6YC / (0.7-0.8 mm)

Lubrication System Wet Sump

Driving System Type

Front Suspension

Rear Suspension

Shift Type

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front/Rear

Brake, Auxiliary Foot-Activated Hydraulic Disc

Brake, Parking Hydraulic lock, all wheel

Headlight

Taillights

Brake Light

Instrument Cluster LCD * Based on EU Directive 76/432/EC

10:1

Electric

ECU

Automatic PVT (POLARIS Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 9.5" (24 cm) travel

H/L/N/R/P

23.91:1

21.74:1

9.75:1

3.82:1

25x8-12 / 5 psi (34.5 kPa)

25x10-12 / 5 psi (34.5 kPa) 25x11-12 / 5 psi (34.5 kPa) (LE models)

Single-Control Hydraulic Disc

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

8.26 watts

26.9 watts

1.6

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GENERAL INFORMATION

2014 Sportsman Forest 570 EFI / EPS

MODEL NUMBER: A14MH57FA, FJ A14MH5EFJ

SPORTSMAN FOREST 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Maximum Weight Capacity

Dry Weight

Fuel Capacity 4.5 gal. (17 l)

Engine Oil Capacity 2 qts. (1.9 l)

Transmission Oil Capacity 32 oz. (948 ml)

Demand Drive Fluid Capacity

Coolant Capacity 2.7 qts. (2.5 l)

Front Rack/Box Capacity 90 lbs. (40.8 kg)

Rear Rack/Box Capacity 180 lbs. (81.6 kg)

Receiver Hitch Tongue Capacity

Hitch Towing Rating 1225 lbs. (555.7 kg)

Unbraked Trailer Towing Capacity*

Overall Length/Width/ Height

Wheelbase

Ground Clearance

Minimum Turning Radius 65 in. (165 cm) unloaded

Engine

Displacement

485 lbs. (220 kg) (operator, cargo, accessories)

720 lbs. (327 kg) +/- 7%, based on configuration

731 lbs. (332 kg) (EPS) +/- 7%, based on configuration

9 oz. (265 ml)

120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg

1786 lbs. (810 kg)

83 in. (211 cm) / 48 in. (122 cm) / 48 in. (122 cm)

50.5 in. (128.3 cm)

11 in. (28 cm)

Dual overhead cam, 4 valve 4 stroke single cylinder

567 cc

SPORTSMAN FOREST 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM

Idle RPM 1200 ± 100 Compression Ratio

Starting System

Fuel System Electronic Fuel Injection

Ignition System

Spark Plug / Gap

Lubrication System Wet Sump

Driving System Type

Front Suspension

Rear Suspension

Shift Type

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front/Rear

Brake, Auxiliary Foot-Activated Hydraulic Disc

Brake, Parking Hydraulic lock, all wheel

Hitch

Winch

Headlight

Taillights

Brake Light

Instrument Cluster LCD * Based on EU Directive 76/432/EC

10:1

Electric

ECU

RG6YC / 0.7-0.8 mm

Automatic PVT (POLARIS Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 9.5" (24 cm) travel

H/L/N/R/P

23.91:1

21.74:1

9.75:1

3.82:1

Off Road Style,

Deep Tread Design

25x8-12 / 5 psi (34.5 kPa)

Off Road Style,

Deep Tread Design

25x10-12 / 5 psi (34.5 kPa)

Single-Control Hydraulic Disc

Rear mounting for attachment of coupling devices

Front permanent installed winch with 2500 lbs. (1125 kg) capacity

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

8.26 watts

26.9 watts

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GENERAL INFORMATION

2014 Sportsman Touring 570 EFI

MODEL NUMBER: A14DM57AA, AJ

SPORTSMAN TOURING 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Gross Vehicle Weight 1200 lbs. (544 kg)

Maximum Weight Capacity

Dry Weight

Fuel Capacity 4.5 gal. (17 l)

Engine Oil Capacity 2 qts. (1.9 l)

Transmission Oil Capacity 32 oz. (948 ml)

Demand Drive Fluid Capacity

Coolant Capacity 2.7 qts. (2.5 l)

Front Rack/Box Capacity 90 lbs. (40.8 kg)

Rear Rack/Box Capacity 180 lbs. (81.6 kg)

Receiver Hitch Tongue Capacity

Hitch Towing Rating 1225 lbs. (555.7 kg)

Unbraked Trailer Towing Capacity*

Overall Length/Width/ Height

Wheelbase

Ground Clearance

Minimum Turning Radius 82 in. (208.3 cm) unloaded

Engine

Displacement

Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM

575 lbs. (261 kg) (includes operator, passenger, cargo, accessories)

728 lbs. (330.2 kg) (570 EFI) 739 lbs. (335.2 kg) (570 EPS)

9 oz. (265 ml)

120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg

1786 lbs. (810 kg)

86 in. (218.4 cm) / 48 in. (122 cm) / 48 in. (122 cm)

56 in. (142.2 cm)

11 in. (28 cm)

Dual overhead cam, 4 valve 4 stroke single cylinder

567 cc

SPORTSMAN TOURING 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Idle RPM 1200 ± 100 Compression Ratio

Starting System

Fuel System Electronic Fuel Injection

Ignition System

Spark Plug / Gap

Lubrication System Wet Sump

Driving System Type

Front Suspension

Rear Suspension

Shift Type

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front/Rear

Brake, Auxiliary Foot-Activated Hydraulic Disc

Brake, Parking Hydraulic lock, all wheel

Headlight

Taillights

Brake Light

Instrument Cluster LCD * Based on EU Directive 76/432/EC

10:1

Electric

ECU

RG6YC / 0.7-0.8 mm

Automatic PVT (POLARIS Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 9.5" (24 cm) travel

H/L/N/R/P

23.91:1

21.74:1

9.75:1

3.82:1 25x8-12 / 5 psi (34.5 kPa)

25x10-12 / 5 psi (34.5 kPa)

25x11-12 / 5 psi (34.5 kPa) (LE models)

Single-Control Hydraulic Disc

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

8.26 watts

26.9 watts

1.8

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GENERAL INFORMATION

2014 Sportsman Touring 570 EFI (Intl.)

MODEL NUMBER: A14DH57FJ

SPORTSMAN TOURING 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Gross Vehicle Weight 1200 lbs. (544 kg)

Maximum Weight Capacity

Dry Weight

Fuel Capacity 4.5 gal. (17 l)

Engine Oil Capacity 2 qts. (1.9 l)

Transmission Oil Capacity 32 oz. (948 ml)

Demand Drive Fluid Capacity

Coolant Capacity 2.7 qts. (2.5 l)

Front Rack/Box Capacity 90 lbs. (40.8 kg)

Rear Rack/Box Capacity 180 lbs. (81.6 kg)

Receiver Hitch Tongue Capacity

Hitch Towing Rating 1225 lbs. (555.7 kg)

Unbraked Trailer Towing Capacity*

Overall Length/Width/ Height

Wheelbase

Ground Clearance

575 lbs. (261 kg) (includes operator, passenger, cargo, accessories)

728 lbs. (330.2 kg) (570 EFI) 739 lbs. (335.2 kg) (570 EPS)

9 oz. (265 ml)

120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg

1786 lbs. (810 kg)

86 in. (218.4 cm) / 48 in. (122 cm) / 48 in. (122 cm)

56 in. (142.2 cm)

11 in. (28 cm)

SPORTSMAN TOURING 570 EFI / EPS CATEGORY DIMENSION / CAPACITY

Minimum Turning Radius 82 in. (208.3 cm) unloaded

Engine

Displacement

Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM

Idle RPM 1200 ± 100 Compression Ratio

Starting System

Fuel System Electronic Fuel Injection

Ignition System

Spark Plug / Gap

Lubrication System Wet Sump

Driving System Type

Front Suspension

Rear Suspension

Shift Type

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, Forward

Drive Ratio, Front

Tires/Pressure, Front

Tires/Pressure, Rear

Brakes, Front/Rear

Brake, Auxiliary Foot-Activated Hydraulic Disc

Brake, Parking Hydraulic lock, all wheel

Headlight

Taillights

Brake Light

Instrument Cluster LCD * Based on EU Directive 76/432/EC

Dual overhead cam, 4 valve 4 stroke single cylinder

567 cc

10:1

Electric

ECU

RG6YC / 0.7-0.8 mm

Automatic PVT (POLARIS Variable Transmission)

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 9.5" (24 cm) travel

H/L/N/R/P

23.91:1

21.74:1

9.75:1

3.82:1 25x8-12 / 5 psi (34.5 kPa)

25x10-12 / 5 psi (34.5 kPa)

25x11-12 / 5 psi (34.5 kPa) (LE models)

Single-Control Hydraulic Disc

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt)

8.26 watts

26.9 watts

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GENERAL INFORMATION

CLUTCHING SPECIFICATIONS

Clutching Chart

ALTITUDE SHIFT

Meters (Feet)

*EBS models require no helix/spring adjustment

0-1800 (0-6000)

1800–3700 (6000–12000)

25–52G PN 5632409

25–48 PN 5632408

DRIVE CLUTCH SPRING

Black PN 7043594

DRIVEN CLUTCH SPRING

Non-EBS: Black PN 7041782 EBS: Red PN 3234451

HELIX*

EBS PN 3234356 Non-EBS PN 5132344

1.10

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GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

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 x 6.895 = kilopascals (kPa)

kilopascals (kPa)

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 0.145

= grams (g)

= fluid ounces

= ounces

= cc

= liters (L)

= US quarts

= US gallons

PSI

= cylinder volume

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Page 16

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. LBS. (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

.3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

.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) 11 (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. LBS. (NM)

GRADE

FT.— LBS. (NM) DRY THREADS

GRADE 8

FT. LBS. (NM)

1.12

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Page 17

GENERAL INFORMATION

SAE Tap / Drill Sizes

THREAD SIZE DRILL SIZE THREAD SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64 53 1/2–20 29/64

#1–72 53 9/16–12 31/64

#2–56

#2–64

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40 38 7/8–14 13/16

#5–44 37 1–8 7/8

#6–32

#6–40

#8–32

#8–36

#10–24

#10–32 21 1 1/2–6 1 11/32

#12–24 17 1 1/2–12 1 27/64

#12–28

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

36 1–12

4.6 mm

F 2–12

U 3–4

2 1/4–4 1/2 2 1/32

9/16–18 33/64

5/8–11 17/32

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

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 3/4–5 1 9/16

1 3/4–12 1 43/64

2–4 1/2 1 25/32

59/64

1 59/64

2 3/4

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Page 18

GENERAL INFORMATION

Metric Tap / Drill Sizes

TAP SIZE DRILL SIZE DECIMAL NEAREST FRACTION

3 x .50 #39 0.0995 3/32

3 x .60 3/32 0.0937 3/32

4 x .70 #30 0.1285 1/8

4 x .75

5 x .80

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277 9/32

8 x 1.25 17/64 0.265 17/64

9 x 1.00

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

11 x 1.50 3/8 0.375 3/8

12 x 1.50 13/32 0.406 13/32

12 x 1.75 13/32 0.406 13/32

16/64

11/32

1/8 0.125 1/8

#19

#20

5/16

0.166

0.161

0.196

0.234

0.3125

0.3437

11/64

5/32

13/64

15/64

5/16

11/32

1.14

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Page 19

Decimal Equivalents

FRACTION DECIMAL MM TO INCHES

1/64

1/32 0.0312″ 1 mm = 0.0394″

3/64 0.0469″

1/16

5/64

3/32 0.0938″

7/64

1/8

9/64 0.1406″

5/32

11/64

3/16 0.1875″ 5 mm = 0.1969″

13/64

7/32

15/64

1/4 0.25″

17/64

9/32 0.2813″

19/64 0.2969″

5/16

21/64

11/32 0.3438″ 9 mm = 0.3543″

23/64

3/8

25/64 0.3906″ 10 mm = 0.3937″

13/32

27/64

7/16 0.4375″

29/64

15/32

31/64

1/2 0.500″ 13 mm = 0.5118″

33/64

17/32

35/64 0.5469″ 14 mm = 0.5512″

9/16

37/64

19/32

39/64 0.6094″

5/8

GENERAL INFORMATION

0.0156″

0.0625″

0.0781″ 2 mm = 0.0787″

0.1094″ 3 mm = 0.1181″

0.1250″

0.1563″ 4 mm = 0.1575″

0.1719″

0.2031″

0.2188″

0.2344″ 6 mm = 0.2362″

0.2656″ 7 mm = 0.2756″

0.3125″ 8 mm = 0.3150″

0.3281″

0.3594″

0.375″

0.4063″

0.4219″ 11 mm = 0.4331″

0.4531″

0.4688″ 12 mm = 0.4724″

0.4844″

0.5156″

0.5313″

0.5625″

0.5781″ 15 mm = 0.5906″

0.5938″

0.625″ 16 mm = 0.6299″

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Page 20

GENERAL INFORMATION

FRACTION DECIMAL MM TO INCHES

41/64

21/32 0.6563″ 17 mm = 0.6693″

43/64

11/16

45/64 0.7031″ 18 mm = 0.7087″

23/32 0.7188″

47/64

3/4

49/64 0.7656″

25/32

51/64

13/16 0.8125″ 21 mm = 0.8268″

53/64

27/32

55/64

7/8 0.875″

57/64

29/32

59/64 0.9219″

15/16

61/64

31/32 0.9688″ 25 mm = 0.9843″

63/64

1 1.000″

0.6406″

0.6719″

0.6875″

0.7344″ 19 mm = 0.7480″

0.750″

0.7813″ 20 mm = 0.7874″

0.7969″

0.8281″

0.8438″

0.8594″ 22 mm = 0.8661″

0.8906″ 23 mm = 0.9055″

0.9063″

0.9375″ 24 mm = 0.9449″

0.9531″

0.9844″

1.16

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Page 21

MAINTENANCE

CHAPTER 2

MAINTENANCE

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . 2.3

INSPECTION / MAINTENANCE INTERVALS ... . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 2.4

PRE-RIDE / DAILY INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . 2.4

BREAK-IN PERIOD .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

PERIODIC MAINTENANCE CHART.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . 2.5

VEHICLE STORAGE . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 2.8

STORAGE TIPS . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

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

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

LUBRICATION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . 2.11

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . 2.11

FUEL LINES .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . 2.11

THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

THROTTLE CABLE / THROTTLE RELEASE SYSTEM (TRS SWITCH) ADJUSTMENT . . . . . . . . . . . . .2.12

AIR FILTER/PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

AIR BOX SEDIMENT DRAIN . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .2.14

CRANKCASE BREATHER VALVE / HOSE.. . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE OIL LEVEL.. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.16

OIL AND FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .2.16

COMPRESSION TEST SPECIFICATION .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

VALVE CLEARANCE INSPECTION . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

EXHAUST PIPE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

TRANSMISSION AND FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . .2.21

TRANSMISSION LUBRICATION .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .2.21

SHIFT LINK ROD MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .2.22

FRONT GEARCASE LUBRICATION. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .2.22

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

LIQUID COOLING SYSTEM OVERVIEW ... . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.24

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

RADIATOR COOLANT LEVEL.. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

COOLING SYSTEM HOSES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . .2.25

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2.25

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

COOLANT DRAIN / FILL . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 2.26

RADIATOR/GRILL SCREEN . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

FINAL DRIVE / WHEEL AND TIRE.. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEELS . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .2.28

WHEEL, HUB, AND SPINDLE TORQUE TABLE ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

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2.1

Page 22

MAINTENANCE

TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

WHEEL REMOVAL FRONT OR REAR... . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

WHEEL INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .2.28

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .2.29

CV SHAFT BOOT INSPECTION . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 2.29

FRAME, NUTS, BOLTS, FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .2.29

BRAKE SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

BRAKE SYSTEM INSPECTION . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

BRAKE PAD INSPECTION . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

HOSE/FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .2.30

AUXILIARY BRAKE TESTING . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . 2.31

AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .2.31

ELECTRICAL AND IGNITION SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .2.32

BATTERY MAINTENANCE .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 2.32

BATTERY REMOVAL . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

SPARK PLUG SERVICE .. . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

ENGINE TO FRAME GROUND. . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35

STEERING .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 2.36

TIE ROD END/STEERING INSPECTION . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .2.36

FRONT SUSPENSION . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . ..2.37

SUSPENSION SPRING PRELOAD ADJUSTMENT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .2.37

TOE ALIGNMENT ADJUSTMENT .. . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37

CAMBER AND CASTER ... . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .2.37

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . .2.37

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SPECIAL TOOLS

Bosch Automotive Service Solutions- 1-800-328-6657 or http://polaris.service-solutions.com

MAINTENANCE

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Page 24

MAINTENANCE

INSPECTION / MAINTENANCE INTERVALS

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check tire condition and air pressures

• Fuel and oil - fill both to their proper level; Do not overfill

• All brakes - check operation and adjustment (includes auxiliary brake)

• Throttle -check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

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

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

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.

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MAINTENANCE

Periodic Maintenance Chart

Periodic Maintenance Overview

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. 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 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

SYMBOL DESCRIPTION

►

SEVERE USE ITEM: Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

Perform these operations more often for vehicles subjected to severe use.

Emission-related Control System Service (California) Failure to conduct this maintenance will not void the emissions warranty but may affect emissions

Have an authorized POLARIS dealer perform these services.

WARNING

Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or

death. Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

HOUR-

ITEM

Steering

Front-suspension

Rear-suspension

Tires Brake fluid level Brake lever /

pedal travel

Brake systems

Wheels /fasteners Frame fasteners Engine Oil Level

Winch (if equipped)

▶

Air filter, pre-filter -

▶

Air box sediment tube

Coolant Power Steering unit - Daily - Inspect daily; clean often

Head lamp / tail lamp / worklight

▶

Air filter, main element

Recoil housing - Weekly 100 (160)

▶

Brake pad wear

Battery

Engine breather

▶

filter (if equipped)

Engine oil change

▶

(break-in)

▶

Demand drive fluid 25 H Rear gearcase oil

▶

Transmission fluid 25 H

▶

General lubrication 50 H 3 M

DEThrottle Cable/

TRS Switch Air intake ducts/

flange

Drive belt 50 H 6 M

Cooling system

▶

Engine oil change

▶

Oil lines and fasteners 100 H 6 M

- Daily - Drain deposits when visible

- Daily -

- Weekly - Inspect; replace as needed

10 H

20 H

25 H

50 H 6 M

100 H 6 M

CALENDAR

Pre-Ride

Pre-Ride Pre-Ride Pre-Ride

Pre-Ride

Pre-Ride Pre-Ride Pre-Ride

Pre-Ride

Daily

Monthly 100 (160) Inspect periodically

Monthly 200 (320)

Monthly 250 (400) Inspect; replace if necessary

Monthly 250 (400) Perform a break-in oil and filter change

Monthly

Monthly 250 (400) Initial fluid level inspection; Change yearly

MILES (KM)

- Inspect; clean often

- Check level daily, change coolant every 2 years

250 (400) Initial fluid level inspection; Change yearly*

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

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

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

500 (800)

1000 (1600)

1000 (1600) Change the oil and filter

1000 (1600) Inspect for leaks and loose

REMARKS

Make adjustments as needed.

Check operation; apply dielectric grease if replacing

Drain water as needed,check often

if operating in wet conditions

Check terminals; clean; test

Inspect coolant strength seasonally; pressure test system yearly

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MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

HOUR-

ITEM

Demand drive fluid

▶

(normal use)

Rear gearcase oil

▶

Transmission oil 100 H 12 M

Valve clearance 100 H 12 M

E D

Fuel System

E D

Fuel Filter 100 H 12 M

Radiator

▶

(if applicable)

Cooling hoses

▶

(if applicable)

Engine mounts

▶

Exhaust muffler / pipe

Spark plug

Wiring

▶

Clutches

(drive and driven)

Front wheel bearings

D Brake fluid 200 H 24 M

Spark arrestor

▶

Shocks 500 H 12 M

Idle speed Adjust as needed.

Toe adjustment -

Headlight aim - Adjust as needed

▶ = Perform these procedures more often for vehicles subjected to severe use.

E= Emission Control System Service (California) D = Have an authorized POLARIS dealer perform these services.

100 H 12 M

100 H 100 H

100 H 12 M

300 H 36 M

CALENDAR

MILES (KM)

1000 (1600) Change fluid

1000 (1600) Inspect; adjust

600 (1000)

1000 (1600) Replace yearly

1000 (1600) Inspect; clean external

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect

1000 (1600) inspect; replace as needed

1000 (1600)

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

2000 (3200) Change every two years

3000 (4800)

REMARKS

Check for leaks at fuel cap, fuel line / rail, and fuel pump; Replace lines every 2 years

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

Clean out Inspect; replace shock oil and seals (if

equipped)

Inspect periodically; adjust when parts are replaced

MAINTENANCE

*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.

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MAINTENANCE

VEHICLE STORAGE

Storage Tips

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

Fog the Engine

1. After stabilizing the fuel, remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

2. Reinstall the spark plugs. Torque to specification.

3. Apply dielectric grease to the inside of the spark plug cap and reinstall the caps onto the plugs.

4. Turn the engine over several times using electric start. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

5. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.

Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Oil and Filter

Change the oil and filter.

Air Filter/Air Box:

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Drain the sediment tube.

4. Clean or replace the breather valve.

Battery Storage:

Refer to Chapter 10 “Electrical” for off season storage procedures.

Clean the Exterior:

Make any necessary repairs and clean the vehicle as recommended.

Storage Area/Covers:

Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.

• Demand drive unit (front gearcase)

• Rear gearcase (if equipped)

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

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LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

PART NO. DESCRIPTION

Fogging Oil (12 oz. Aerosol)

PS-4 Syn. 4-Cycle Engine Oil (Quart)

PS-4 Syn. 4-Cycle Engine Oil (Gallon / 3.8 l)

PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)

PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)

AGL Gearcase Lubricant (1 Qt. / .95 l) (12 Count)

AGL Gearcase Lubricant (1 Gal. / 3.8 l) (4 Count)

AGL Gearcase Lubricant (2.5 Gal. / 9.5 l) (2 Count)

Demand Drive fluid (Quart / .95 l)

Demand Drive fluid (2.5 Gallon / 9.5 l)

Oil Pump for 1 Gallon Jug

60/40 Coolant (1 Gallon / 3.8 l) (6 Count)

60/40 Coolant (Quart / .95 l) (12 Count)

Premium All Season Grease (3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

U-Joint Grease (3 oz.) (24 Count)

U-Joint Grease (14 oz.) (10 Count)

Dielectric Grease (Nyogel™)

Premium Carbon Clean (12 oz.) (12 count)

Fuel Stabilizer (16 oz.) (12 count)

DOT 4 Brake Fluid (12 count)

Loctite™ Threadlock 242 (6 ml.) (12 count)

Crankcase Sealant, 3-Bond 1215 (5 oz.)

POLARIS Battery Tender™ Charger

Engine Lubricant

Gearcase / Transmission Lubricants

Coolant

Grease / Specialized Lubricants

Miscellaneous

2870791

2876244

2876245

2878920

2878919

2878068

2878069

2878070

2877922

2877923

2870465

2871323

2871534

2871312 Grease Gun Kit

2871322

2871423

2871460 Premium Starter Grease

2871515

2871551

2871329

2871326

2870652

2872189

2871950

2871956 Loctite™ 565 Thread Sealant

2871557

2859044

MAINTENANCE

NOTE: Each item can be purchased separately at your local Polaris dealer.

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

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MAINTENANCE

Lubrication Components

# ITEM LUBE METHOD

Engine Oil

Transmission

Front

Gearcase

4. Brake Fluid

5. Front A-Arm

6. Rear A-Arm

Propshafts

* Perform more often under severe use, such as operation in water and under severe loads.

(A) Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads).

(B) Annually or 100 hours of operation Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads). ADC gearcase fluid should be changed every 25hrs of operation in extreme use conditions (i.e. continuous operation on hilly or mountainous terrain or if ADC ‘on’ is primary mode of AWD operation).

(C) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special.

Polaris PS-4 5W-50 4-Cycle Oil

Polaris AGL Synthetic Gearcase Lube

Demand Drive

Polaris DOT 4 Brake Fluid

Polaris All Season Grease

Polaris U-Joint Grease

(C)

Check oil tank dipstick and add to proper level.

Add lube to bottom fill hole.

Drain as directed. Add specified quantity.

Fill master cylinder reservoir to indicated level

Locate fitting and grease. Semi-annually (A)

Locate fitting and grease Semi-annually (A)

Locate fitting and grease. Semi-annually (A)

FREQUENCY*

Change after 1st month, 6 months, or 100 hours thereafter; Change more often (25-50 hours) in extremely dirty conditions, or short trip cold weather operation.

Change annually (B)

As required, change fluid every 2 years

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FUEL SYSTEM AND AIR INTAKE

MAINTENANCE

Fuel System

WARNING

* Gasoline is extremely flammable and explosive under

certain conditions.

* EFI components are under high pressure. Verify

system pressure has been relieved before disassembly.

* Never drain the fuel system when the engine is hot.

Severe burns may result

* Do not overfill the tank. The tank is at full capacity

when the fuel reaches the bottom of the filler neck.

Leave room for expansion of fuel. * Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous

and can cause loss of consciousness and death in a

short time.

* Do not smoke or allow open flames or sparks in or

near the area where refueling is performed or where

gasoline is stored.

* If you get gasoline in your eyes or if you should

swallow gasoline, seek medical attention immediately.

* If you spill gasoline on your skin or clothing,

immediately wash with soap and water and change

clothing.

* Always stop the engine and refuel outdoors or in a

well ventilated area.Keep away from open flames and

electrical components when removing fuel filter.

Fuel Lines

1. Check fuel lines for signs of wear, deterioration, damage, or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly, the connectors latched and the lines secured with cable ties.

CAUTION

Make sure lines are not kinked or pinched.

3. Replace all fuel lines every two years.

NOTE: See Chapter 4 for fuel line routing diagram.

Vent Lines

Check fuel tank, oil tank, crankcase, battery and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

Be sure vent lines are routed properly and secured with cable ties.

CAUTION

Make sure lines are not kinked or pinched.

• 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 loss of consciousness or death in a short time.

• Never drain the system when the engine is hot.

Severe burns may result.

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MAINTENANCE

Throttle Inspection

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in Park.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speed increases at any point in the turning range, inspect throttle cable routing and condition. Adjust cable tension as needed until lock-to-lock turning can be accomplished with no rise in engine rpm.

5. Replace the throttle cable if worn, kinked, or damaged.

Throttle Cable / Throttle Release System (TRS Switch) Adjustment

1. Slide boot off throttle cable adjuster and jam nut.

2. Place shift selector in neutral and set parking brake.

3. Loosen lock nut on in-line cable adjuster (Ill. 1).

4. Turn adjuster until specified freeplay is achieved at thumb lever. (see illustration). After making adjustments, quickly actuate the thumb lever several times and reverify freeplay.

To remove the TRS cover:

6. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position.

7. Twist screwdriver slightly while lifting on the cover to release snap.

8. Repeat procedure at the other five locations as shown.

NOTE: Do not attempt to remove cover until all latch points are released.

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9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Throttle Freeplay:

.0625 - .1250" (1.58 - 3.17mm)

5. Tighten lock nut securely and slide boot completely in place to ensure a water-resistant seal.

6. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure

Page 33

MAINTENANCE

Air Filter/Pre-Filter Service

It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often.

The pre filter should be inspected before each ride, and if required, cleaned using the following procedure:

1. Lift up on the rear of the seat.

2. Pull the seat back and free of the tabs.

NOTE: When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.

3. Remove clips (1) from air box cover and remove cover (2). Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

Cleaning:

5. Slip the pre-filter element (1) off of main element . Clean the pre filter with hot, soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Installation:

9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps.

4. Loosen clamp (1) and remove air filter assembly.

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MAINTENANCE

10. Reinstall filter on main filter mount. Place filter clamp over the assembly and tighten.

NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling.

NOTE: The air filter should rest on the filter supports (1,2). Proper placement of the air filter is important to prevent rattles and air leaks. See Illustration above.

Air Box Sediment Drain

Periodically check the air box drain (1) located in the bottom of the air box. Drain whenever deposits are visible in the air box.

1. Remove drain plug (1) from air box.

11. Install air box cover and secure with the clips.

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9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

2. Drain air box.

3. Reinstall drain plug.

NOTE: The sediment drain will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

Page 35

Crankcase Breather Valve / Hose

The breather valve is on the hose that runs between the engine and air box. Be sure breather line is routed properly and secured in place.

1. Remove the left side panel

2. Remove the hose clamps from the valve and pull the valve out of the hoses.

3. Inspect the valve for debris. Blow gently through the valve to check for clogging. Replace a damaged or clogged valve.

NOTE: In-line breather filter service life is extended when the foam air box pre-filter is in place and maintained properly. Never operate the engine without the pre-filter.

MAINTENANCE

4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

CAUTION

Make sure lines are not kinked or pinched.

5. Reinstall the valve and hose clamps.

CAUTION

Operation of your vehicle without a breather valve can

cause engine damage. Always reinstall the breather

6. Install the left side panel

valve after removing it for service.

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MAINTENANCE

ENGINE

Engine Oil Level

Access the oil dipstick and fill tube from the right side of the ATV. 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/safe mark, change the oil immediately.

1. Set machine on a level surface.

2. Clean the area around the dip stick.

3. Remove dipstick and wipe dry with a clean cloth.

4. Reinstall dipstick completely.

NOTE: The dipstick must be screwed completely in to ensure accurate measurement.

5. Remove dipstick and check to see that the oil level is in the normal range (2). The oil should be between the top line and the bottom line on the dipstick. Add oil as indicated by the level on the dipstick. Do not overfill.

NOTE: Rising oil level between checks in cool weather driving, can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil.

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing oil.

Oil Filter Torque: Turn by hand until filter gasket contacts sealing surface, then

turn an additional 1/2 turn

Oil Filter Wrench:

PV-50105

Recommended Engine Oil:

Polaris PS–4

Synthetic 5W-50

CAUTION

Personal injury can occur when handling used oil. Hot

oil can cause burns or skin damage.

NOTICE: Care must be taken to ensure that the fluids are contained. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembly of any component containing fluids.

1. Place vehicle on a level surface.

2. Place the transmission in PARK (P).

3. Clean area around drain plug at bottom of oil pan.

4. Start the engine. Allow it to warm up at idle for two to three minutes.

5. Stop the engine.

6. Place a drain pan under the crank case.

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MAINTENANCE

7. Remove the drain plug. Allow oil to drain completely.

8. Replace sealing washer on drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

9. Reinstall the drain plug and torque it to specification.

21. Check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

22. Dispose of used filter and oil properly.

Oil pan Drain Plug: 14–18 ft-lbs (19–24 Nm)

10. Place a drain pan under the oil filter.

11. Place shop towels beneath oil filter. Use Oil Filter Wrench (PV-50105), turn filter counterclockwise to remove.

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

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

14. Install the new filter and turn it by hand until the filter gasket contacts the sealing surface, then turn an additional 1/2 of a turn.

15. Remove dipstick (see “Engine Oils Level”).

16. Add two quarts (1.9 l) of of Polaris Premium 4 Synthetic Oil.

17. Place the transmission in PARK (P).

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

19. Start the engine. Allow it to idle for two minuets.

20. Stop the engine and check for leaks.

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MAINTENANCE

Compression Test Specification

NOTE: This engine does have 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)

Engine Mounts

Inspect rubber engine mounts for cracks or damage. Check engine fasteners and ensure they are tight.

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 air box cover and PVT ducting tubes. (Non-Touring models require fuel tank removal.

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 (3) T40 bolts retaining the valve cover.

NOTE: Discard valve cover Isolators upon removal. New Isolators are required once removed.

Inspect the valve cover gasket and replace if damaged or signs of leaking are present.

5. Remove the valve cover from the engine.

2.18

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

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MAINTENANCE

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.

9. If the valve clearance is out of specification, proceed to “Valve Clearance Adjustment” (see Chapter 3).

Intake Valve Clearance (cold):

.006 ± .002 in. (0.152 ± .050 mm)

Exhaust Valve Clearance (cold):

.008 ± .002 in. (0.203 ± .050 mm)

10. Repeat steps 8-9 until all (4) valves have been inspected.

11. Inspect the valve cover gasket and replace if damaged or signs of leaking are present.

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

NOTE: New valve cover isolators are required.

13. Install drive belt and outer clutch cover and (8) retaining screws (see Chapter 6). Torque to specification.

Outer Clutch Cover Screws:

14. Connect the negative (-) battery cable to the battery.

15. Start the engine to ensure proper operation.

16. Reinstall the air box cover, PVT ducting and seats (see Chapter 5).

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45-50 in-lbs (5 Nm)

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MAINTENANCE

Exhaust Pipe

WARNING

Do not perform clean out immediately after the engine

has been run, as the exhaust system becomes very

hot. Serious burns could result from contact with

exhaust components.

To reduce fire hazard, make sure that there are no

combustible materials in the area when purging the

spark arrestor.

Wear eye protection.

Do not stand behind or in front of the vehicle while

purging the carbon from the spark arrestor.

Never run the engine in an enclosed area.Exhaust

contains poisonous carbon monoxide gas.

Do not go under the machine while it is inclined.Set the

hand brake and block the wheels to prevent roll back.

Failure to heed these warnings could result in serious

personal injury or death.

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the clean out plugs located on the bottom of the muffler.

3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.

4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE

WARNING

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE

WARNING

2. Place the transmission in Park and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

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6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the clean out plugs.

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TRANSMISSION AND FRONT GEARCASE

MAINTENANCE

Transmission Lubrication

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

• Be sure vehicle is level and in Park before proceeding.

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

• Follow instructions to check/change transmission lubricant.

Transmission Check/Fill Plug:

14 ft-lbs (19 Nm)

2. Remove transmission drain plug to drain the oil. Discard used oil properly.

NOTE: The check/fill plug is a 3/16” hex.

3. Clean and reinstall the drain plug. Torque to specification.

Transmission Drain Plug:

14 ft-lbs (19 Nm)

To Check the Fluid Level:

1. Remove check / fill plug from the left side of transmission and visually inspect the oil level. Level is correct when it reaches the bottom of the fill hole threads.

NOTE: The check/fill plug is a 5/16” hex.

To Change Lubricant:

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

4. Remove fill plug.

5. Add the correct amount of Polaris AGL Plus Gearcase Lubricant.

Transmission - Specified Lubricant:

Polaris AGL Gearcase Lubricant

(Gallon - PN 2878069) (1qt. - PN 2878068)

Capacity: 33.8 oz. (1000 ml)

6. Check for leaks.

7. Install fill plug. Torque to specification.

Transmission Check/Fill Plug:

14 ft-lbs (19 Nm)

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MAINTENANCE

Shift Link Rod Maintenance

NOTE: Shift rod is preset at time of manufacturer.

1. Lubricate pivot points with a light aerosol lubricant or grease if desired.

Front Gearcase Lubrication

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

• Be sure vehicle is level before proceeding and in

PARK

• Check vent hose to be sure it is routed properly

and unobstructed

• The correct front gearcase lubricant to use is Polaris Demand Drive PLUS Hub Fluid.

Specified Lubricant:

Demand Drive PLUS Hub Fluid

Gearcase Capacity: 8.97oz. (265 ml.)

Fill Plug: 8-10 ft-lbs (11-14 Nm)

Drain Plug: 11 ft-lbs (15 Nm)

2.22

To Check the Lubricant Level:

The front gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and refilled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.

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MAINTENANCE

To Change Gearcase Lubricant:

1. Remove gearcase drain plug (A) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (A) using a new sealing washer (B). Torque to specification.

4. Fill with the recommended fluid amount or to the bottom of the fill plug hole threads. (See Illustration below).

5. Install / torque fill plug and check for leaks.

3. Remove fill plug. Inspect the O-ring.

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MAINTENANCE

COOLING SYSTEM

Liquid 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.

Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period.

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.

Coolant Level Inspection

The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.

3. Reinstall cap.

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.

Radiator Coolant Level

WARNING

Never remove the radiator pressure cap when the

engine is warm or hot. Escaping steam and fluid can

cause severe burns. The engine must be allowed to

cool before removing the pressure cap.

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected via the radiator cap first and coolant added if necessary.

Use of a non-standard pressure cap will not allow the recovery system to function properly.

To Access the Radiator Pressure Cap:

1. Open the front rack storage area.

2. Remove the (4) T-25 screws securing the access cover to the front cab as shown below.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If not:

1. Remove reservoir cap. Inner splash cap vent hole must be clear and open.

2. Fill reservoir to upper mark with Polaris Premium 60/ 40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

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MAINTENANCE

3. Move the seal out of the sealing channel and pull up on the front of the access cover. Remove the access cover.

4. The pressure cap is now accessible.

5. Remove the pressure cap and inspect fluid level. Using a funnel, add coolant until the fluid level is to the top of the filler neck.

6. Reinstall the pressure cap and install the front access cover.

Cooling System Hoses

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

2. Check tightness of all hose clamps.

CAUTION

Do not over-tighten hose clamps at radiator,

or radiator fitting may distort,

causing a restriction to coolant flow.

Radiator hose clamp torque is 36 in-lbs (4 Nm).

Cooling System Pressure Test

System Pressure Test

1. Remove radiator cap cover located under the storage box access panel. See Chapter 3.

2. Remove recovery bottle hose from coolant filler.

3. Connect a Mity-Vac™ (PN 2870975) to radiator and pressurize system to 10 PSI (68.9 kpa). The system must retain 10 lbs of pressure for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps, or water pump seal.

Radiator Cap Pressure Test

4. Remove radiator cap and test using a cap tester (commercially available).

5. The radiator cap relief pressure is 13 lbs (89.6 kpa).

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.

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MAINTENANCE

Coolant Strength / Type

Test the strength of the coolant using an antifreeze hydrometer.

• A 50/50 or 60/40 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 60/40 Anti-Freeze/ Coolant

(PN 2871323)

Coolant Drain / Fill

Coolant Drain

1. Remove the front cover located under the front rack, right inner fender and footwell plastics.

2. Slowly remove the pressure cap (1) to relieve any cooling system pressure.

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.

2.26

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 hose (1) from the radiator as shown. Properly dispose of the coolant.

5. Allow coolant to completely drain.

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MAINTENANCE

6. Place a suitable drain pan underneath the lower engine hose(1) on the right-hand side of the 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”.

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

Radiator/Grill Screen

1. Check radiator air passages for restrictions or damage. Check and clean the radiator grille if needed.

2. Carefully straighten any bent radiator fins.

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

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MAINTENANCE

FINAL DRIVE / WHEEL AND TIRE

Wheels

Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.

WARNING

Operating an ATV with worn tires will increase the

possibility of the vehicle skidding and possible loss of

Worn tires can cause an accident.

Always replace tires when the tread depth measures 1/

Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.

control.

8” (.3 cm) or less.

Wheel, Hub, And Spindle Torque Table

ITEM

Steel - Front Wheel Nuts

Steel - Rear Wheel Nuts

Aluminum Front Wheel Nuts

Aluminum Rear Wheel Nuts

Front Hub Retaining Nut 60 ft-lbs (81 Nm)

Rear Hub Retaining Nut 80 ft-lbs (109 Nm)

SPECIFICATION

27 ft-lbs (37 Nm)

27 ft-lbs (37Nm)

30 ft-lbs + 1/4 Turn (41 Nm + 1/4 Turn)

Wheel Removal Front or Rear

1. Stop the engine, place the transmission in Park and lock the parking brake.

2. Loosen the wheel nuts slightly.

• Elevate the side of the vehicle by placing a

suitable stand under the footrest frame.

3. Remove the wheel nuts and remove the wheel.

Wheel Installation

1. With the transmission in Park and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

Tire Pressure

CAUTION

Maintain proper tire pressure. Refer to the warning tire

Tire Pressure (Cold)

Front Rear

5 (34.5 Kpa) 5 (34.5Kpa)

pressure decal applied to the vehicle.

2.28

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MAINTENANCE

4. Securely tighten the wheel nuts to the proper torque listed in the table.

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.

Tire Inspection

• Improper tire inflation may affect ATV

maneuverability.

• When replacing a tire always use original

equipment size and type.

• The use of non-standard size or type tires may

affect ATV handling.

Tire Tread Depth

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

WARNING

Operating an ATV 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 cm) or less.

CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear of the ATV for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement.

Frame, Nuts, Bolts, 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.

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MAINTENANCE

BRAKE SYSTEM

Brake System Inspection

The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.

• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir.

• Use Polaris DOT 4 Brake Fluid

Use Polaris DOT 4 Brake Fluid

Brake Pad Inspection

Pads should be changed when the friction material is worn to .180” / 4.6 mm, or about the thickness of a dime.

Brake Pad Service Limit:

.180" (4.6 mm)

Hose/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.

• Check brake for excessive travel or spongy feel.

• Check brake system for fluid leaks.

• Check friction pads for wear, damage or looseness.

• Check surface condition of the disc.

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MAINTENANCE

Auxiliary Brake Testing

The auxiliary brake should be checked for proper function.

1. Support the rear wheels off the ground.

2. While turning the rear wheels by hand, apply the auxiliary foot brake. This brake should not stop the wheels from turning until the lever is half way between its rest position and bottoming on the footrest.

Auxiliary Brake Adjustment (Hydraulic)

Use the following procedure to inspect the hydraulic auxiliary (foot) brake system and adjust or bleed if necessary:

First, check foot brake effectiveness by applying 50 lb. (approx.) downward force on the pedal. The top of the pedal should be at least 1 inch, (25.4mm) above the surface of the footrest.

If less than one inch, two things must be examined:

Free Play:

1/8 - 1/4" (3.2 - 6.35 mm)

If free play is excessive, inspect pedal, linkage, and master cylinder for wear or damage and replace any parts as needed.

Bleeding:

If free play is correct and brake pedal travel is still excessive, air may be trapped somewhere in the system. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Brake Chapter 9.

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Foot Brake Freeplay:

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MAINTENANCE

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Complete battery servicing information for both conventional and sealed batteries can be found in Chapter 10 of this manual.

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, birth defects, or other reproductive harm.

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

a 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.

Battery Removal

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.

1. Remove body panel above the left footwell.

2. Disconnect the black (2) negative battery cables(s).

3. Disconnect the red (1) positive battery cable(s).

NOTE: Expected battery shelf life is 6-8 months depending on storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly.

New Batteries: Batteries must be fully charged before use or battery life can be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/ hour capacity (i.e. 12amp hr x .10 = 1.2 amp charging). Do not use the alternator to charge a new battery.

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MAINTENANCE

4. Remove the screw (see (2) shown in step 3) that fastens the hold-down strap and remove the hold down strap(1).

NOTE:

5. Lift the battery out of the vehicle.

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 installing the battery.

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.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with hold-down strap. (see (2) shown in step 4)

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

4. Connect and tighten the red positive cable(s) first.

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MAINTENANCE

5. Connect and tighten the black (negative) cable last.

6. Verify that cables are properly routed and reinstall the body panel above the footwell.

Spark Plug Service

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

WARNING

A hot exhaust system and engine can cause serious

burns. Allow engine to cool or wear protective gloves

when removing the spark plugs.

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

3. Remove the spark plug wire from the engine.

2.34

NOTE: Image For Reference Only.

4. Remove spark plug.

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

6. Clean with electrical contact cleaner only.

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MAINTENANCE

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

8. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

9. Apply Anti-seize compound to the spark plug threads.

10. Install spark plugs and torque to specification.

Recommended Spark Plug:

Champion RG6YC

Spark Plug:

7 ft-lbs (10 Nm)

Apply Anti-seize

Engine To Frame Ground

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

The engine ground cable runs from the upper starter motor mounting bolt to the battery.

The chassis ground runs from the battery to the terminal block located at the front of the machine near the fuse box.

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

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

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MAINTENANCE

STEERING

The steering components should be checked periodically for loose fasteners, worn tie rod ends, 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 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.

NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in

this chapter, Polaris recommends steering component

repair and adjustment be performed by an authorized

MSD-certified technician when replacing worn or

damaged steering parts.

Use only genuine Polaris replacement parts.

Tie Rod End/Steering Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Repeat inspection for inner tie rod end on steering post.

• 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.

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

2.36

• Refer to the Body/Steering Chapter 5 or Final Drive Chapter 7 for service procedures.

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Front Suspension

Compress and release front suspension. Damping should be smooth throughout the range of travel.

Check all front suspension components for wear or damage.

Inspect front strut cartridges for leakage.

Suspension Spring Preload Adjustment

Shock Spanner Wrench

(PN 2871095)

Operator weight and vehicle loading affect suspension spring preload requirements. Adjust as necessary, using the spanner wrench (2) to turn the adjustment cam (1).

MAINTENANCE

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.

• 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. See illustration 2.

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

Toe Alignment Adjustment

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

handlebars are straight ahead before determining which tie rod(s) need 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.

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Tie Rod Jam Nut:

12-14 ft-lbs (16-19 Nm)

Camber and Caster

The camber and caster are non-adjustable.

Wheel Alignment

1. Place machine on a smooth level surface.

2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering arm center section can be used as an indicator of whether the handlebars are straight. The center section should always point straight back from the steering post.

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MAINTENANCE

3. 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 that the height of both marks be equally positioned in order to get an accurate measurement.

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

5. Rotate the tires 180 backward. Position chalk marks facing rearward, even with the hub/axle centerline.

6. 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 cm) toe out. This means the measurement at the front of the tire (A) is 1/8" to 1/4" (.3 to .6 cm) wider than the measurement at the rear (B)

by moving vehicle forward or

2.38

(A) - (B) = 1/8” to 1/4" (3 to 6 mm)

Wheel Toe-Out:

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ENGINE

CHAPTER 3

ENGINE

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

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

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

OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . 3.5

ENGINE OIL FLOW CHART .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 3.7

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . . . . . . . . . . . . . . . . . .. . . . . . . 3.9

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE. . . . . . . . . . . . . . . . . . . . . 3.9

CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . 3.10

CYLINDER / OIL FILTER / OIL PUMP / BREATHER . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . 3.11

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER. . . . . . . . .. . . . . . . 3.12

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

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

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM . . . .. . . . . . . . . . . . . . . . . . . . .3.16

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.17

PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

RADIATOR.. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .3.18

THERMOSTAT REPLACEMENT ... . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

COOLING SYSTEM BLEEDING PROCEDURE . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .3.20

WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . .3.22

WATER PUMP COVER AND IMPELLER SERVICE (STATOR COVER REMAINS ON ENGINE) . . . ..3.22

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

ENGINE SERVICE .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30

ACCESSIBLE ENGINE COMPONENTS . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .3.30

TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .3.30

ENGINE REMOVAL . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

ENGINE INSTALLATION . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 3.34

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

ENGINE LUBRICATION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .3.37

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

SETTING TDC (TOP-DEAD-CENTER) ... . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . .3.39

ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.40

VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.40

CAMSHAFT / CARRIER REMOVAL . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.40

CAMSHAFT SPROCKET INSPECTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . .3.42

CAMSHAFT INSPECTION . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

EXHAUST CAMSHAFT DECOMPRESSION MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .3.43

CAM CHAIN AND GUIDE SERVICE . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 3.43

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ENGINE ASSEMBLY - TOP END. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 3.54

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

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.43

CYLINDER HEAD DISASSEMBLY . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .3.46

COMBUSTION CHAMBER CLEANING. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

VALVE SEAT RECONDITIONING . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

CYLINDER REMOVAL . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 3.49

CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . .3.50

PISTON-TO-CYLINDER CLEARANCE . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . .3.51

PISTON / ROD INSPECTION.. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52

HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53

CYLINDER HONE SELECTION / HONING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .3.53

CLEANING THE CYLINDER AFTER HONING . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53

PISTON RING INSTALLATION . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .3.54

PISTON / CONNECTING ROD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . .3.55

CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 3.55

CYLINDER HEAD INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .3.56

VALVE SEALING TEST . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . .3.57

VALVE CLEARANCE CHECK / ADJUSTMENT . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.58

INTAKE VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .3.61

EXHAUST VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62

CAMSHAFT INSTALLATION / TIMING. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63

CAMSHAFT TIMING - QUICK REFERENCE. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66

VALVE COVER INSTALLATION . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . .3.67

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

FLYWHEEL / STATOR HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . 3.68

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

STARTER ONE-WAY CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.70

FLYWHEEL INSTALLATION. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .3.70

STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.71

STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3.71

OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . ..3.74

CRANKCASE BREATHER VALVE / HOSE.. . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75

CRANKCASE SEPARATION ... . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .3.76

BALANCE SHAFT REMOVAL / INSPECTION. . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77

CRANKSHAFT REMOVAL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .3.78

CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . .3.78

PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79

MAG SIDE CRANKCASE BEARING SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .3.81

OIL PICKUP ASSEMBLY INSPECTION. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81

OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.81

CRANKCASE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .3.82

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ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .3.83

CRANKCASE ASSEMBLY – PTO SIDE. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83

BALANCE SHAFT INSTALLATION / TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.85

FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.85

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

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

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

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GENERAL INFORMATION

Special Tools

PART NUMBER TOOL DESCRIPTION

PW-47053

PU-50658 Clutch Center Distance Tool

PU-50784 Crankshaft Removal / Installation Tool Kit

PU-50563

PU-50624

PU-50824-A

PU-50625

PW-47054

PA-49316

PU-50105 Oil Filter Wrench

PV-43531

PU-50569

PA-49317 Stator Cover Removal Handles

PV-1253 or PV-4019 (Quick Release) Valve Spring Compressor

PV-43513-A

PU-50689

Bench Mount Engine Stand Adapter

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 Adapter

Water Pump Mechanical / Oil Seal Installation Kit

Bosch Automotive Service Solutions- 1-800-328-6657 http://polaris.service-solutions.com/.

Engine Lubrication Specifications

Oil Capacity:

Approx. 2 Quarts (1.9 L)

Oil Filter Wrench:

PU-50105 or 2.5” (64 mm)

Oil Type:

Polaris PS-4

Synthetic Engine Oil

Oil Pressure

(using Polaris PS-4 at operating temperature)

Minimum Specification:

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

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Oil Pressure Test

1. Attach the Oil Pressure Gauge Adapter (PU-50569) to the Oil Pressure Gauge (PV-43531).

Oil Pressure Gauge Adapter: PU-50569

Oil Pressure Gauge: PV-43531

2. Remove the seat, Left footwell, and left side pannel.

3. Clean the area around the main oil gallery plug (1), located on the oil filter adapter housing.

4. Remove the plug (1) 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.

Oil Capacity:Approx. 2 Quarts (1.9 L)

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

Oil Type:Polaris PS-4

Synthetic Engine Oil

Oil Pressure

Minimum Specification:

(using Polaris PS-4 Plus at operating temperature)

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

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

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Oil Gallery Plug:

11 ft-lbs (15 Nm)

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ENGINE

Engine Oil Flow Chart

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ENGINE SERVICE SPECIFICATIONS

Engine Specifications

CAMSHAFT / CYLINDER HEAD / CYLINDER (IN. / MM)

Cam Lobe Height - Intake

Cam Lobe Height - Exhaust

Camshaft Journal O.D. All (Standard)

Camshaft Journal O.D. All (Service Limit)

Camshaft Journal Bore I.D. -

Camshaft

Cylinder Head

Valve Seat

Valve Guide Valve Guide Inner Diameter

Valve

Valve Spring Free Length (Standard)

Cylinder

All (Standard)

Camshaft Journal Bore I.D. All (Service Limit)

Camshaft Oil Clearance (Standard)

Camshaft Oil Clearance (Service Limit)

Camshaft End Play (Standard)

Camshaft End Play (Service Limit)

Cylinder Head - Surface Warp Limit

Cylinder Head - Standard Height

Contacting Width - Intake (Standard)

Contacting Width - Intake (Service Limit)

Contacting Width - Exhaust(Standard)

Contacting Width - Exhaust (Service Limit)

Valve Seat Angles

Valve Lash (Cold) - Intake

Valve Lash (Cold) - Exhaust

Valve Stem Diameter - Intake

Valve Stem Diameter - Exhaust

Valve Stem Oil Clearance - Intake

Valve Stem Oil Clearance - Exhaust

Valve Stem Overall Length - Intake

Valve Stem Overall Length - Exhaust

Cylinder - Surface Warp Limit (mating with cylinder head)

Cylinder Bore - Standard

1.5704" ± 0.0038" (39.89 ± 0.097 mm)

1.5405" ± 0.0038" (39.13 ± 0.097 mm)

0.9029" - 0.9037 " (22.933 - 22.954 mm)

0.9025" (22.923 mm)

0.9055" - 0.9063" (23.000 - 23.021 mm)

0.9072" (23.044 mm)

0.0018" - 0.0034" (0.046 - 0.088 mm)

0.0047" (0.121 mm)

0.0069" - 0.0128" (0.175 - 0.325 mm)

0.0157" (0.4 mm)

0.0024" (0.060 mm)

4.745" ± 0.0020" (120.53 ± 0.05 mm)

0.0393" ± 0.0039" (1.0 ± 0.10 mm)

0.0551" (1.4 mm)

0.0590" ± 0.0039" (1.5 ± 0.10 mm)

0.0748" (1.9 mm)

30.0° ± 1.5° /

45.0° ± 0.5° /

60.0° ± 1.5°

0.2165" - 0.2171" (5.500 - 5.515 mm)

0.006" ± 0.002" (0.152 ± 0.050 mm)

0.008" ± 0.002" (0.203 ± 0.050 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)

3.7704" (95.77 mm)

3.7964" (96.43 mm)

1.7263” (43.85 mm)

0.00098" (0.025 mm)

3.8976" ± 0.0003" (99.0 mm ± 0.008 mm)

ENGINE

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ENGINE

CAMSHAFT / CYLINDER HEAD / CYLINDER (IN. / MM)

Cylinder Out of Round Limit

Cylinder Taper Limit

Cylinder to Piston Clearance

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.

Piston

Piston Pin

Piston Ring

Connecting Rod

Crankshaft

Balance Shaft

See text.

Piston Pin Bore I.D. (Standard)

Piston Pin Bore I.D. (Service Limit)

Piston Pin O.D. (Standard)

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

Top Ring (Standard)

Top Ring (Service Limit)

Second Ring

Installed Gap

Ring to Groove Clearance

Small End I.D. (Standard)

Small End I.D. (Service Limit)

Big End I.D.

Main Journal O.D. (Service Limit)

Crankshaft Runout Limit (PTO and MAG)

Bearing Journal O.D. (Standard)

(Standard)

Second Ring (Service Limit)

Oil Control Rails

(Standard)

Oil Control Rails (Service Limit)

Top Ring (Standard)

Top Ring (Service Limit)

Second Ring (Standard)

Second Ring (Service Limit)

0.001" (0.025 mm)

0.00019" - 0.00216" (.005 - .055 mm)

3.8957” - 3.8968” (98.953 - 98.980 mm)

0.8662” - 0.8665” (22.004 - 22.010 mm)

0.8677" (22.042 mm)

0.8659" - 0.8661" (21.995 - 22.000 mm)

0.0059" - 0.0122" (0.15 - 0.31 mm)

0.0137" (0.35 mm)

0.0094" - 0.0196"

(0.24 - 0.50 mm)

0.0220" (0.56 mm)

0.0098" - 0.0401" (0.25 - 1.02 mm)

0.0480" (1.22 mm)

0.0011" - 0.0037" (0.030 - 0.095 mm)

0.0042" (0.108 mm)

0.0007" - 0.0029" (0.020 - 0.076 mm)

0.0035" (0.089 mm)

0.8665" - 0.8670" (22.010 - 22.023 mm)

0.8682" (22.053 mm)

See Service Procedure Listed In This Chapter

1.6137" (40.990 mm)

See Service Procedure Listed In This Chapter

1.1798” - 1.1802" (29.969 - 29.979 mm)

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ENGINE

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES

Main Engine Components - Torque Specification and Sequence

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ENGINE

Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve

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Page 69

Cylinder / Oil Filter / Oil Pump / Breather

ENGINE

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ENGINE

Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

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Page 71

Spark Plugs / Starter / Throttle Body / Valve Cover

ENGINE

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ENGINE

Piston / Crankshaft / Balance Shaft

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Page 73

ENGINE COOLING SYSTEM

Cooling System Specifications

ENGINE

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:

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 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 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

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

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ENGINE

Cooling System Exploded View and Coolant Flow Diagram

REF.

PART DESCRIPTION NOTE

1 CAP, PRESSURE 13 psi 17 CLAMP, SPRINGBAND, BLACK

2 ASM., RADIATOR 18 SCREW

3 ASM., GROMMET AND INSERT 19 TANK, SURGE

4 HOSE, ENGINE, LOWER 20 FITTING, BARBED, 90 DEG

HOSE, BYPASS, FORMED 21 HOSE, CLEAR

6 CONNECTOR, TEE 22 LINE, FUEL

CLAMP, SPRINGBAND, BLACK 23 SPRING, COOLANT HOSE GUIDE

8 CLAMP, HOSE, SPRING 24 BUSHING, MOUNT, LOWER RADIATOR

9 ASM., FAN AND MOTOR 25 CAP, OVERFLOW BOTTLE W/FITTING

10 SPACER 26 GASKET, OVERFLOW CAP

11 NECK, FILLER 27 CABLE TIE

12 HOSE, FILLER NECK 28 CLAMP, HOSE

13 HOSE, RADIATOR, UPPER 29 SCREW 36 in-lbs ± 10%

14 HOSE, RADIATOR, LOWER 30 SCREW 6 ft-lbs ± 10%

15 CONDUIT, FLEX 31 SCREW

16 CLAMP, SPRINGBAND, GREEN 32 CLAMP, HOSE

REF.

PART DESCRIPTION NOTE

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Page 75

Coolant Flow

ENGINE

Cooling System Pressure Test

1. Remove the center cover under the front rack.

WARNING

Never remove pressure cap when engine is warm or

hot. The cooling system is under pressure and serious

Allow the engine to cool before servicing.

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

3. The system must maintain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the filler neck, radiator, hoses, clamps and water pump weep hole for leakage.

burns may result.

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Pressure Cap Test

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

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.

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ENGINE

Radiator

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

2. Carefully straighten any bent radiator fins.

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

CAUTION

Coolant Drain / Radiator Removal

Coolant Drain

1. Remove the center cover 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 (1) to relieve any cooling system pressure.

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.

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3. Place a suitable drain pan underneath the water pump inlet housing on the front right-hand side of the vehicle.

4. Drain the coolant from the cooling system by removing the lower coolant hose from the water pump housing then the lower radiator outlet (2) as shown. Properly dispose of the coolant.

5. Allow coolant to completely drain.

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

7. Remove the hose and completely drain the engine.

Radiator Removal

1. Remove the front bumper.

2. Remove the upper engine outlet hose and recovery

hose from the top of the radiator.

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ENGINE

3. Remove the upper radiator retaining bolts and the bolts retaining the lower radiator mount bracket. Remove the bracket from the frame.

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

5. Reverse procedure for installation.

Thermostat Replacement

1. Remove the left side panel and PVT intake / exhaust ducting as required.

WARNING

The cooling system is under pressure and serious

burns may result.

Allow the engine to cool before servicing.

2. Remove front rack , front cab and fuel tank . (not required for touring models)

3. Remove the pressure cap to relieve any system pressure (see “Pressure Cap Test”).

4. Drain coolant to a level below the thermostat housing.

5. Remove the spark plug wire from the engine.

6. Remove the (2) bolts (X) retaining the thermostat cover.

NOTE: Image For Reference Only.

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.

Thermostat Cover Bolts:

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7.5 ft-lbs (10 Nm)

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ENGINE

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

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.

Use caution when performing these procedures.

Coolant may be hot and may cause severe injury or

burns.

If the coolant level is LOW in the radiator, or if there are

leaks in the system, the coolant system will not draw

coolant from the reservoir tank.

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.

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.

4. Remove the recovery bottle cap (2) and fill the bottle to the MAX line.

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

6. Open the bleed screw (C) to allow any trapped air to escape.

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

2. Remove Left side panel, required PVT ducting and Center panel under the front rack.

3. Remove the pressure cap (1) and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

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

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).

Page 79

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.

Coolant Bleed Screw:

6 ft-lbs (8 Nm)

14. Fill the recovery bottle to the MAX line.

15. Reinstall the Left side panel, required PVT ducting and Center panel under the front rack.

ENGINE

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ENGINE

WATER PUMP SERVICE

Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)

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

injury or burns.

2. Remove the seat, right side panel, and right footwell.

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 Center cover under the front rack.

6. Remove the pressure cap from the filler neck.

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

8. Remove the bolts(1) attaching the water pump cover to the stator cover.

9. Remove the water pump cover (2) and water pump cover gasket (3). Discard the water pump gasket (3).

10. Using an 8mm socket, remove the water pump impeller (4).

NOTE: The water pump impeller (4) uses reverse (LH) threads.

12. Follow this procedure in reverse to assemble the water pump impeller and cover. Always use a new water pump cover gasket(3). Torque all fasteners in sequence to specification.

Water Pump Cover Fastener:

9 ft-lbs (12 Nm)

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

Water Pump Mechanical Seal / Oil Seal Replacement

Removal

NOTE: The stator cover must be removed from the engine to service the water pump drive shaft, oil seal, mechanical seal and bearing.

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

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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 the seat, right side panel and footwell.

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 center cover under the front rack.

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ENGINE

6. Remove the pressure cap from the filler neck.

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

8. Disconnect the stator wire connector and unsecure the wiring from the front engine mount bracket.

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

10. Remove the oil dipstick.

11. Remove the bolts (1) retaining the water pump cover to the stator cover.

12. Remove the water pump cover (2) and water pump cover gasket (3). Discard the water pump gasket (3).

13. Remove the water pump impeller (4).

NOTE: The water pump impeller (4) uses reverse (LH) threads.

15. If needed, install the stator cover removal handle tool (PA-49317) to the water pump cover bolt holes to aid in stator cover removal.

NOTE: Image For Reference Only.

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.

14. Remove the bolts (5) securing the stator cover (6) to the engine.

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

16. Remove and discard the stator cover gasket.

CAUTION

Be sure engine coolant does not contaminate the

engine oil during stator cover service.

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

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ENGINE

18. 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.

19. Extract the mechanical seal (E) and the oil seal (F) from the stator cover.

20. Press out the water pump drive shaft bearing (G) from the stator cover. Discard bearing and replace with new.

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ENGINE

Water Pump Assembly

1. Thoroughly clean the stator cover.

2. Press in a new water pump drive shaft bearing (G) until it is fully seated in the cover.

CAUTION

Be sure bearing is fully seated in cover or severe

engine damage may result.

4. Press in the water pump drive shaft (H) into the bearing using PU-50869 Item #1.

3. Clean and de-grease the water pump drive shaft (H).

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ENGINE

5. 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.

7. Use the water pump oil seal installation tool in kit PU50869 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

8. Use the water pump mechanical seal installation tool in kit PU-50869 to fully install the new water pump mechanical seal (J) until it is fully seated in the cover.

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

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

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ENGINE

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

IMPORTANT: The crank shaft and water pump drive shaft must me aligned for the case to be assembled.

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

14.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.

NOTE: Image for Reference Only.

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.

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

12.Apply a small amount of crankcase sealant to the area indicated below (1).

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ENGINE

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

Stator Cover and Water Pump Cover:

9 ft-lbs (12 Nm)

16.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.

Mechanical Water Pump Seal Installed Height:

0.280” - 0.287” (7.2 +/- 0.1 mm)

17.Install the water pump impeller (4).

NOTE: The water pump impeller (4) uses reverse (LH) threads. Finger tighten only.

18.Install a new water pump cover gasket.

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Page 87

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

ENGINE

Stator Cover and Water Pump Cover:

9 ft-lbs (12 Nm)

20.Install the oil dipstick.

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

22.Connect the stator wire connector and securing the wiring to the front engine mount bracket.

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

24.Install the seat, right side panel and footwell.

25.Connect the (-) negative battery cable.

26.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.

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

28.Check for leaks.

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ENGINE

ENGINE SERVICE

Accessible Engine Components

The following components can be serviced or removed with the engine installed:

• Camshaft

• Camshaft Sprockets

• Cylinder Head and Gaskets

• Cylinder and Gaskets

• Piston and Rings

• Flywheel

• Starter Motor / Idler Gear Asm

• Stator (Alternator)

• Thermostat

• Valve Cover

• Water Pump

• Camshaft Timing Chain and Guides

• Crankshaft Seal (PTO)

• Oil Pump / Oil Pump Sprocket or Chain

The following components require engine removal for service:

• Counterbalance Shaft and Bearings

• Crankshaft and Bearings

• Crankcase

• Oil Pressure Regulator

• Oil Pump Pickup Assembly

Top-End Service (Engine in Chassis)

ALL of the top-end engine components can be serviced while the engine is mounted in the chassis.

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ENGINE

Engine Removal

NOTE: Some engine repair procedures can be performed without removing the engine assembly from the vehicle. Refer to “Accessible Engine Components” for further information.

The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine.

Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

Drive Clutch Puller P/N PA-48595

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in

this Service Manual.

Failing to do so may lead to possible injury.

1. If vehicle was recently operated, allow it to cool down

before attempting to perform any work.

2. Thoroughly clean the engine and chassis.

3. Disconnect the (-) negative battery cable from the

battery prior to engine removal. (see Battery Removal, page 2.32)

4. Drain the engine oil (See Oil and Filter Change ,

page 2.16) and engine coolant (See Coolant Drain / Fill, page 2.26) prior to engine removal.

5. Remove the seats, footwells, side panels, front cab

and fuel tank. (see BODY, page 5.3and Fuel Tank Removal, page 4.20)

NOTE: Removal of the front cab is not required for touring models.

6. Remove the PVT inlet and exhaust ducts. (See PVT Sealing And Ducting Components, page 6.8)

7. Remove the outer clutch cover, drive belt, drive clutch, driven clutch and inner clutch cover.

NOTE: Be sure to use the correct Drive Clutch Puller (PA-48595) to prevent damage to crankshaft.

8. Remove the fasteners retaining the airbox and the airbox top.

9. Loosen the crank case ventilation hose (1) and disconnect it from the engine (note routing for reassembly).

Remove the right passenger footwell on touring models when performing engine removal.

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ENGINE

10. Loosen the hose clamp (2) securing the throttle body to the air box. Lift air box up and rearward as an assembly to disengage it from the throttle body and remove it from the vehicle.

11. Disconnect the IAC valve (3), TPS (4), T-MAP sensor (5), harness leads from the throttle body.

12. Loosen the hose clamp (6) securing the throttle body to the engine intake boot. Remove throttle body from the engine and wrap it with a clean shop towel. Place throttle body on the left-hand side frame rail area.

NOTE: Be sure dirt and debris do not enter the engine, air box or throttle body. Use clean shop towels to plug engine and air box intake holes.

13. Disconnect the fuel injector harness lead (7) from the fuel injector.

14. Properly relieve fuel pressure from the fuel rail.

15. Place a shop to beneath the fuel line quick connector to catch any excess fuel. Disconnect the fuel line (8) from the fuel rail by pressing in on the quick connector tabs.

16. Move fuel line to the left-hand side of the engine compartment. Make note of line routing for installation.

17. Disconnect the ignition coil harness connector and remove the spark plug wire from the engine.

18. Disconnect the stator wire connector and cut the tie strap securing the wiring to the left front engine mount bracket. Replace tie strap for engine installation. (note routing for reassembly)

19. Disconnect the CPS sensor (1) from the vehicle wiring harness (2) and remove the strain relief (3). (note routing for reassembly)

20. Remove (+) positive cable from the starter motor.

1. If desired, remove the remaining starter motor

bolt and remove the starter motor from the engine.

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ENGINE

21. Remove (-) negative cable(1) by removing the starter mounting bolt.

22. Disconnect the upper engine coolant hose (H), bypass hose (I) and ECT (J) harness connector.

29. With the help of an assistant lift the engine and rotate it out the frame opening at the left side of the vehicle.

NOTE: Rest the engine on the left footwell supports.

30. Use an overhead or portable engine hoist and suitable engine straps to secure the engine in its current position.

NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to the vehicle components.

31. Install the engine stand adapter (PU-50824-A) onto the engine PTO side mounting ears as shown below.

23. Remove the exhaust springs and fasteners retaining the exhaust manifold heat shields.

24. Remove the heat shields and exhaust pipe from the vehicle to gain engine removal clearance.

NOTE: Dispose of exhaust seals at this time.

25. Remove front Prop shaft. (See PROP SHAFT FRONT OR REAR, page 7.34)

26. Remove the fastener that connects the rear engine mount to the frame.

27. Remove the front engine mounts to aid in engine removal.

28. With the help of an assistant rotate the top of the engine forward until the top of the cylinder head is facing the front of the vehicle.

9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

32. Select the proper engine stand sleeve adapter and install it onto the engine stand adapter.

• Sleeve adapter for a 2” bore engine stand:

• (PU-50625)

• Sleeve adapter for a 2.375” bore engine stand:

• (PW-47054)

33. Place engine onto the engine stand (PU-50824-A) for service.

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ENGINE

Engine Installation

Use the following procedure to reinstall the engine assembly.

1. Attach engine with suitable lifting straps to an overhead or portable engine hoist.

2. Remove the engine stand adapter plate.

3. Use the overhead or portable engine hoist and suitable engine straps to lower the engine onto the left footwell support.

NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

4. Remove the lifting straps and overhead or portable engine hoist and remove the support previously installed under the transmission case during the engine removal process.

5. Have an assistant help lift and rotate the engine into the frame.

6. Install the rear engine mount fasteners .

IMPORTANT: Do not tighten fasteners at this time.

7. Install the front engine mounts and fasteners.

IMPORTANT: Do not tighten fasteners at this time.

9. Install the Clutch Center Distance Tool (PN 2871710) onto the crankshaft and transmission input shaft to properly position the clutch center distance. (See CLUTCH ALIGNMENT, page 6.13)

NOTE: Verify clutch center to center alignment at this time.

If necessary shim the rear engine to frame mount as required.

10. Torque the fasteners that attach the front engine mounts to the engine to specification.

8. Torque the rear engine mount fasteners to specification.

23 ft-lbs ± 10% (50 Nm ± 10%)

Flanged nut:

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9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual

Front engine mount:

37 ft-lbs ± 10% (50 Nm ± 10%)

Page 93

11. Torque the fasteners that attach the front engine mounts isolators to specification.

Front engine mount

Isolators:

23 ft-lbs ± 10% (50 Nm ± 10%)

ENGINE

12. Remove the clutch center-to-center tool.

NOTE: The clutch center to center alignment tool should not have pressure on it at this time.

If pressure is observed, adjust as necessary.

13. Install front prop shaft.(See PROP SHAFT - FRONT OR REAR, page 7.34)

14. Reposition the head pipe assembly in the chassis and install new exhaust seals . Install the head pipe bolts and torque to specification.(if removed)

Exhaust Head Pipe Bolts:

18 ft-lbs (24.5 Nm)

15. Install the springs securing the muffler to the head pipe.

16. Install the coolant hoses onto the engine.

17. Install the throttle body and air box. Tighten the hose clamps(see 2 and 6 before step 21) that secure the throttle body to the intake duct, intake boot and air box.

18. Install the lower stater motor bolt through the lower starter motor mounting boss.

19. Instal the starter motor onto the engine.

20. Install the starter motor and battery cables as outlined in Chapter 10.

Starter Motor Fastener:

7 ft-lbs (10 Nm)

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21. Connect the harness leads to the IAC valve (3), TPS (4), T-MAP sensor (5). Verify routing is correct.

22. Connect the fuel injector harness lead (7) to the fuel injector.

23. Connect the fuel line (8) to the fuel rail.

24. Connect the ignition coil harness connector and install the spark plug wire.

25. Install the CPS and mounting bolt into the stator cover and torque to specification. (if removed)

CPS Fastener:

9 ft-lbs (12 Nm)

26. Connect the stator wire connector and verify that it is secure to the front engine mount bracket.

27. Install the inner clutch cover as outlined in chapter 6.

28. Install the drive clutch, driven clutch, belt and outer clutch cover as outlined in Chapter 6. Be sure all hose and wire routings are correct. Torque all fasteners to specification as outlined in Chapter 6. (See CLUTCH ALIGNMENT, page 6.13)

29. Install the PVT inlet/exhaust ducts and the airbox top.

30. Remove the pressure cap and fill the cooling system through the filler neck with properly mixed anti-freeze / coolant.

31. If the engine oil was completely drained, add approximately 2 quarts (1.9 L) of Polaris PS-4 Synthetic Engine Oil into the crankcase.

32. Install a new oil filter. Lubricate the seal with engine oil prior to installation (see ).

33. Connect the (-) negative battery cable to the battery.

34. Install the fuel tank, front cab (if required) , footwells, side panel, and seats. (See BODY, page 5.3)

NOTE: Install the right passenger footwell on touring models at this time.

35. Follow the “Cooling System Bleeding Procedure” as outlined in this chapter. (See Cooling System Bleeding Procedure, page 3.20)

36. Start engine and check for any oil or coolant leaks.

37. Check the engine oil level (see Engine Oil Level, page 2.16).

38. Refer customer to “ Engine Break-In Period, page

3.37” upon returning vehicle to customer.

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Engine Break-In Period

The break-in period consists of the first 25 hours of operation, or the time it takes to use 15 gallons (57 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION

Use only Polaris PS-4

Synthetic Engine Oil.

Never substitute or mix oil brands.

Serious engine damage and voiding of warranty can

result.

Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

1. Fill fuel tank with unleaded fuel which has a minimum pump octane number of 87 = (R+ M)/2.

2. Refer to Chapter 2, “Engine Oil Level”. Check oil level indicated on oil tank dipstick. Add oil if necessary.

3. Drive slowly at first to gradually bring engine up to operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important bolt torques.

6. Change oil and oil filter after break-in period at 25 hours.

Engine Lubrication Specifications

Oil Capacity:

Approx. 2 Quarts (1.9 L)

Oil Filter Wrench:

PU-50105 or 2.5” (64 mm)

Oil Type:

Polaris PS-4

Synthetic Engine Oil

Oil Pressure

Minimum Specification:

(using Polaris PS-4 at operating temperature)

10 PSI @ 1200 RPM(Minimum)

40 PSI @ 7000 RPM (Minimum)

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Engine Mounting and Torque Values

REF.

1 MOUNT, ENGINE, REAR

2 ISOLATOR Replace if excessively worn or damaged.

3 TUBE, ISOLATOR, REAR

4 ISOLATOR, RUBBER Replace if excessively worn or damaged.

6 MOUNT, ENGINE, REAR, CAST

8 SCREW

9 SCREW

10 BOLT 37 ft-lbs ± 10% (31 Nm ± 10%)

11 SCREW

12 NUT, FLANGE, LOCK 23 ft-lbs ± 10% (50 Nm ± 10%)

13 NUT, FLANGE, LOCK 37 ft-lbs ± 10% (50 Nm ± 10%)

DESCRIPTION NOTE

MOUNT, ENGINE, FRONT, LH, CAST

MOUNT, ENGINE, FRONT, RH, CAST

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Setting TDC (Top-Dead-Center)

There are three ways to ensure the piston is at TDC. Remove the outer clutch cover to access the drive clutch to aid in engine rotation (manually turn the drive clutch counter clockwise).

1. With the CPS sensor removed, rotate the engine until the “V” marked on the flywheel is aligned with the CPS mounting hole. This will set TDC, but not

necessarily TDC of the compression stroke.

NOTE: View the timing marks on the camshaft sprockets to ensure the engine is at TDC of the compression stroke.

2. With the valve cover and thermostat housing removed, rotate the engine so the cam lobes are facing outward and the Cylinder Holding and Camshaft Timing Plate (PU-50563) can be installed into the slots of the camshafts as shown below. This will set TDC of the compression stroke.

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.

3. With the stator cover and flywheel removed, rotate the engine and position the piston at TDC by aligning the timing hole in crank case with a timing hole in the crankshaft.

4. Insert a 1/4” drive socket extension through the crankcase and into the crankshaft locating hole. This

will set TDC, but not necessarily TDC of the compression stroke. View the timing marks on the

cam shaft sprockets to ensure the engine is at TDC of the compression stroke.

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ENGINE DISASSEMBLY / INSPECTION - TOP END

Valve Cover Removal

NOTE: The valve cover, camshafts, cylinder head, cylinder and piston can be serviced with the engine installed in the chassis.

1. If needed, remove the spark plug wire from the engine.

2. Remove dirt and debris from valve cover area.

3. Remove the (3) valve cover shoulder bolts (A) and isolators (B) using a T40 driver.

4. Carefully lift valve cover from the engine and remove it out of the right-hand rear wheel well area.

Camshaft / Carrier Removal

NOTE: The camshafts can be removed with the engine installed in the chassis.

1. Rotate the engine so the piston is at Top Dead Center (TDC) on the compression stroke.

NOTE: To verify TDC, see the “SETTING TDC” section in this chapter.

2. Remove the hydraulic cam chain tensioner (E) from the cylinder. Replace the sealing washer (F) upon reassembly.

5. Replace isolators (B) and valve cover seal (C) if oil leaks are evident.

6. Remove the spark plug (D). Stuff spark plug hole with a shop towel to prevent anything from falling into the combustion chamber (if further engine disassembly is required).

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3. Remove the (2) bolts retaining the fixed cam chain guide (G) and remove the assembly from the engine. Inspect the guide for wear and replace if necessary.

4. Remove the remaining (6) bolts that retain the camshaft carrier (H) and carefully lift the carrier off the camshafts.

7. Lift upward on the intake camshaft while rotating it counter-clockwise. Walk the timing chain off of the sprocket. Carefully remove the intake camshaft from the engine.

8. Remove the cam chain from the exhaust camshaft sprocket (J) and remove the exhaust camshaft from the engine.

NOTE: The crankcase has a lower guide to prevent the chain from falling off the crankshaft.

5. Attach a hook or other tool to the camshaft chain to prevent it from dropping down into the engine.

6. Mark the intake (I) and exhaust (J) camshafts to ensure proper assembly.

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Camshaft Sprocket Inspection

NOTE: Camshaft sprocket removal is not necessary unless the replacement of the sprockets is required.

Inspect cam sprocket teeth for wear or damage. Replace timing chain and sprockets as a set if worn or damaged.

NOTE: Replace intake camshaft sprocket bolt if loosened or removed.

2. Measure the height of each cam lobe from the base circle to highest point on the lobe using a micrometer. Compare to specification.

NOTE: Replace camshafts if damaged or if any part is worn past the service limit.

Camshaft Lobe Height:

Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)

Intake Camshaft Sprocket Bolt:

33 ft-lb (45 Nm)

Camshaft Inspection

Inspect all main journals and cam lobes as described below and compare to specifications. Replace camshafts or cylinder head if worn beyond service limit or if any surface is pitted or damaged.

1. Visually inspect each cam lobe for wear or damage.

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Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)