Polaris 2012 RANGER RZR 570 INTL Service Manual

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2012 RANGER RZR 570 / INTL

SERVICE MANUAL

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent

version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a p roperly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from

the operator's perspective when seated in a normal riding position.

Some pro cedures ou tlined i n th is man ual re quire a sou nd kn owledge of me chanical t heory, to ol use, and sho p

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the

service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper

tools as specified. If you ha ve any doubt as to yo ur ability to perform any of th e procedures outlined in th is Service

Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in 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 'Publications Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,

2100 Hwy 55, Medina, MN 55340.

Publication Printed November 2011 (PN 9923523) Rev. 3

improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Dep ictions an d/or p rocedures in t his pu blication are int ended for re ference use only. N o liability can be accept ed for omissions or inaccura cies. Any

reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris 2012 RANGER RZR 570 INTL

Page 1 Publication Printed November 2011 (PN 9923523) Rev. 3 © Copyright 2011 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 2 IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co.
Page 3: Table Of Contents
GENERAL INFORMATION MAINTENANCE ENGINE / COOLING SYSTEM ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
Page 5 2012 RANGER RZR 570 INTL ........
Page 6: Model Information
The engine model and serial number can be found on a decal applied to the crankcase on the front of the engine.  (see Figure 1-2) Engine Serial Number Figure 1-1 Figure 1-2 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 7: Vehicle Information
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe su bstituted with a similar to ol, if ava ilable. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.
Page 8 (Includes rider(s), cargo, accessories Capacity (Payload) and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 9 Drive / Fuel Pump: 10 Amp Fuses (Fuse/Relay Box) Lights / EFI / Accessory: 20 Amp EFI: 30 Amp Fuses (Power Fuse Holder) Chassis: 30 Amp 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 10: 2012 Ranger Rzr 570 Intl
GENERAL INFORMATION MODEL: 2012 RANGER RZR 570 INTL MODEL NUMBER: R12VH57FX ENGINE NUMBER: 1204286 Category Dimension / Capacity Length 107.5 in. / 273.05 cm Width 50 in. / 127 cm Height 69 in. / 175.26 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in.
Page 11 GENERAL INFORMATION MODEL: 2012 RANGER RZR 570 INTL Drivetrain Transmission Type Polaris Automatic PVT MODEL NUMBER: R12VH57FX Drive Ratio - Front 3.818:1 ENGINE NUMBER: 1204286 Drive Ratio - Final 3.70:1 Engine Shift Type In Line Shift - H / L / N / R / P...
Page 12: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 13: Standard Bolt Torque Specification
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) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 14: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 16 PARKING BRAKE PAD INSPECTION (INTL) ....... . 2.38 SPECIAL TOOLS SPX Corporation: 1-800-328-6657 or on-line at http://polaris.spx.com/. 9923523 - RANGER RZR 570 Service Manual...
Page 17: Periodic Maintenance Chart
 = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Page 18: Pre-Ride - 25 Hour Maintenance Interval
 Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 19: 50 - 500 Hour Maintenance Interval
Perform these procedures more often for vehicles subjected to severe use.  E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 20: Maintenance Quick Reference
“MAX and “MIN” lines on the inspection; change fluid every master cylinder reservoir two years * More often under severe use, such as operated in water or under severe loads. 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 21 Lube Rec. Method Frequency* Add lubricant until it is visible Check level every 25 hours; Front Gearcase Polaris Demand Drive Plus at the fill hole threads change fluid yearly Polaris AGL Plus Add lubricant until it is visible Check level every 25 hours;...
Page 22: Grease Lubrication Points
Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or Stabilizer Bar Bushings submerging the vehicle. Prop Shaft Rear Stabilizer Bar Front Suspension Front Stabilizer Bar Rear Suspension 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 23: Lubricants / Service Products
Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871329 Dielectric Grease (Nyogel™) Coolant 2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count) 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 24: General Vehicle Inspection And Maintenance
Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. Jam Nut (B) Jam Nut (A) 2.10 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 25: Fuel System And Air Intake
Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time. Never drain the fuel when the engine is hot. Severe burns may result. 2.11 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 26: Fuel Pump / Fuel Filters
Periodic Maintenance Chart and adjust the play if necessary. NOTE: Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System. 2.12 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 27: Throttle Freeplay Adjustment
NOTE: While adj usting, li ghtly move th e t hrottle 3. Reinstall the dry pre-filter s an d inst all the pr e-filter pedal in and out. cover. 2.13 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 28: Air Filter Service
Remove Hose 4. Reinstall the clea n intake h ose a nd tigh ten ho se clamp (A). 5. Reinstall the cargo box access cover. 2.14 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 29 Remove Hose From Air Box Cover for Filter Removal Engine Pre-filter Air Filter Clip (6) Boot PVT Pre-filter Intake Baffle Box Air Intake Clamp Grommets Drain Mount Clamps 2.15 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 30: Engine
7. Reinstall the dipstick completely. 2. Place the transmission in PARK (P). NOTE: Make certain th e dipst ick is thr eaded all the way into the engine case. 2.16 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 31 Wrench (PU-50105) and a 3/8” extension, turn the oil filter counter-clockwise to remove it. Oil Filter 10. Using a clean dry cloth, clean filter sealing surface on the crankcase. 2.17 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 32: Engine Breather Hose Inspection
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) 2.18 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 33 14. Connect the negative (-) battery cable to the battery. 15. Start the engine to ensure proper operation. 16. Reinstall the cargo box access panel and seats (see Chapter 5). 2.19 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 34: Exhaust - Spark Arrestor
5. Reinstall the arrestor and torque the screw to 40 in. lbs. (4.5 Nm). 40 in. lbs. (4.5 Nm) Gaskets and Seals - Replace Each Time Component is Removed 18 ft. lbs. 18 ft. lbs. (24.5 Nm) (24.5 Nm) 2.20 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 35: Transmission And Front Gearcase
Maintain lubricant level even with the bottom of the fill plug hole. 1. Position vehicle on a level surface. 2. Remove the fill plug and check the lubricant level. 2.21 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 36 8. Check for leaks. Dispose of used lubricant properly. 4. Clean the drain plug magnetic surface. 5. Reinstall drain plug with a new O-ring and torque to specification. 2.22 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 37: Front Gearcase Lubrication
5. Reinstall drain plug with a new O-ring and torque to specification. 3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill. 2.23 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 38 7. Reinstall fill plug with a new O- ring an d tor que to specification. Fill / Drain Plug Torque: 8-10 ft. lbs. (11-14 Nm) 8. Check for leaks. Dispose of used fluid properly. 2.24 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 39: Cooling System
Cooling System Exploded View Upper Engine Hose Water Pump Bypass Hose Upper Radiator Hose Lower Engine Cooling Fan Hose Recovery Bottle Radiator Pressure Cap Filler Neck Hoses 2.25 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 40: Cooling System Overview
7. Remove recovery bottle cap and add coolant using a use. Do not dilute with water. funnel. 8. Fill recov ery bottle to M AX level w ith Polaris 60/40 Coolant Level Inspection premix Anti Freeze/Coolant or 50/50 or 60/40 mixture...
Page 41: Coolant Strength / Type
6. Place a su itable d rain pan underneath t he lo wer engine hose on the right-hand rear side of the vehicle. 2. Check tightness of all hose clamps. 2.27 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 42: Final Drive / Wheel And Tire
5. Remove the wheel nuts and remove the wheel. 6. If hub removal is re quired, remove the hub nut and washers. 2.28 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 43: Wheel Installation
If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. 2.29 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 44: Tire Pressure
Ch arge battery acc ording t o “Charging Procedure” provided in Cha pter 1 0. Do not u se the vehicle’s stator/alternator to charge a new battery. 2.30 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 45: Battery Removal
Verify that cables are properly routed and reinstall the driver’s seat. Battery Off Season Storage Refer to Chap ter 10 “Electrical” for o ff sea son stor age procedures. 2.31 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 47: Engine To Frame Ground
WARNING Engine Due to the critical nature of the procedures Ground Cable outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. Use only genuine Polaris replacement parts.
Page 48: Steering Wheel Freeplay
(loose wheel nuts or loose front hub nut). • Refer to Chap ter 7 “ Final Drive” for fro nt hu b service procedures. 2.34 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 49: Wheel Toe Alignment Inspection
1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement at the rear (B). = In. / mm. Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm) 2.35 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 50: Suspension
Preload Shock Spanner Wrench (PN 2871095) 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 2.36 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 51: Brake System
Check b rake system hoses and fitting s for cracks, deterioration, ab rasion, an d leaks. Tighten an y loo se fittings and replace any worn or damaged parts. 2.37 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 52: Parking Brake Cable Adjustment (Intl)
/ shift cable bracket. The mount bracket is located on the right-hand side of the transmission. Adjustment Procedure: Refer to Chapter 9 “Brakes” for complete adjustment procedure. 2.38 9923523 - RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 55: General Information
Synthetic Engine Oil 10 PSI @ 1200 RPM Oil Pressure (Minimum) Minimum Specification (using Polaris PS-4 Plus 40 PSI @ 7000 RPM at operating temperature) (Minimum) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 56: Oil Pressure Test
(Pola ris PS- 4 Plus) at operating temperature, and may vary considerably if any ot her oil is used or if engine is not up to temperature. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 58: Engine Service Specifications
Cylinder Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 59 Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter Balance Shaft Bearing Journal O.D. (Standard) 1.1798” - 1.1802" (29.969 - 29.979 mm) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 60: Engine Detail - Torque Values / Sequences / Assembly Notes
ENGINE / COOLING SYSTEM ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES Main Engine Components - Torque Specification and Sequence 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 61: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
ENGINE / COOLING SYSTEM Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve Replace Bolts if Loosened or Removed 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 62: Cylinder / Oil Filter / Oil Pump / Breather
ENGINE / COOLING SYSTEM Cylinder / Oil Filter / Oil Pump / Breather Replace Bolts if Loosened or Removed Apply Loctite® 272™ 3.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 63: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover Replace Bolts if Loosened or Removed Loosened or Removed Replace Gasket if Loosened or Removed Replace Nut if Loosened or Removed Apply Loctite® 272™ 3.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 64: Spark Plugs / Starter / Throttle Body / Valve Cover
ENGINE / COOLING SYSTEM Spark Plugs / Starter / Throttle Body / Valve Cover Apply Anti-seize Replace Bolts if Loosened or Removed 3.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 66: Cooling System Exploded View And Coolant Flow Diagram
Cooling System Exploded View and Coolant Flow Diagram Upper Engine Hose Water Pump Bypass Hose Upper Radiator Hose Lower Engine Cooling Fan Hose Recovery Bottle Radiator Pressure Cap Filler Neck Hoses 3.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 68: Pressure Cap Test
Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a hig h- pressure washer is not recommended. 3.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 69: Coolant Drain / Radiator Removal
6. Place a s uitable drain p an u nderneath th e lower Screws engine hose on the right-hand rear side of the vehicle. Grommets Engine Inlet Hose 7. Remove the hose and completely drain the engine. 3.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 70: Thermostat Replacement
MAX Line Thermostat Cover Bolts: 7.5 ft. lbs. (10 Nm) 9. Be sure to properly fill and bleed cool ing system as outlined in this chapter. 3.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 71 4. Remove the pressure cap (B) and add the necessary 13. Tighten the b leed scr ew to sp ecification, to p off amount of Polaris Premium Antifreeze to the radiator coolant and properly install the pressure cap. filler neck.
Page 72: Water Pump Service
(C). Discard the water pump gasket (C). Water Pump Cover Fastener Torque: 9 ft. lbs. (12 Nm) 14. Fill and bleed cooling s ystem as outlined in this chapter. 3.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 73: Water Pump Mechanical Seal / Oil Seal Replacement
14. Remove the water pump impeller (D). NOTE: The water pump impeller (D) uses reverse (LH) threads. 3.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 74 Disca rd bea ring an d r eplace with new. CAUTION Be sure engine coolant does not contaminate the engine oil during stator cover service. 3.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 75 3. Clean and de-grease the water pump drive shaft (H). 4. Press in th e wa ter pu mp dr ive shaft (H) into the bearing using PU-50869 Item #1. PU-50869 Item #1 3.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 76 Drive Shaft Seal 13. If needed, install the stator cover removal handles tool PA-49317 to the water cover bolt holes to aid in stator cover installation. 3.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 77 NOTE: The water pump impeller (K) uses reverse (LH) threads. 9 ft. lbs. (12 Nm) Finger Tighten (Reverse Threads) 18. Install a new water pump cover gasket. 3.25 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 78: Engine Service
28. Fill cooling s ystem with rec ommend coolant and bleed the system of air as outlined in this chapter. 29. Check for leaks. 3.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 79: Engine Removal
2. Thoroughly clean the engine and chassis. 8. Elevate the rear of the vehicle off the ground using a suitable lift and remove the left rear wheel. 3.27 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 80 Make note of line routing for installation. 17. Disconnect the ignition coil har ness co nnector an d remove the spark plug wire from the engine. 3.28 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 82 • Sleeve adapter for a 2” bore engine stand:  (PU-50625) • Sleeve adapter for a 2.375” bore engine stand:  (PW-47054) 35. Place engine onto the engine stand (PU- 50624) for service. 3.30 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 83: Engine Installation
( 8) bo lts and washe rs ( C). Do no t tighten fasteners at this time. Tool Fully Seated Inward IMPORTANT: DO NOT torque fasteners at this time. 3.31 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 84 16. Install the starter motor and battery cables as outlined in Chapter 10. 40 ft. lbs. (54 Nm) Starter Motor Fastener: 7 ft. lbs. (10 Nm) Isolator Center Bolt: 40 ft. lbs. (54 Nm) 3.32 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 85 26. Install the in take ba ffle as sembly. Se cure the 3 clamps that attach the a ssembly to the crankc ase vent, air box lid and inner clutch cover. 3.33 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 86: Engine Break-In Period
30. If the e ngine o il wa s com pletely d rained, a dd extended periods during the first three hours of approximately 2 quarts (1.9 L) of Polaris PS-4 Plus use. Excessive heat can build up and cause Synthetic Engine Oil into the crankcase.
Page 87: Engine Mounting And Torque Values
Synthetic Engine Oil 10 PSI @ 1200 RPM Oil Pressure (Minimum) Minimum Specification (using Polaris PS-4 Plus at 40 PSI @ 7000 RPM operating temperature) (Minimum) 3.35 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 88: Setting Tdc (Top-Dead-Center)
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. 1/4” Drive Extension PU-50563 3.36 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 89: Engine Disassembly / Inspection - Top End
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). 3.37 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 91: Camshaft Sprocket Inspection
3. Visually insp ect each camsha ft journal for sco ring, wear or damage. 4. Measure the diameter of the camshaft journals using a micrometer. Compare to specification. 3.39 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 92 = In. / mm. Camshaft Carrier Bolts: 7.5 ft. lbs. (10 Nm) Calculated Camshaft Oil Clearance: 0.0018" - 0.0034" (.046 - .088 mm) Service Limit: .0047" (.121 mm) 3.40 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 94: Cylinder Head Removal
5. Remove the cylinder head (B) and head gasket (D). 2. Compress the valve spring by hand using valve spring compressor adapter (PV-43513-A). PV-43513-A 3.42 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 95 7. Repeat the previous steps to re move the re maining valves. 8. Clean the co mbustion ch amber and he ad g asket surface. 3.43 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 96: Cylinder Head Inspection
NOTE: The valves can be re-faced or end ground, if necessary. T hey mu st be re placed if e xtensively worn, burnt, bent or damaged. 3.44 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 97: Combustion Chamber Cleaning
0.2165" - 0.2171" (5.500 - 5.515 mm) 8. Be su re to mea sure each guide a nd valve combination individually. NOTE: The valve guides cannot be replaced. 3.45 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 98: Valve Seat Reconditioning
3. Place 46° cutter on the pilot and make a light cut. 4. Inspect the cut area of the seat: 3.46 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 101: Piston Removal
4. Repeat procedure for second ring. 5. Remove oil control ring top rail first, then bottom rail. 6. Remove oil control ring expander. 3.49 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 102: Piston-To-Cylinder Clearance
Piston O.D.: 3.8957 - 3.8968” (98.953 - 98.980 mm) Piston Pin O.D.: Standard.: 0.8659” - 0.8661” (21.995 - 22.0 mm) Service Limit: 0.8651” (21.975 mm) 3.50 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 103: Piston Ring Installed Gap
0.0011” - 0.0037" (0.030 - 0.095 mm) Service Limit: 0.0042" (0.108 mm) Second Ring Standard: 0.0007” - 0.0029" (.020 - 0.076 mm) Service Limit: 0.0035" (0.89 mm) 3.51 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 104: Honing To Oversize
Polaris recommends using a rigid hone or arbor rough honing followed by finish honing. honing machine which also has the capability of oversizing.
Page 105: Engine Assembly - Top End
1. 6. Be sure top a nd second rings rota te fr eely in their grooves and do not bind when compressed by hand. 3.53 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 106: Piston / Connecting Rod Assembly
5. Install th e re maining cir clip ( D) with ga p at the top (12:00 position) or bottom (6:00 position). Push the piston pin in both directions to make sure the clips are properly seated in the groove. 3.54 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 108: Cylinder Head Assembly
12. Exercise each valve th rough its tr avel to ensure the clean engine oil. valve keepers are seated correctly. 6. Install the valve spring seat (C). 3.56 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 109: Valve Sealing Test
IMPORTANT: If a ny va lve tr ain compo nents were replaced, refer to “Valve Clea rance Adjust ment” procedure prior to “Camsh aft Inst allation / Timin g” procedure. 3.57 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 110: Cylinder Head Installation
Step 3: Torque the (4) M11 Bolts in Sequence Additional 180° (1/2 turn) Step 4: Torque the Outer M6 Head Bolts 89 ± 9 in. lbs. (10 ± 1 Nm) 3.58 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 111: Valve Clearance Check / Adjustment
7. Torque the camshaft ca rrier bolts in se quence to specification. 3. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 Plus engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head. The camshaft lobes should face out.
Page 113: Intake Valve Lash - Shim Selection Matrix
1.126-1.150 288 290 292 295 298 300 1.151-1.175 290 292 295 298 300 1.176-1.200 292 295 298 300 1.201-1.225 295 298 300 1.226-1.250 298 300 1.251-1.275 300 3.61 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 114: Exhaust Valve Lash - Shim Selection Matrix
1.226-1.250 288 290 292 295 298 300 1.251-1.275 290 292 295 298 300 1.276-1.300 292 295 298 300 1.301-1.325 295 298 300 1.326-1.350 298 300 1.351-1.375 300 3.62 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 115: Camshaft Installation / Timing
“E” mark s a ligned wit h gasket surface. 5. Wrap the cam chain around the exhaust cam sprocket and hold the exhaust cam in its current position. 3.63 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 116 12. Remove the Cylin der Ho lding & Camsha ft Timin g Plate (PU-50563) from the end of the camshafts. 13. If needed, install the camshaft carrier and bolts. 3.64 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 117 Cam Chain Tensioner: 30 ft. lbs. (40 Nm) 17. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 3.65 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 118: Camshaft Timing - Quick Reference
Stator Cover / Flywheel Installed “V” Marking on Alignment Hole 1/4 “ Drive Extension Flywheel Stator Cover / Flywheel Removed BOTTOM END CPS Mounting Bolt Hole 3.66 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 119: Valve Cover Installation
4. Install a new valve cover seal (B). 5. Install th e ( 3) va lve co ver sh oulder bo lts (C) an d isolators (D) using a T40 driver. 3.67 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 120: Engine Disassembly / Inspection - Lower End
Inspect fit of shaft inside gear and replace ge ar a ssembly if clea rance is e xcessive. Inspect shaft and shaft bearing surfaces in case and stator housing for wear. 3.68 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 121: Starter One-Way Clutch Inspection
8. Remove clutch and inspect both sides of drive rollers (B) and roller contact surface (C) inside hub for wear, damage, or uneven surface. 3.69 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 122: Starter One-Way Clutch Installation
3. Apply Loctite® 272™ on the (3) bolts. Place hub on flywheel and install (3) bolts. 4. Torque screws to specification. One Way Clutch Retaining Bolts: 9 ft. lbs. (12 Nm) Apply Loctite® 272™ 3.70 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 123: Flywheel Installation
(A) on the MAG side crankshaft. DO NOT apply engine oil to the crankshaft taper. 8. Install the flywheel washer. 9. Hold fly wheel with comm ercially availab le strap wrench. 3.71 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 124: Stator Removal
5. Remove the stator (E) from the stator cover. Apply Crankcase Sealant 6 ft. lbs. (8 Nm) 9 ft. lbs. Apply Loctite (12 Nm) Apply Loctite 3.72 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 125: Stator / Stator Cover Installation
Use caution when installing the stator cover. DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 3.73 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 126 10. Inspect su rfaces of pum p ca vity in cr ankcase and surface of pump cover for scoring or wear. 5. Remove the (3) bolts securing the oil pump cover to the crankcase. Spacer 3.74 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 127: Oil Pump Assembly
Synthetic Engine Oil 10 PSI @ 1200 RPM Oil Pressure (Minimum) Minimum Specification (using Polaris PS-4 Plus 40 PSI @ 7000 RPM at operating temperature) (Minimum) 3.75 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 128: Crankcase Breather Service
3. Remove and discar d the ( 15) flan ge bolts fro m To Intake magneto side cr ankcase evenly in a cr iss-cross Baffle Box pattern. 3.76 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 129: Balance Shaft Removal / Inspection
( radial) movement. 2. Pull upward on the balance shaft and remove it from the crankcase. 3.77 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 130: Crankshaft Removal
“C ” unt il the crankcase is completely separated from the crankshaft. 5. Remove all special tools from the crankcase. 3.78 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 131: Pto Side Crankcase Bearing Service
M AG si de b earing s urface i s n ot groved, pitted, damaged or excessively worn. Retaining Ring 8 ft. lbs. (11 Nm) Bearing Apply Loctite® 272™ 3.79 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 132: Mag Side Crankcase Bearing Service
NOTE: Bearings are st ressed during the remo val process and must not be re-used! 3.80 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 133: Oil Pickup Assembly Inspection
2. Be sure alignment pins are in place where used. fully seated. 3. Be sur e oil p assages are clean an d fr ee of a ny cleaning solvent. 3.81 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 134: Engine Assembly - Lower End
7. Remove the crankshaft removal / installation tool  PU- 50784 from the crankcase. 8. Be su re crankshaft is fully se ated and r otates smoothly. 3.82 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 135 • Firmly hold the crankshaft installation screw “D” with a wrench while tightening the large nut against the adaptor “B”. Nut and Washer 3.83 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 136: Balance Shaft Installation / Timing
Be sure alignment pins (A) are in place. Crankcase Sealant: 2871557 3. Assemble MAG crankca se to PTO crankc ase immediately. Do not allow sealant to dry. 3.84 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 137 10. Place engine onto the engine stand (PU- 50624) for top end engine assembly as outlined in this chapter. Crankcase Bolts (In Sequence): 22 ft. lbs. (30 Nm) 3.85 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 138: Troubleshooting
Slow Engine Cranking • Restricted fuel supply • Weak battery • Low compression • Loose Electrical connections • Crankcase breather restricted • Decompression Mechanism not functioning properly. 3.86 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 139: Cooling System
Poor connections in ignition system • Faulty water pump mechanical seal (coolant leak) Ignition timing incorrect • Faulty pump shaft oil seal (oil leak) Sheared flywheel key 3.87 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 142: General Information
9-pin serial port, a USB to serial port adaptor SPX Corporation: 1-800-328-6657or http://polaris.spx.com/. will be necessary. A USB to serial port adaptor can be purchased through DSA at: www.diagsys.com 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 143 SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Int erface Cab le PU-4 7470. This module kit is u sed on all 8 pin co nnector-based Polaris EFI systems. This kit is availa ble to Pola ris dealers through our...
Page 145: Efi System Exploded View
6. Fuel Pump / Regulator / Fuel Level Sender (located in fuel tank) 7. Fuel Rail / Regulator 8. Engine Coolant Sensor (ECT) 9. Throttle Position Sensor (TPS) 10. Throttle Body 11. Ignition Coil 12. Spark Plug 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 146: Efi System Component Locations
Pump / Sending Unit Fuel Pump Connection Preliminary Filter 3. Crankshaft Position Sensor (CPS) - Located in the magneto cover on the right-hand side of the Engine. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 147 TPS. 10. Ignition Coil - Located in the LH rear wheel well area, behind the PVT inlet hose. Ignition Coil PVT Inlet Hose Throttle Body 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 148: Fuel Tank
ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Fuel Flow Fuel Injector Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 149 4. Snap the fuel line back over the nipple and slide the locking me chanism ba ck into p lace. Ve rify the connector tabs snap back into place. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 150: Principal Components
When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned. 4.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 151: Electronic Control Unit (Ecu)
The determine the EC U to be faulty, contact the Polaris Servic e ECU then sends output signals to set the injector duration Department for specific h andling instructions. Do not and ignition timing.
Page 152: Ecu Replacement
NOTE: Upon remov ing th e ECU c onnector, you should he ar a “clic k” whe n t he c onnector is f ully open. 4.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 153: Temp / Manifold Absolutepressure Sensor (T-Map)
4. Remove the r etaining bolt a nd r emove the se nsor from the intake boot. 5. Use a light coating of soapy water on the grommet to aid installation of the new sensor. 4.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 154: Crankshaft Position Sensor (Cps)
If the sensor fails or becomes disconnected for any reason, the engine will stop running. 1000 ± 10% CPS Resistance Specification: 1000 Ohms ± 10% 4.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 155: Fuel Injectors
“injection duration” or “pulse width”. It may vary in length depending on the speed and load requirements of the engine. 4.15 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 156 Additives an d hig her gr ades o f fuel can be used as a preventative measure if clogging has been a problem. 4.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 157: Fuel Injector Replacement
12. Thoroughly clean the area around the fuel injector port on the cylinder head. 13. Lightly lubricate the injector O-rings and reinstall the fuel rail / injector assembly into the cylinder head. 4.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 158: Fuel Pump
19. Reinstall the cargo box access panel. Located in Fuel Tank Fuel Line Connection Pump / Sending Unit Connection Fuel Pump Regulator Preliminary Filter 4.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 159: Fuel Sender Test
Fuel Sender Resistance Specifications: Full: 6 ± 1 Ohms PU-43506-A Empty: 90 ± 4.5 Ohms PV-48656 4.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 160 “3” and “4”' at the white fuel pump connector to check for continuity within the fuel pump. NOTE: If there was no continuity between the pump terminals, replace the fuel pump assembly. 4.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 161: Fuel Pump Replacement
NOTE: A small amount of fuel may come out of the flange while removing the fuel pump PFA nut. fuel line or tank. Prop erly dra in fuel in to a su itable container. 4.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 163 PFA nut o nto fuel tan k and h and tighten . Use care when starting PFA nut, ensuring threads are properly aligned. Verify orientation marks are still aligned between fuel pump and fuel tank. 4.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 164: Fuel Tank Removal
24. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 4.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 166 12. Remove the (2) tank bracket fasteners that retain the fuel tank in the chassis. Swing the tank brackets clear of the fuel tank for removal. 4.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 168: Throttle Position Sensor (Tps)
If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced. 4.28 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 169: Tps Resistance Tests
TPS . Reconnect the vehicle ha rness to the TPS. NOTE: If re placing t he TPS o r thr ottle bod y, you must set the TPS voltage to specification. 4.29 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 170 6. Verify volta ge reading did n ot cha nge. If voltage reading is now out of specification, repeat steps 3 - 5. 7. Reinstall item s that wer e r emoved to access TPS sensor. 4.30 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 171: Engine Coolant Temperature Sensor (Ect)
ECT Sensor Refer to Ch apter 10 for additional ECT sensor information. Polaris dealers can test th e se nsor b y using the Digital Wrench™ Diagnostic Software (dealer only). PVT Outlet Hose Removed ECT Sensor Resistance Readings...
Page 172: Ect Sensor Replacement
ECT Torque: 17 ft. lbs. (23 Nm) 10. Add the r equired amount of coo lant and p roperly bleed the cooling system (see Chapter 3). 4.32 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 173 8. Reinstall the PVT in take hose and tighten hose cla mp. 9. Reconnect the ba ttery cable an d insta ll th e dr ivers seat. 4.33 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 174: Efi Diagnostics
MODE button or turn the ignition key OFF once the diagnostics code menu. codes are recorded.             4.34 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 175 Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 P1353 Driver Circuit Open / Grounded P0230 Fuel Pump Driver Circuit Driver Circuit Short to B+ 1347 P0232 Driver Circuit Grounded P0231 4.35 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 176 Driver Circuit Open / Grounded P1535 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520270 P1539 M17; IAC Stepper Pin 6 Driver Circuit Grounded P1538 4.36 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 177: Efi Troubleshooting
• Spark Plug fouled • Fouled spark plug • Throttle stop screw set incorrectly (out of sync with • TPS setting incorrect ECU) • Injector failure 4.37 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 178: Digital Wrench™ Operation
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench™ Diagnostic Kit to install the Polaris Digital Wrench™ diagnostic software on your computer. The Digital Wrench™ diagnostic software allows the technician to perform the following tests and observations: •...
Page 179 ‘Connected’ in the lower left corner of the screen. 5. Once connected, pr oceed wit h us ing Digital Wrench™. 4.39 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 180 4. The Digital Wrench™ portal website should appear in a new web browser. 5. Click on “Digital Wrench Version Updates”. 2. Proceed to http://polaris.diagsys.com to se e if a newer update is available. Digital Wrench Update IMPORTANT: You must alrea dy hav e the cur rent version inst alled be fore ad ding an upda te.
Page 181 Selec t "sa ve" a nd download t hem t o your PC before running the install. Version NOTE: Versions and updates are subject to change. 4.41 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 183 ELECTRONIC FUEL INJECTION Engine Controller Reprogramming (Reflash) • CLOSE NON-ESSENTIAL PROGRAMS : Polaris recommends that yo u DO NOT inst all n on- essential pr ograms o n a Ser vice De partment Process Overview laptop. Ca mera detection sof...
Page 184 3. Open the Digital Wrench™ program. 4. Select the mo del year , pr oduct line and vehicle description by sele cting the “Ch ange Ve hicle T ype” icon. 4.44 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 185 NOTE: Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. Enter ALL the information and click on the “Authorize” button 4.45 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 186 Verify th e r eflash was a success by sta rting th e ‘Continue’ button and follow instructions provided on vehicle. screen to complete the re programming procedure. Enter the “Authorization Key” 4.46 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 190: Torque Specifications
Lower Steering Shaft to Box 30 ft. lbs. (41 Nm) Steering Gear Box 17 ft. lbs. (23 Nm) SPECIAL TOOLS SPX: 1-800-328-6657 or on-line at http://polaris.spx.com/ Pliers Push Rivet 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 191: Cab Frame
6. To r emove the ca b fra me, r everse th e a ssembly brackets to vehicle with four (5/16-18) bolts and (5/16- procedure (steps 1-5). 18) nuts. Tighten bolts to 16-18 ft. lb s. (22-24 Nm). 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 193: Dash Instruments / Controls / Glovebox
 C. Headlight Switch or Hazard Switch (INT’L) D. 12 Volt Accessory Receptacle E. Key Switch / Headlight Switch  F. Switch; Turn, Lights, Horn (INT’L) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 194: Hood / Front Body Work
Washer Grommet T25 Screws Push Rivets Hood / Dash Front LH Fender Flair Front RH Fender Flair T27 Screws Push Rivets Front Bumper Winch Pocket Cover 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 195: Front Bumper
Front Bumper Radiator Screen O-Ring Bulb Screw Screw Headlight Winch Pocket Cover Rear Bumper LH Tail Light Screws RH Tail Light Rear Bumper Speed Nuts Screws 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 196: Seat Assembly
Seat Base (54 Nm) Latch Plunger 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 40 ft. lbs. 17 ft. lbs. (54 Nm) (23 Nm) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 197: Floor / Rocker Panels
Support Bracket Self-Tapping Screw Screws Screws Push Rivets U-Type Nuts Close Off Torx Panel Screws Screws Plastic Dart Front Self-Tapping Support Bracket Screws RH Rocker Lower Floor 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 198: Rear Cargo Box / Fenders
LH Panel RR Fender Divider Grommet 1/4 Turn Latch Heat Shield Seal (Mounts Under Box) Cover Engine Service Panel INTL Units Heat Shield LH Panel Divider 5.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 199: Chassis / Main Frame
Bolt-In Brace Front Cross Member Rear Bumper Support Shield Plug 17 ft. lbs. (23 Nm) Main Frame Skid Plate Washer 6-8 ft. lbs. (8-11 Nm) 5.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 200: Body Component Removal
3. Remove the rear bumper from the vehicle. 3. Lift the p anel up ward an d towar ds the fr ont of the vehicle to remove it. 5.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 201: Hood And Front Body Work
3. Remove the front portion of the cab frame assembly to allow dash removal. Refer to appropriate “CAB FRAME - Asse mbly / Remo val” p rocedure for assembly torque specifications. Remove 5.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 202: Rear Fender Flair Removal
8. Remove the (6) T-27 Torx Screws (C) from both sides of the cargo box / rocker panels. 9. Remove the (2) push pins (D) from both sides of the cargo box / rocker panels. 5.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 203: Rocker Panels, Console And Floor
5. Remove the Torx screws retaining the rear portion of the rocker panel and remove panel from the vehicle. the floor and remove the lower floor from the vehicle. Push Rivets Screws 5.15 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 204: Steering Assembly
42.5 ft. lbs. (58 Nm) Boot 17 ft. lbs. 17 ft. lbs. (23 Nm) (23 Nm) 12-14 ft. lbs. (16-19 Nm) Tie Rod Cotter Pin Rod End 5.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 205: Steering Wheel Removal
15. Wipe the pivot tube clean of any excess Loctite. ® get in the bearing. 16. Install steer ing wh eel cap and fie ld test steering operation. 5.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 206: Front A-Arms
12. Insert u pper A-arm ball jo int e nd into the b earing carrier. Install upper ball jo int pinch bolt (B) into the bearing carrier and torque bolt to specification. 5.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 207: Exploded View
Steel Wheels: 27 ft. lbs. (37 Nm) Zerk Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) Bushing Pinch Bolts Ball Joint CV Shield Screws 5.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 208: Ball Joint Service
1.75 in. (4.45 cm). - Inside diameter cannot be any smaller than 1.375 in. (3.49 cm). - Driver must be at least 3 in. (7.62 cm) tall. 5.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 209: Installation
NOTE: Properly support th e bumpe r support an d 4. Repeat the b all jo int ser vice procedure for an y wires that are attached. additional A-arm ball joint replacements. 5.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 210 7. Remove th e ( 4) bo lts re taining t he up per ra diator mount br acket an d r emove the br acket fr om th e frame. Main Frame Mount Bracket 5.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 211: Exploded View
BODY / STEERING / SUSPENSION Exploded View Grease Zerk Screws Stabilizer Bushings 30 ft. lbs. (40.5 Nm) Linkage Linkage Bushings Linkage 37 ft. lbs. (50 Nm) Spacer Washer 5.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 212: Rear A-Arms
DO NOT reuse old hardware. Serious injury or death could result if fasteners come loose during operation. 5. Insert new A-arm bushings and pivot tubes into new A-arm. 5.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 213: Installation
Upper and Lower Bearing Carrier Bolts: 40 ft. lbs. (54 Nm) Wheel Nuts: Steel Wheels: 27 ft. lbs. (37 Nm) Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) 5.25 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 214: Rear Stabilizer Bar
9. Torque th e bu shing re taining nu t ( A) o n the upp er portion of the stabilizer bar linkage to specification. Stabilizer Bushing Retaining Nut Torque: 30 ft. lbs. (40.5 Nm) 5.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 215: Shocks / Springs / Fasteners
Rear Shock Mounting Retainer gap should be 180° from spring end 37 ft. lbs. (50 Nm) Spring Adjusting Cam 37 ft. lbs. (50 Nm) Front of Vehicle 5.27 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 216: Shock Replacement
2. Apply the de cal on on e e dge first. Slowly lay do wn remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 5.28 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 218: Special Tools And Supplies
Du ring the d evelopment of Driven Clutch Retaining Bolt 36 ft. lbs. (48.5 Nm) the Polaris vehicle, the PVT system is matched first to the PVT Inner Cover Bolts 12 ft. lbs. (16 Nm) engine power curve;...
Page 220: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD cer t ified Clutch malfunction.
Page 221: Pvt System Service
CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. 5. Remove the left rear wheel. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 222 Drive Clutch Puller PA-48595 Drive Clutch Holder 9314177 IMPORTANT: Be sure to use the correct Drive Clutch Puller (PA- 48595) to prevent damage to crankshaft. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 223: Pvt Assembly
17. Reconnect the battery cable. transmission input shaft. 18. Install engine service panel and both seats. 9. Apply a light film of grease to the splines on the shaft. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 224: Drive Belt
See the Troubleshooting Chart at the end of this chapter for possible causes. NOTE: Removal of left rear wheel is NOT necessary for belt replacement. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 225: Belt Installation
5-7 times to properly seat the belt in the driven clutch. 4. Install the outer clutch cover and (8) screws. Torque screws to specification. Outer Clutch Cover Retaining Screws: 45-50 in. lbs. (5 Nm) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 226: Clutch Center Distance
3. If the tool fits as shown above, the clutch center to center distance is correct. 4. If the tool does not fit as shown above, adjustment is needed. 6.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 227 8. Remove the Clu tch Ce nter Distan ce tool a reassemble the P VT system as out lined in t his chapter. Rear Trans. Isolator Bolts: 25 ft. lbs. (34 Nm) 6.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 228: Drive Clutch Service
210 ft. lbs. (284 Nm) Bushing Bushing Non-Braking Bearing Spacer Cover Button Screws 100 in. lbs. (12Nm) Roller Washers Button Bolt Washers Shift 25 in. lbs. (2.8 Nm) Weight 6.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 229: Clutch Disassembly
(B). Belt life will be greatly reduced. Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 230: Drive Clutch Spring Inspection
See “Roller, Pin and Thrust Washer Inspection”. Color Black Free Length 2.8” (71.12mm) 6.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 231: Spider Removal
Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.15 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 232: Roller, Pin, And Thrust Washer Inspection
2. Verify there is no binding or rough spots. If problems are noted continue with disassembly. 6.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 233: Clutch Inspection
3. Lift bearing (C) an d th rust wa shers (D) off shaft. Replace as a n assembly if wor n, d amaged, o r if problems were noted. 6.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 234: Bushing Service
7. Install removal tool (Item A, B) into center of sheave bushing bore prior to installing new bushing. with “A side" toward sheave. 6.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 235 8. Remove nut from puller rod and set aside. 6. Remove nut from puller rod. Take installation tool and clutch cover off rod. 9. Remove sheave from puller. 6.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 236: Clutch Assembly
/ spacers beneath the spider during assembly. Cover Screw Torque: 100 in. lbs. (12 Nm) Spacer PTFE Washers Spider Non-braking Bearing 6.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 237: Driven Clutch Service
Use caution when removing, the snap ring pressure is loaded by the compression spring. 1. Remove d riven c lutch from t he tr ansmission in put shaft. 6.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 238 (E). 7. Remove the inne r spr ing retainer from the inn er sheave. Inspect for wear and replace as needed. Inspect for Abnormal Wear 6.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 239 9. Inspect the bearings inside the moveable sheave. Inspect Bearings for Wear Moveable Sheave Bearing Inspection: Replace the clutch assembly if more brass than Teflon™ is visible on the bearing. 6.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 240: Clutch Assembly
7. Compress the outer retainer and install the snap ring. Snap Ring Assemble Sheaves 3. Install the spring into the inner retainer. 4. Install the spacer over the shaft. 6.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 241: Troubleshooting
 Belt burnt, thin -Dragging brake  spots -Inspect brake system.   -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 6.25 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 242 -Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting Engagement and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 244: Special Tools
Castle Nut Cone Washers Cotter Pin 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 245: Bearing Replacement
4. Inspect the be aring car rier hou sing for scr atches, wear or dam age. Replace fr ont b earing car rier if damaged. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 246: Bearing Carrier Installation
8. Wipe the housing clean of any excess compound and install the snap ring. Ball Joint Pinch Bolts: 23 ft. lbs. (31 Nm) 4. Apply grease to drive shaft axle splines. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 247 11. Rotate wheel and check for smooth operation. Bend both en ds of cotte r pin around end of sp indle in different directions. Tie Rod End 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 248: Front Drive Shaft
CAUTION: Do not hang the caliper by the brake line. Use wire to h ang calip er to pr event damage to the brake line. 5. Remove the front wheel hub assembly. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 250 15. Install and secure the CV boot with the lar ge clamp using the “earless” clamp pliers. CV Boot Clamp Pliers Earless Type: 8700226 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 252: Drive Shaft Installation
3. Install drive shaft into the front bearing carrier. Grease Capacity 80 Grams CV Joint 4. Install the upp er ball joint end into th e front bearing carrier. 7.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 253 Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) 11. Rotate wheel and check for smooth operation. Bend both en ds of cotte r pin around end of sp indle in different directions. 7.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 254: Propshaft Service
Torx Screws Roll Pin Removal Tool (PN 2872608) 5. Remove the o uter clutch cover, drive belt and drive clutch as outlined in Chapter 6. 7.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 255: Transmission
47 ft. lbs (63.5 Nm) Outer Clutch Cover Screws: 50 in. lbs. (5 Nm) Brake Line Junction Block Mounting Screws: 36 in. lbs. (4 Nm) 7.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 256: Propshaft U-Joint Service
2. Support inn er yoke as sh own an d d rive ou ter yo ke down (bearing cap out) with a soft face hammer. 7.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 257: Assembly
5. Install ou ter yo ke, a ligning m arks ma de a t disassembly and repeat Steps 1-3 to install bearing caps on outer yoke. 7.15 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 258: Front Gearcase / Centralized Hilliard
Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic Roll Cage Retaining Ring, External Hub / Race Assembly 7.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 259: All Wheel Drive Operation
“over-running” condition for the rollers upon disengagement. Centers Roll Cage and Rollers in Ring Gear Output Hubs Ring Gear Torsion Roll Cage Spring & Rollers 7.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 260: Awd Diagnosis
6. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in a nd out freely within the r oll cage sliding surfaces and H-springs. 7.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 261: Gearcase Removal
4. Disconnect the wire harness above the front gearcase and remove the harness from the retaining dart. AWD Harness 5. Remove the vent line from the front gearcase. 7.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 262: Gearcase Disassembly / Inspection
NOTE: Nylon spa cer is non- serviceable a nd sh ould not be removed. 4. Remove an d inspect the ar mature pla te. Refer to “AWD Diagnosis” for detailed inspection process. Armature Plate 7.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 263 9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. Inspect 7.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 264 13. Inspect clutch housing ring gear (C) for a consistent wear pattern. Ins pect th e r ing ge ar fo r ch ipped, broken, or missing teeth. 7.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 265: Gearcase Assembly
7. Align the spring retainer dowel pin with the ring gear dowel pin and install the retainer on top of the torsion spring. Align during installation 7.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 266 10. Carefully install the ring gear and roll cage assembly into the gearcase housing. Cover Plate Screws: 7-11 ft. lbs. (10-15 Nm) 7.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 267: Gearcase Installation
6.75 fl. oz. (200 ml) Vent Line Connect Harness Gearcase image is for reference only. 30 ft. lbs. (41 Nm) Front Gearcase Mounting Bolts: 30 ft. lbs. (41 Nm) 7.25 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 268: Rear Bearing Carrier
7. Remove the bolts, nuts and washers that attach the Washers rear bearing carrier to th e upper and lower A-arms. Discard nuts and replace with new. 7.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 269: Bearing Replacement
4. Inspect the be aring car rier hou sing for scr atches, wear or da mage. Re place rear be aring car rier if damaged. 7.27 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 270: Bearing Carrier Bushing Replacement
NOTE: Use ca re to no t allow any of the L octite ® compound to get in the bearing. 4. Wipe the housing clean of any excess compound and install the snap ring. 7.28 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 271: Bearing Carrier Installation
Upper and Lower Rear Bearing Carrier Nuts: upon assembly. 40 ft. lbs. (54 Nm) 3. Apply grease to drive shaft axle splines. 7.29 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 272: Rear Drive Shaft
CAUTION: Do not hang the caliper by the brake line. Use wire to hang cal iper to p revent da mage to the brake line. Remove 7.30 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 273 8. Grasp the rear drive shaft and pull sharply outward on the shaft to disengage it from the rear gearcase. 7.31 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 274: Outer Cv Joint / Boot Replacement
7. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 7.32 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 275 NOTE: The amount of grease that’s provided is pre- measured, so use all the grease. Boot Replacement Grease Requirement: Grease Only Service Kits 1350047 (50g) Outer CV Joint Capacity: RZR - 80g 7.33 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 276 Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft. 7.34 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 277: Inner Plunging Joint / Boot Replacement
Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint. 7.35 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 278 DO NOT use substitutes into the grooves on the joint housing and shaft. Make or mix with other lubricants. sure the boot is not dimpled or collapsed. 7.36 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 279: Drive Shaft Exploded View
Grease Pack Large Clamp Spring Ring CV Joint Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.37 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 280: Drive Shaft Installation
Install washers with domed side out. Cone Washers Wheel 3. Slide the rear drive shaft into the rear bearing carrier. 7.38 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 282: Wheel Hubs
(Steel) Sealed Ball Bearing Bolts Bearing Studs Carrier Cone Washers Retaining Ring Brake Disc Wheel Hub Castle Nut Cotter Pin 80 ft. lbs. (108 Nm) 7.40 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 283 TRANSMISSION EXPLODED VIEW (INTL) ........8.46 SPECIAL TOOLS SPX Corporation - 1-800-328-6657 or http://polaris.spx.com/. 9923523 - 2012 RANGER RZR 570 Service Manual...
Page 284: Special Tools
(54 Nm) (74.5 Nm) See Torque Sequence 40 ft. lbs. Isolator Mount (54 Nm) 25 ft. lbs. 40 ft. lbs. (34 Nm) Front Engine Mount (54 Nm) 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 285: Shift Lever
1. Perform the removal steps in reverse order to install to the shift lever and disconnect the ca ble end from the gear shift lever (lever, cable, console, shift knob). the lever. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 286: Shift Cable
7. Start engine and shift through all gears to ensure the Mount shift c able is properly adjusted. If trans mission s till ratchets after cable adjustment, the transmission will require service. Dust Boot 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 287: Transmission Service
10. Pull s harply fo rward to r emove th e p ropshaft fr om transmission shaft. 11. Remove th e r ear bu mper and cargo b ox as a n assembly (see Chapter 5). 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 288 IMPORTANT: Be sure dirt and debris do not enter the engine, air box or throttle bod y. Use clea n sh op towels to plug engine and air box intake holes. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 289 INTL - Remove the parking break cable and asm. 27. Place a support in-between the main frame and the engine crankcase to support the engine in its current position. Do not pinch brake line. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 290: Transmission Installation
30. Rotate the top of the transmission to the left-hand side of the vehicle. With the help of an assistant, lift the assembly up and out of the vehicle frame. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 291 8. Remove the clutch center distance tool. 9. Remove th e s pacer o r su pport b etween th e ve hicle frame and engine. Tool Fully Seated Inward 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 292 Shift Cable Bracket Bolts: 17 ft. lbs. (23 Nm) 18. Lubricate th e transmission splines with Polaris All Purpose Gr ease. Install th e pr opshaft on to th e 13. Install the thr ottle b ody in to the en gine in take bo ot.
Page 293 44 ft. lbs. (60 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 8.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 294: Transmission Disassembly
29. Verify all wire and hose routings are correct. Connect the (-) negative battery cable. 30. Install the engine service panel and seats. 31. If transmission lubricant was drained, fill the transmission with th e sp ecified a mount of Polaris AGL Plus ee Ch apter 2 “Transmission Lubrication”).
Page 295 Using suitable pr y b ars, rem ove the cover using the designated pry points (indicated by the black arrows in the illustration below). 8.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 296 No te th e lon ger scr ew (W) tha t lo cks th e snorkel tube. 18. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 8.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 297 CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 8.15 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 298 29. Use an arbor press to remove the snorkel tube from the snorkel shaft. 30. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. PA-50231 8.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 300: Gear / Shaft / Bearing Inspection
Inspect all bearings for signs of wear or damage. If replacement is required, use a standard bearing puller or an arbor press. 8.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 301: Snorkel Gear Backlash Procedure
IMPORTANT: Failure to press the gear back against the wash er a nd re taining ring will le ad t o a g ear backlash change after vehicle is placed into service. 8.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 302 IMPORTANT: DO NOT install the lo nger sc rew (A ). (4th notch). Installing the longer screw will lock the snorkel tube and not allow for backlash setting adjustment. 8.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 303: Transmission Assembly
(see illustrations). 16. Torque the locking screw to specification. 8-10 ft. lbs. (11-14 Nm) Snorkel Locking Screw: 8-10 ft. lbs. (11-14 Nm) 8.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 304 NOTE: Both sh ift forks n eed to be orientated t he same way, s o that the shift fork pins are both offset to the same side of the rail. 8.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 305 Transmission Case Bolts: 12. Thoroughly clean the shift shaft housing. Be sure the 15-20 ft. lbs. (20-27 Nm) transmission is in High gear prior to reassembly. 8.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 306 20. Install th e secto r cover an d a lign the tran smission case dowel with the alignment hole. Install and torque the bolts to specification. Sector Cover Bolts: 7-9 ft. lbs. (9-12 Nm) 8.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 307 Install the nut and torque to specification. Bellcrank Nut: 12-18 ft. lbs. (16-24 Nm) 23. Refer to “ Transmission Installa tion” to complete the repair. 8.25 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 308: Transmission Service (Intl)
Differential Cover Solenoid Assembly Screw Female Side Gear Assembly Planet Gear Bearing Assembly Male Side Gear Engagement Dog Assembly Ring Gear Assembly Planetary Differential Assembly 8.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 309: Transmission Disassembly
7. Remove the detent star (I). Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly. 8.27 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 311 (see Figure 8-1). 25. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 8.29 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 312 PA-50231 CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 8.30 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 313 32. Use an arbor press to remove the snorkel tube from the snorkel shaft. 33. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 8.31 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 314: Planetary Differential Disassembly
3. Remove th e (6 ) p lanet ge ars a nd ea ch sid e ge ar assembly from the ring gear. Planet Gears Side Bushing Gears 8.32 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 315 3. Press the new bushing into the planet gear until it is flush on each en d. Repeat th is procedure for the remaining planet gears. 8.33 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 316 2. Thoroughly clean the bore of the side gear and check for any unwanted burs. 3. Press the ne w bushing into the side gea r un til it bottoms out. 8.34 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 317: Planetary Differential Assembly
Inspect all bearings for signs of wear or damage. If replacement is required, use a standard bearing puller or an arbor press. 8.35 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 318: Snorkel Gear Backlash Procedure
NOTE: If pinion shaft was disassembled, the bearing Seize on the threads of the snorkel tube. cover must be installed on the shaft before installing the 46T gear. Grease Threads 8.36 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 320: Transmission Assembly
Snorkel Locking Screw: 8-10 ft. lbs. (11-14 Nm) Shift Fork Screws: 7-10 ft. lbs. (10-14 Nm) 4. Slide engagement dog (U) onto retaining pins of shift fork. 8.38 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 321 NOTE: Both s hift fo rks nee d t o be orien tated the same way, so that the shift fork pins are both offset to the same side of the rail. 8.39 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 322 Lift up o n the s hift sh aft rail (D ) a nd m ove the r ail assembly towards the shift drum to allow the shift fork ends to be installed into the shift drum (E). 8.40 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 323 Timing Marks High Gear Shown 18. Install the spacer onto the shift drum shaft. Spacer Park Brake Disc Mounting Bolt: 18-22 ft. lbs. (24-30 Nm) 8.41 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 324 24. Install the se ctor cover and alig n the tr ansmission case dowel with th e alignment hole. Install and torque the bolts to specification. Sector Cover Bolts: 9-12 ft. lbs. (12-16 Nm) 8.42 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 325: Troubleshooting
If t ransmission pr oblem rema ins, dis assemble transmission an d inspect all gear dog s for wear (rounding) or damage. Inspect all be arings, circlips, thrust washers and shafts for wear. 8.43 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 327 Spring, Compression Seal, Triple Lip Spring, Compression Sensor, Speed Spring, Compression, Detent Washer, Spring Tube, Snorkel Cover, Sector Gears Case, LH Case, LH Drum, Shift 8.45 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 329 104. Planet Gear Drum, Shift 105. Screw, M8 x 1.25 x 25 Gear, Sector 16T 106. Ring Gear, 53T Gear, Sector 31T 108. Bearing, Plain 8.47 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 332: General Specifications
Brake Pedal Mounting Bracket to Frame Park Brake Assembly Bolts Park Brake Disc Mounting Bolt 18-22 24-30 Park Brake Lever Mount Bolts Park Brake Mount Bracket to Transmission Bolts 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 333: Brake System Service Notes
Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 334: Hydraulic Brake System Operation
MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.
Page 335: Brake System Exploded View
Switch MC Rear Brake Line Seal Cross Fitting Master Cylinder Seal Seal LH Front Brake Line RH Front Master Cylinder View Brake Line Front Calipers Seal 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 336: Master Cylinder
(C). Brake Pedal Freeplay: CAUTION .090” (2.28 mm) Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 337: Brake Bleeding / Fluid Change
Attach a clean, clear hose to fitting an d place the othe r end in a cle an container. Be sure the hose fits tightly on fitting. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 338: Parking Brake (Intl Model)
Mount Bracket Nuts 16 ft. lbs. (22 Nm) Clip Mounting Bolts 37 ft. lbs. Bolts (50 Nm) Clevis Clevis Clip Parking Brake Lever Mount Bracket Cable 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 339 NOTE: See Ch apter 10 for more information on the Reconnect the conn ector as soo n a s practicable a nd parking brake switch. adjust the parking brake cable to proper tension. 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 340: Parking Brake Caliper Service (Intl Model)
NOTE: Be sure the parking brake is not engaged. Bracket 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. 9.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 341 Outboard Inboard Outboard Pad Thickness Inboard Pad Thickness New 0.250” (6.35 mm) New 0.300” (7.62 mm) Limit: 0.190” (4.83 mm) Limit: 0.240” (6.10 mm) 9.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 342: Parking Brake Disc (Intl Model)
Tor que th e mou nting bo lt to specification. Disc Bolt Washer Parking Brake Disc Mounting Bolt: 18-22 ft. lbs. (24-30 Nm) 9.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 343: Front Brake Pads
. Supp ort c aliper so t o avo id kinking or bending brake line. 5. Push caliper pis ton in to caliper bore slowly using a C-clamp or locking pliers with pads installed. 9.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 344: Pad Inspection
Front Brake Pad Thickness: .300” ± .007” (7.6 mm ± .178 mm) Service Limit: .180” (4.6 mm) Front Caliper Mount Bolt Torque: 31-34 ft. lbs. (42-46 Nm) 9.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 345: Brake Burnishing Procedure
7. Install wheel and torque wheel nuts to specification. Wheel Nuts: Steel Wheels: 27 ft. lbs. (37 Nm) Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) 9.15 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 346: Front Caliper Service
BRAKES FRONT CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid 47 in. lbs. (5.3 Nm) to Component Apply Silicone Grease A. Socket Set Screw  B. Bleeder Screw  C. Caliper Assy.  D. Boot  E. Square O-ring (thick)...
Page 347: Caliper Disassembly
IMPORTANT: Do not remove the caliper pistons with a st andard p liers. The piston se aling su rfaces will become damaged if a standard pliers is used. 9.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 348: Caliper Inspection
Seal Grooves O-Rings 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. = In. / mm. Install pistons with a twisting motion while pushing inward. Pisto n sh ould slide in and ou t of b ore smoothly, with light resistance.
Page 349: Caliper Installation
1/2 turn (counterclockwise). 1/2 Turn 5. Perform brake bleeding procedure as outlined earlier in this chapter. 9.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 350: Front Brake Disc
Service Limit .170” (4.32 mm) Brake Disc Thickness Variance Brake Disc Runout Service Limit: .002” (.051 mm) Service Limit .010” (.254 mm) difference between measurements 9.20 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 351: Disc Replacement
18 ft. lbs. (24 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 352: Rear Brake Pads
7. Remove the inner brake pad. NOTE: When re moving ca liper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 353: Pad Inspection
3. Install caliper and torque the new mounting bolts to specification. 44 ft. lbs. (60 Nm) Rear Caliper Mount Bolt Torque: 44 ft. lbs. (60 Nm) 9.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 354: Brake Burnishing Procedure
Repeat this pr ocedure 1 0 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 355: Rear Caliper Service
BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component 47 in. lbs. Apply Silicone Grease (5.3 Nm) A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F. Square Ring (thin)...
Page 356: Caliper Disassembly
4. Using a h ammer and a small p unch, r emove the piston (C) from the ca liper bo dy (D) . Rem ove the square O-rings (E) and (F) from the caliper body (D). 9.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 357: Caliper Inspection
Replace if damage is evide nt or if wor n be yond may drag upon assembly. service limit. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). In stall piston (D) with a twisting motion = In. / mm.
Page 358: Caliper Installation
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) NOTE: If ne w pa ds a re i nstalled, re fer to “R EAR BRAKE PADS - Brake Burnishing Procedure”. 9.28 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 359: Disc Replacement
6. Install wheel hub assembly, washers, and castle nut. Torque castle nut to 80 ft. lbs. (108 Nm) and install a new cotter pin. 9.29 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 360: Troubleshooting
• Residue build up under caliper seals • Operator riding brakes Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.30 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 363: General Information
• Digital Wrench Diagnostic Connector • AWD S witch • 12 Vdc Accessory Power Point • Ignition Switch / Headlamp Switch • Fuse / Relay Box 10.3 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 364: Switches / Controls
A a nd B; C and D; E and • Turn the ignition key to START. There should be continuity between switch pins A and B; C and D; E and F. 10.4 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 365: Awd / 2Wd Switch
• Move the switch to TURF . Th ere shou ld be continuity between switch pins 1 and 2; 4 and 5. 10.5 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 366: Transmission (Gear Position) Switch
Resistance Value Gear Position when measured at switch terminals A and B HIGH 24 Ohms 75 Ohms 160 Ohms 300 Ohms PARK 620 Ohms 10.6 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 367: Brake Light Switch
1500 RPM until the park ing brake is relea sed. This f eature has be en ad ded t o prevent drive-away with the parking brake applied. 10.7 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 368: Rear Diff Solenoid (Intl)
CAUTION Do not power the solenoid with 12 Volts for more than 1 se cond, or damage may occur to sole noid. 10.8 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 369: Vehicle Speed Sensor
4. Be sur e con nections are go od and 9V battery is in good condition. If the light flashes, the sensor is good. 10.9 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 370: Instrument Cluster
Certain products, including insect repellents and chemicals, will damage the instrument cluster lens. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. 10.10 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 371: Rider Information Display
11. TURF Indicator - Illuminated when the AWD / TURF traveled by the vehicle. The odometer can not be reset. switch is in the TURF position (INTL Models Only). 10.11 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 372 Tachometer (RPM) Engine hours are logged anytime the e ngine is ru nning. Total hours can not be reset. Engine RPM can be displayed digitally. 10.12 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 373 4. To tu rn off th e ser vice in terval fu nction, togg le the segment, step 4 w ill save the new settings and exit the MODE button until “OFF” is displayed. clock mode. 10.13 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 374 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat th e pr ocedure to change re maining displ ay settings. 10.14 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 376: Instrument Cluster Pinouts
NOTE: Do no t re move t he ru bber mount f rom th e dash p anel. Only remove the ru bber moun t if necessary. The bezel is a snap-on assembly and is a serviceable part. 10.16 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 377: Instrument Cluster Installation
80% of all electrical issues are caused by bad/failed connections and grounds. 10.17 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 378: Head Lights
NOTE: Make s ure the t abs on t he bulb loc ate properly in the housing. 6. Adjust th e b eam to de sired po sition. Repe at the procedure to adjust the other headlight. 10.18 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 379: Headlamp Housing Removal
(B). 3. Reconnect wire harness or re-insert bulb if previously removed. 4. Adjust h eadlights using the “ Headlight Adj ustment” procedure in this section. 10.19 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 381: Fan Control Circuit Operation / Testing
If the fan runs with the se nsor ha rness disconnected, but will not turn on when the engine is hot, ch eck th e coolant te mperature sensor and connector terminals. 10.21 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 382: Efi Diagnostics
4. Slowly tilt the tank so that gravity moves the sender float to the full position and compare to specification. Fuel Sender - Full: 6 ± 1  10.22 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 383: Charging System
7. Repeat te st, ob serving a mmeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 10.23 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 384: Charging System Stator (Alternator) Tests
Open Line Coil to Ground (Infinity) NOTE: Any meas urement ot her than Inf inity ( open) will indicate a failed or shorted stator leg. 10.24 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 385: Regulator / Rectifier
Image for Reference Only Regulator Heat Sink 75 in. lbs. (7 Nm) Keep Regulator Cooling Fins Clean To Stator To Battery Terminals 10.25 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 386: Charging System Testing Flow Chart
If all of the previous tests indicate a good condition, but the charging voltage does not rise above battery voltage at the connector or wire harness, replace the voltage regulator. 10.26 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 387: Battery Service
Ventilate when charging or using in closed space. Always shield eyes when working near batteries. Keep out of reach of children. 10.27 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 388: Battery Activation
NOTE: New Battery: Battery must be fully charged before use or b attery life will b e significantly reduced 10-30% of the battery’s full potential. 10.28 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 389: Battery Off Season Storage
NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging once a Authorized Polaris dealers/distributors are required to use month to make up for normal self-discharge. Battery...
Page 392: Starter Motor Removal
9. Lower vehicle. 5. Remove the starter from the engine. 10. Connect the (-) negative battery cable and install the driver’s side seat. 10.32 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 393: Starter Solenoid Bench Test
12V power via the Green / White wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 10.33 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 394: Starting System Testing Flow Chart
If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. 10.34 9923523 - 2012 RANGER RZR 570 Service Manual © Copyright 2011 Polaris Sales Inc.
Page 399 Air Box / Air Filter Exploded View ....2.15 Cab Frame, Assembly / Removal ....5.3 Air Filter Service .
Page 400 Engine Exploded Views ..3.9 3.10 3.11 3.12 3.13 Engine Installation ......3.31 Dash Instruments / Controls / Glove box .
Page 401 Front Gearcase, Installation ....7.25 Front Gearcase, Removal ..... 7.19 MAG Side Crankcase Bearing Service .
Page 402 Parking Brake Caliper, Disassembly (INT’L) ..9.11 Radiator ........3.16 Parking Brake Caliper, Exploded View (INT’L) .
Page 403 Specifications, Engine ......3.6 Transmission Disassembly ..... 8.12 Specifications, Engine Lubrication .

Polaris 2012 RANGER RZR 570 INTL Service Manual

Table of Contents

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling System

Chapter 4 Electronic Fuel Injection

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

Clutching Chapter 6 Clutching

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Polaris 2012 RANGER RZR 570 INTL