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

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting

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

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris RANGER 500 2017

Page 1 Publication Printed January 2021 (PN 9850043 R01) © Copyright 2021 Polaris 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 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 4 REVISION INDEX DATE CHANGES 01/13/2021 Initial release...
Page 5 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
Page 7 2017-2021 RANGER 500 / 570 Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING SYSTEM CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION CHAPTER 8 :...
Page 10 ............1.74 POLARIS MOBILE DIGITAL WRENCH® (PMDW) .
Page 12: Vehicle Information
M = 2021 VIN / ENGINE NUMBER LOCATION Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the Vehicle Identification Number (VIN) and the engine model and serial number. can be found stamped on the upper frame rail on the rear LH side of the vehicle below the cargo box.
Page 13: Reference Information
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.) SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 14: Publication Part Numbers
2018 RANGER 570 EPS Tractor (Intl.) R18RMS57CV R18RMS57E1 2019 RANGER 500 2x4 R19RM250B1 R19RMA50B1 2019 RANGER 500 R19RMA50B4 9928852 R19RMA57B1 2019 RANGER 570 / EPS R19RMA57B9 R19RME57BX 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 15 R21MAS57CK NOTICE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 16: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 17: Master Special Tools Table
(Use With 2” Bore Stand) (Use With 2.375” Bore Stand) PA-49316 PU-50625 PW-47054 Stator Cover Removal Handles Valve Spring Compressor Water Pump Seal Installation Tool PA-49317 PV-1253 PU-50869 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 18 Oil Pressure Gauge Adapter (2018 Valve Spring Compressor Adapter and earlier models) and later models) PV-43513-A PU-50569 PU-52502 570 ONLY Cylinder Holding & Camshaft Timing Plate PU-50563 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.10 © Copyright Polaris Inc.
Page 19 *Digital Wrench® SmartLink Module PU-47470 Interface Cable PU-47468 PU-47469 Digital Wrench® Wireless Fuel Pressure Gauge Kit Fuel Pressure Gauge Adapter Vehicle Link PU-43506-A PV-48656 PU-51435 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.11 © Copyright Polaris Inc.
Page 20 (Includes: 547927, PU-47466) Laptop or Desktop Computer USB/ Serial Adaptor: Saelig RS-232 Commercially Available (refer to diagnostic software user manual or HELP section for minimum requirements) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.12 © Copyright Polaris Inc.
Page 21 Drive Clutch Spider Removal and Install Tool 2870386 2870910-A 2870341 Universal Clutch Compressor Tool Standard Clutch Alignment Tool Clutch Center Distance Tool PU-50518-A 2870654 PU-50658-A 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.13 © Copyright Polaris Inc.
Page 22 FINAL DRIVE 1 3/4” Straight Wrench ADC Gearcase Piston CV Boot Clamp Pliers 2870772 Installation Tool 8700226 or PU-48951 PA-48542 Roller Pin Removal Tool 2872608 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.14 © Copyright Polaris Inc.
Page 23 Strut Compression Tools Shock Absorber Spring 2870871 2871573, 2871574 Compression Tool 2870623 BRAKES Mity Vac® Pressure Test Tool 2870975 BODY / FRAME Multi-Function Pliers 2876389 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.15 © Copyright Polaris Inc.
Page 24 Fluke® 77 Digital Multimeter PU-50338 PU-50296 PV-43568 Hall Sensor Probe Harness Static Timing Light Harness Timing Light 2460761 2871745 2870630 Relay Bypass Connector Test Kit PU-49466 PV-43526 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.16 © Copyright Polaris Inc.
Page 25: Master Torque Table
Front Bumper / Fender 5 ft-lbs (7 Nm) Head Bolts 89 ± 9 in-lbs Screws (10 ± 1 Nm) Front Gearcase Cover Plate 11 ft-lbs (15 Nm) Screws 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.17 © Copyright Polaris Inc.
Page 26 Stator Mounting Bolts 9 ft-lbs (12 Nm) Wheel Lug Nuts (Aluminum 30 ft-lbs + 90º (41 Nm + 90º) Wheels) 6 ft-lbs (9 Nm) Stator Wire Retainer 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.18 © Copyright Polaris Inc.
Page 27: Clutching Chart
(7043594) RANGER CREW 570 SHIFT DRIVE ALTITUDE WEIGHT SPRING 0-1800 25-52G Black (0-6000) (5632409) (7043594) Meters (Feet) 1800-3700 25-48 Black (6000 - 12000) (5633217) (7043594) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.19 © Copyright Polaris Inc.
Page 28: General Specifications
1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.20 © Copyright Polaris Inc.
Page 29 Drive: 10 Amp Lights: 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift - P/ H / L / N / R 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.21 © Copyright Polaris Inc.
Page 30 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.22 © Copyright Polaris Inc.
Page 31 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.23 © Copyright Polaris Inc.
Page 32: 2017-2018 Ranger 570 4X4 (Intl.)
1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.24 © Copyright Polaris Inc.
Page 33 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.25 © Copyright Polaris Inc.
Page 34 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.26 © Copyright Polaris Inc.
Page 35 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.27 © Copyright Polaris Inc.
Page 36 1250 lbs. / 567 kg (Includes weight of riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.28 © Copyright Polaris Inc.
Page 37 DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI / Chassis / Fan / Fuel Pump / Headlight / EPS (EPS model only) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.29 © Copyright Polaris Inc.
Page 38 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.30 © Copyright Polaris Inc.
Page 39 Drive: 10 Amp Lights: 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift - P/ H / L / N / R 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.31 © Copyright Polaris Inc.
Page 40 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.32 © Copyright Polaris Inc.
Page 41 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.33 © Copyright Polaris Inc.
Page 42 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.34 © Copyright Polaris Inc.
Page 43 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.35 © Copyright Polaris Inc.
Page 44 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.36 © Copyright Polaris Inc.
Page 45 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.37 © Copyright Polaris Inc.
Page 46 1250 lbs. / 567 kg (Includes weight of riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.38 © Copyright Polaris Inc.
Page 47 DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI / Chassis / Fan / Fuel Pump / Headlight / EPS (EPS model only) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.39 © Copyright Polaris Inc.
Page 48 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.40 © Copyright Polaris Inc.
Page 49 Drive: 10 Amp Lights: 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift - P/ H / L / N / R 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.41 © Copyright Polaris Inc.
Page 50 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.42 © Copyright Polaris Inc.
Page 51 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.43 © Copyright Polaris Inc.
Page 52 1250 lbs. / 567 kg (Includes weight of riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.44 © Copyright Polaris Inc.
Page 53 DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI / Chassis / Fan / Fuel Pump / Headlight / EPS (EPS model only) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.45 © Copyright Polaris Inc.
Page 54 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.46 © Copyright Polaris Inc.
Page 55 Drive: 10 Amp Lights: 20 Amp DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift - P/ H / L / N / R 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.47 © Copyright Polaris Inc.
Page 56 1000 lbs. / 454 kg (Includes weight of Vehicle Payload riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.48 © Copyright Polaris Inc.
Page 57 Brake Light: 5 Amp EFI: 20 Amp Fuel Pump: 10 Amp EPS (EPS model only): 20 Accessory: 20 Amp Drive: 10 Amp Lights: 20 Amp 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.49 © Copyright Polaris Inc.
Page 58 1250 lbs. / 567 kg (Includes weight of riders, cargo and accessories) Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.50 © Copyright Polaris Inc.
Page 59 DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI / Chassis / Fan / Fuel Pump / Headlight / EPS (EPS model only) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.51 © Copyright Polaris Inc.
Page 60: Misc. Specifications And Charts
π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.52 © Copyright Polaris Inc.
Page 61: Sae Tap / Drill Sizes
5/16–18 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 3–4 7/16–14 2 3/4 7/16–20 25/64 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.53 © Copyright Polaris Inc.
Page 62: Metric Tap / Drill Sizes
10 x 1.25 11/32 0.3437 11/32 10 x 1.50 0.339 11/32 11 x 1.50 0.375 12 x 1.50 13/32 0.406 13/32 12 x 1.75 13/32 0.406 13/32 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.54 © Copyright Polaris Inc.
Page 63: Decimal Equivalents
17/32 0.5313″ 0.5469″ 14 mm = 0.5512″ 35/64 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 0.5938″ 19/32 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.55 © Copyright Polaris Inc.
Page 64 23 mm = 0.9055″ 57/64 29/32 0.9063″ 59/64 0.9219″ 15/16 0.9375″ 24 mm = 0.9449″ 61/64 0.9531″ 31/32 0.9688″ 25 mm = 0.9843″ 63/64 0.9844″ 1.000″ 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.56 © Copyright Polaris Inc.
Page 65: General Diagnostics
Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.57 © Copyright Polaris Inc.
Page 66: Guided Symptom References
Refer to the Symptom Checklist for various conditions. – If the concern has been verified and all of the information has already been collected, please start an Ask Polaris case at this time. If this information has not yet been gathered, gather this information first.
Page 67: Engine And Drivability Diagnostic Procedures
Functional with MIL ON) page 1.98 • Connect to Digital Wrench®. Check codes and continue with Digital Wrench® Guided diagnosis. • If no codes are present, proceed to step 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.59 © Copyright Polaris Inc.
Page 68 • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.62 for more information. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.60 © Copyright Polaris Inc.
Page 69 These concerns may also be caused by a mechanical failure. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.61...
Page 70: Engine Cranks But Does Not Start
10. Listen for unusual noises while cranking. • If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.62 © Copyright Polaris Inc.
Page 71 – Bent valve or stuck valve – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.63 © Copyright Polaris Inc.
Page 72: No Crank No Start Or Slow Crank
(starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake Switch operation. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.64 © Copyright Polaris Inc.
Page 73: Over Heating
• Check level and correct as necessary. Check maintenance history to determine if oil need to be changed. 7. Check Cooling Fan operation. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.65 © Copyright Polaris Inc.
Page 74: Warning Lights
Guided Diagnostic for further diagnosis. 5. BRAKE WARNING • Detects brake system failure. • Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.66 © Copyright Polaris Inc.
Page 75: Engine Troubleshooting
• Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.67 © Copyright Polaris Inc.
Page 76 • Low fuel pressure electrical concern / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.68 © Copyright Polaris Inc.
Page 77: Cooling Troubleshooting
• Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.69 © Copyright Polaris Inc.
Page 78: Digital Wrench
GENERAL INFORMATION DIGITAL WRENCH DIGITAL WRENCH® SOFTWARE OVERVIEW The Polaris Digital Wrench® software allows a technician to perform the following tasks: • Analyze real-time engine data • Create customer service account records • Generate / upload service reports • Perform guided diagnostic procedures •...
Page 79: Digital Wrench® Software Installation And Updates
To check if a Digital Wrench® software update is following: available, do the following: 1. Open a web browser and log on to your Polaris dealer 1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com).
Page 80: Digital Wrench® Communication Errors
DIGITAL WRENCH® COMMUNICATION ERRORS If you experience problems connecting to a vehicle, or any other Digital Wrench® software-related problem, visit the Digital Wrench® home page (www.polaris.diagsys. com) and locate the following information under Knowledge Base: • Errors and Troubleshooting • Frequently Asked Questions (FAQs) •...
Page 81: Digital Wrench® Feature Map
Perform specialized testing Access the Digital Wrench® and adjustment functions System Help. service reports. Print the current screen as a Open the ASSERT ASK formatted printout. form. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.73 © Copyright Polaris Inc.
Page 82: Engine Controller Reprogramming (Reflash)
– Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®. progress. 10. Open a web browser and log on to your Polaris dealer • Understand the Process website (www.polarisdealers.com). Review the Digital Wrench® System Help before you 11.
Page 83: Engine Electrical Diagnostics
You can download the PMDW app on your Android 2. Press either toggle button to cycle to the device from the Polaris dealer website. From the Service “DIAGCODE” option. Press MODE to select. and Warranty drop-down, select Digital Wrench, and 3.
Page 84: Master Trouble Code List
Voltage Above Normal, Or Shorted To High Source P0108 Manifold Absolute Pressure Sensor Voltage Too Low P0107 Mechanical System Not Responding Or Out Of Adjustment P1106 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.76 © Copyright Polaris Inc.
Page 85 P1568 Data Valid But Above Normal Operating Range - Moderately Severe P1571 Level Data Valid But Below Normal Operating Range - Moderately Severe P1573 Level 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.77 © Copyright Polaris Inc.
Page 86 Mechanical System Not Responding Or Out Of Adjustment P0016 Camshaft Position Sensor Abnormal Frequency Or Pulse Width Or Period P0340 Voltage Above Normal, Or Shorted To High Source P1739 Tachometer Driver Circuit 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.78 © Copyright Polaris Inc.
Page 87 Wheel Speed Sensor (Rear or Voltage Above Normal, Or Shorted To High Source C113D Rear Left) Voltage Below Normal, Or Shorted To Low Source C123D 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.79 © Copyright Polaris Inc.
Page 88 1485 Current Below Normal Or Open Circuit P0685 Voltage Above Normal P0694 1557 Fan Driver 2 Voltage Below Normal, Or Shorted To Low Source P0693 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.80 © Copyright Polaris Inc.
Page 89 P17AE ECU Output Supply Voltage 3 3599 Voltage Above Normal, Or Shorted To High Source P17AA Voltage Below Normal, Or Shorted To Low Source P17AB 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.81 © Copyright Polaris Inc.
Page 90 Data Valid But Below Normal Operating Range - Least Severe Level P0174 Data Erratic, Intermittent Or Incorrect P1684 520206 Reverse Alarm Voltage Above Normal, Or Shorted To High Source P1682 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.82 © Copyright Polaris Inc.
Page 91 Current Below Normal Or Open Circuit C1029 ABS Solenoid (Front Right Out) 520257 Condition Exists C1329 Voltage Above Normal, Or Shorted To High Source C1020 520260 ABS Motor 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.83 © Copyright Polaris Inc.
Page 92 520287 Condition Exists P1542 ECU Monitoring of Injection Cut Off 520288 (Level 1) Condition Exists P1543 ECU Monitoring of Injection Cut Off 520289 (Level 2) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.84 © Copyright Polaris Inc.
Page 93 Drive Mode Select Switch Voltage Below Normal, Or Shorted To Low Source P153B Voltage Above Normal, Or Shorted To High Source P251C Operator Presence Switch 524070 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.85 © Copyright Polaris Inc.
Page 94 EPS Fault Lamp Driver Circuit 524085 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.86 © Copyright Polaris Inc.
Page 95: Cylinder Misfire Detection
Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.87 © Copyright Polaris Inc.
Page 96: Fluid Leaks
• If a fluid is contaminated with metal or debris, suspect that there is a mechanical failure causing the fluid contamination. Refer to the Service Manual information related to the system in question. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.88 © Copyright Polaris Inc.
Page 97: Fuel System Diagnostics
• Intake air leak (throttle shaft, intake ducts, air box cover) • Spark plug erosion / fouling • Faulty oxygen sensor • Engine runs hot • Surging • High / Erratic idle 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.89 © Copyright Polaris Inc.
Page 98 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.90 © Copyright Polaris Inc.
Page 99: Pvt System Diagnostics
Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.91 © Copyright Polaris Inc.
Page 100 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.92 © Copyright Polaris Inc.
Page 101: Pvt System Overheating / Diagnosis
PVT system. than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel Poor engine performance.
Page 102: Transmission Diagnostics
• If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.94 © Copyright Polaris Inc.
Page 103: Final Drive Diagnostics
Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.95 © Copyright Polaris Inc.
Page 104: Brake System Diagnostics
• Brake Disc damaged VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING) • Alignment issues • Worn Suspension components 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.96 © Copyright Polaris Inc.
Page 105: Caliper Overheats (Brakes Drag)
• Failed brake hose / line • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder • Faulty distribution block (INTL models only ) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.97 © Copyright Polaris Inc.
Page 106: Steering / Suspension Diagnostics
Check wiring from Connector to Ignition Switch 12 VDC on Pin 3 of the 8 pin EPS Connector? Circuit ↓ Begin Digital Wrench EPS Troubleshooting Procedure 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.98 © Copyright Polaris Inc.
Page 107: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)
Instrument during MIL lamp Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.99 © Copyright Polaris Inc.
Page 108: Eps Troubleshooting (Using Digital Wrench®)
If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.100 © Copyright Polaris Inc.
Page 109: Shock Analysis
(weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.101 © Copyright Polaris Inc.
Page 110: Electrical Diagnostics
• All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.105 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) DYNAMIC TESTING for electrical testing.
Page 111 To avoid causing damage, use of the appropriate Back probing is typically not advisable on sealed adapters is required. Most terminals used on Polaris connectors, as it can easily cause damage to the wire, machines can be tested using terminal test kit PV–...
Page 112: Testing For A Short To Ground
9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.105 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.104 © Copyright Polaris Inc.
Page 113: Testing For A Short To Voltage
For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.105 © Copyright Polaris Inc.
Page 114: Testing For Intermittent Conditions
Failure to do so can lead to serious injury and/or damage to the machine. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.106 © Copyright Polaris Inc.
Page 115: Current Draw - Key Off
IMPORTANT Charging system damage will occur if incompatible components are installed. Always reference the Polaris TESTING VOLTAGE DROP Electronic Parts Catalog for the proper part numbers. NOTICE If you disconnect the connector at the load, and...
Page 116 GENERAL INFORMATION For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 1.108 © Copyright Polaris Inc.
Page 117 ....... 2.11 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ENGINE ....................2.12 .
Page 119: Maintenance
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 120: Break-In Period
Do not operate at full throttle at or high speeds during the first three hours of operation. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. Polaris recommends you use Polaris PS-4 Synthetic Engine Oil.
Page 121: Periodic Maintenance Chart Key
NOTICE Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or death.
Page 122 Inspect for leaks; clean external surfaces 100 H 12 M ▶ Engine mounts Inspect 100 H 12 M Exhaust muffler /pipe Inspect 100 H 12 M 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 123 ▶ = Perform these procedures more often for vehicles subjected to severe use. E= Emission Control System Service (California) D = Have an authorized POLARIS dealer perform these services. *Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.
Page 124: Grease Lubrication Points
RECOMMENDED LUBE METHOD FREQUENCY Grease before long periods Grease fittings of storage, and after Front Propshaft Yoke Polaris Premium U-Joint Grease (3 pumps maximum) pressure washing or submerging the vehicle. ** Locate fitting and grease. Semi-annually ** Front A-Arm Polaris All Season Grease...
Page 125: Component Quick Reference
Check level at pre-ride between “MAX and inspection; change fluid Brake Fluid Polaris DOT 4 Brake Fluid “MIN” lines on the every two years master cylinder reservoir * More often under severe use, such as operated in water or under severe loads.
Page 126: Storage Tips
Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 5. If Polaris fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
Page 127: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS PART NO. DESCRIPTION Fogging Oil (12 oz. Aerosol) 2870791 PS-4 Syn. 4-Cycle Engine Oil (Quart) 2876244 Engine Lubricant PS-4 Syn. 4-Cycle Engine Oil (Gallon / 3.8 l) 2876245 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
Page 128: Engine
COMPRESSION AND LEAKDOWN TEST 4. Reinstall dipstick completely. NOTICE NOTICE This Polaris 4-Stroke engine is equipped with an The dipstick must be screwed completely in to ensure automatic decompressor. Compression readings will accurate measurement. vary in proportion to cranking speed during the test.
Page 129: Breather Hose
14. Install the new filter and turn it by hand until the filter gasket contacts the sealing surface, then turn an additional 3/4 of a turn. 15. Remove dipstick. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.13 © Copyright Polaris Inc.
Page 130: 500 Sohc
NOTICE Isolators must be replaced after each use. 4. Remove the PVT cover to access the drive clutch. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.14 © Copyright Polaris Inc.
Page 131 MEASUREMENT Intake Valve Clearance: 0.006 ± 0.002" (0.15 ± 0.05 mm) Exhaust Valve Clearance: 0.008 ± 0.002" (0.20 ± 0.05 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.15 © Copyright Polaris Inc.
Page 132: Cooling System
1. Position the vehicle on a level surface. 2. The coolant level must be maintained between the Polaris recommends the use of Polaris 50/50 Extended “MAX” and “MIN” levels indicated on the recovery Life Antifreeze or a 50/50 mixture of high quality...
Page 133 Use of a non-standard pressure cap will not allow the recovery system to function properly. 6. Remove the recovery bottle cap. 7. Fill the recovery bottle to the “MAX” mark with Polaris Premium 50/50 Anti-Freeze/Coolant or a 50/50 mixture of antifreeze/coolant and distilled water as required for freeze protection in your area.
Page 134: 50/50 Extended-Life Engine Antifreeze
MAINTENANCE 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE All liquid-cooled Polaris vehicles use 50/50 Extended Life antifreeze, which has a 5-year service life. It’s important to note that conventional, 60/40 antifreeze can be mixed with 50/50 Extended Life antifreeze. However, mixing the two will affect the service interval. To receive the full 5-year service interval benefit, the cooling system must be fully drained and replenished with the Extended Life antifreeze.
Page 135: Coolant Strength / Type
2. Check tightness of all hose clamps. CAUTION Do not over-tighten hose clamps at radiator, or radiator fitting may distort. TORQUE Radiator Hose Clamp: 36 in-lbs (0.4 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.19 © Copyright Polaris Inc.
Page 136: Radiator Inspection / Cleaning
Use of a high-pressure washer is not 5. Remove the screws that retain the recovery bottle to recommended. the frame bracket. Set the recovery bottle out of the way. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.20 © Copyright Polaris Inc.
Page 137 9. Carefully lift the radiator straight up and out of the vehicle. Take care not to damage the cooling fins. 10. Remove the four bolts that retain the fan motor and shroud to the radiator. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.21 © Copyright Polaris Inc.
Page 138: Fuel System And Air Intake
1. Lift the rear cargo box to access the airbox cover. For all other information related to the Fuel System, refer to Chapter 4. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.22 © Copyright Polaris Inc.
Page 139: Engine Air Intake Inspection
1. Remove the PVT intake cover REF. DESCRIP- NOTES TION Cover Filter Seal Clamp Airbox 2. Verify there is no debris obstructing the airway. 3. Reinstall the cover. Boot Installation 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.23 © Copyright Polaris Inc.
Page 140: Transmission And Gearcase
5. Remove the fill plug (refer to “Transmission Lubricant adjustment is made to the shift cable. Level Check”). 6. Place a drain pan under the transmission drain plug. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.24 © Copyright Polaris Inc.
Page 141: Front Gearcase Lubrication
Access the drain plug through the 11. Check for leaks. Dispose of used lubricant properly. skid plate. 6. Remove the fill plug (refer to “Front Gearcase Fluid Level Check”). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.25 © Copyright Polaris Inc.
Page 142 12. Reinstall fill plug with a new O-ring and torque to specification. TORQUE Front Gearcase Drain / Fill Plug: 10 ft-lbs (14 Nm) 13. Check for leaks. Dispose of used fluid properly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.26 © Copyright Polaris Inc.
Page 143: Final Drive / Wheel / Tire
3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and washers and remove the wheel. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.27 © Copyright Polaris Inc.
Page 144: Wheel Installation
• The use of non-standard size or type tires may affect vehicle handling. MEASUREMENT Tread Depth Service Limit: Replace if 1/8″ (3 mm) or less. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.28 © Copyright Polaris Inc.
Page 145: Steering
NOTICE Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component...
Page 146: Wheel Toe Alignment Inspection
To adjust toe alignment: 1. Hold tie rod end to keep it from rotating. 2. Loosen jam nuts at both end of the tie rod. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.30 © Copyright Polaris Inc.
Page 147: Camber And Caster
4. After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) CAMBER AND CASTER The camber and caster are non-adjustable. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.31 © Copyright Polaris Inc.
Page 148: Suspension
Vehicle loads effect suspension spring pre-load requirements. Use Spanner Wrench to adjust pre-load as necessary to avoid bottoming of the shocks. Shock Spanner Wrench 2871095 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.32 © Copyright Polaris Inc.
Page 149: Suspension Pivot Point Lubrication
. See the maintenance chart for service intervals or grease as needed. NOTICE Wheels removed for clarification only. Procedure can be done with wheels installed on unit. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.33 © Copyright Polaris Inc.
Page 150: Shock Analysis
(weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.34 © Copyright Polaris Inc.
Page 151: Brake System
BRAKE HOSE AND FITTING INSPECTION Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.35 © Copyright Polaris Inc.
Page 152: Brake Disc Inspection
Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.36 © Copyright Polaris Inc.
Page 153: Electrical And Ignition System
A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.37 © Copyright Polaris Inc.
Page 154: Battery Installation
Look for a sharp outer edge with no rounding or erosion of the electrodes. NOTICE Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery...
Page 155: 570 Dohc
4. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION A wire brush or coated abrasive should not be used. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.39 © Copyright Polaris Inc.
Page 156: Main Frame/Engine Ground
. Be sure ground wires are tight and not corroded. The main chassis ground can be found below the fuse box under the driver’s seat base. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 2.40 © Copyright Polaris Inc.
Page 161: General Engine Information
Valve Spring Compressor PV-1253 Valve Spring Compressor Adapter PV-43513-A Water Pump Mechanical / Oil Seal Installation Kit PU-50689 Bosch Automotive Service Solutions: 1-800-345-2233 http://polaris.service-solutions.com/. ENGINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Oil Capacity Approx. 2 Quarts (1.9 L) Oil Filter Wrench PU-50105 or 2.5″ (64 mm)
Page 162: Oil Pressure Test
NOTICE Test results are based on the use of the recommended engine oil (Polaris PS-4) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.
Page 164: Engine Specifications
Cylinder Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00177" - 0.00295" (0.045 - 0.075 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 165 Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter Bearing Journal O.D. (Standard) 1.1798 - 1.1802″ (29.969 - 29.979 mm) Balance Shaft 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 166: Engine Service
ALL of the top-end engine components can be serviced before attempting to perform any work. while the engine is mounted in the chassis. 2. Thoroughly clean the engine and chassis. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.10 © Copyright Polaris Inc.
Page 167 10. Remove the CPS sensor from the stator cover on the right-hand side of the engine. Plug CPS hole with clean shop towel. Inspect CPS O-ring and replace if needed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.11 © Copyright Polaris Inc.
Page 168 28. Place engine onto the engine stand (PU- 50624) for 24. Loosen the (2) bolts and nuts (Item 6) so the engine service. mount bracket can be slightly tilted away from engine. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.12 © Copyright Polaris Inc.
Page 169: Engine Installation
RZR XP 1000 2013 RANGER 900 2014-16 2015-19 ACE 570 2015-16 RGR ETX 2013–19 RZR 570 2014–19 RANGER 500/570 2015-19 RANGER 570 Full-Size 2014-19 RANGER 900/1000 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.13 © Copyright Polaris Inc.
Page 170 14. Install the throttle body and air box. Tighten the hose clamps that secure the throttle body to the intake duct, intake boot and air box. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.14 © Copyright Polaris Inc.
Page 171 / coolant. 30. If the engine oil was completely drained, add approximately 2 quarts (1.9 L) of Polaris PS-4 Synthetic Engine Oil into the crankcase. 31. Install a new oil filter. Lubricate the seal with engine oil prior to installation (see Maintenance chapter).
Page 172: Engine Break-In Period
Oil Filter Wrench CAUTION PU-50105 or 2.5” (64 mm) Use only Polaris PS-4 Synthetic Engine Oil. Oil Type Never substitute or mix oil brands. Polaris PS-4 Synthetic Engine Oil Serious engine damage and voiding of warranty can result.
Page 173: Engine Mounting And Torque Values
Torque to 55 ft-lbs (75 Nm) Bolt Torque to 40 ft-lbs (54 Nm) Torque to 25 ft-lbs (34 Nm) Bolt Torque to 18 ft-lbs (25 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.17 © Copyright Polaris Inc.
Page 174: Setting Tdc (Top-Dead-Center)
3. With the stator cover and flywheel removed, rotate the engine and position the piston at TDC by aligning the timing hole in crank case with a timing hole in the crankshaft. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.18 © Copyright Polaris Inc.
Page 175 This will set TDC, but not necessarily TDC of the compression stroke. View the timing marks on the cam shaft sprockets to ensure the engine is at TDC of the compression stroke. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.19 © Copyright Polaris Inc.
Page 176: Cooling System
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM REF. DESCRIPTION NOTES Radiator Fan Shroud Cooling Fan Recovery Bottle Radiator Drain Plug Upper Radiator Hose Lower Radiator Hose Bypass Hose Water Pump Hose 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.20 © Copyright Polaris Inc.
Page 177: Cooling System Specifications
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 50/50 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 178: Radiator
7. Remove the hose and completely drain the engine. Radiator Removal 8. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.22 © Copyright Polaris Inc.
Page 179: Thermostat Replacement
TORQUE Thermostat Cover Bolts: 8 ft-lbs (10 Nm) 8. Be sure to properly fill and bleed cooling system as outlined in this chapter. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.23 © Copyright Polaris Inc.
Page 180: Cooling System Bleeding Procedure
2. Open the hood. 11. Remove the pressure cap. Add the necessary 3. Remove the recovery bottle cap (Item 1) and fill the amount of Polaris Premium Antifreeze to the radiator bottle to the MAX line. filler neck. 12. Open the bleed screw to allow any trapped air to escape.
Page 181: Water Pump Cover And Impeller Service (Stator Cover Remains On Engine)
11. Inspect the water pump cover and impeller for 6. Completely drain cooling system and engine as damage. Replace as necessary. outlined in this chapter. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.25 © Copyright Polaris Inc.
Page 182 Be sure engine coolant does not contaminate the engine oil during stator cover service. 11. Remove the water pump cover and water pump cover gasket . Discard the water pump gasket. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.26 © Copyright Polaris Inc.
Page 183 20. Press out the water pump drive shaft bearing from the stator cover. Discard bearing and replace with new. Water Pump Assembly 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.27 © Copyright Polaris Inc.
Page 184 26. Lubricate the new water pump oil seal with clean engine oil. 29. Install a new stator cover gasket onto the engine. 30. Align the water pump drive slot as shown below. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.28 © Copyright Polaris Inc.
Page 185 PA-49317 to the water cover bolt holes to aid in stator cover installation. TORQUE Stator Cover and Water Pump Cover: 9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt threads) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.29 © Copyright Polaris Inc.
Page 186 48. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 49. Check for leaks. 38. Install a new water pump cover gasket. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.30 © Copyright Polaris Inc.
Page 187: Troubleshooting
Slow Engine Cranking • Restricted fuel supply • Weak battery • Low compression • Loose Electrical connections • Crankcase breather restricted • Decompression Mechanism not functioning properly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.31 © Copyright Polaris Inc.
Page 188: 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 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.32 © Copyright Polaris Inc.
Page 189: 500Cc Sohc Engine
Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00138" - 0.00256" (.035 - .065 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.33 © Copyright Polaris Inc.
Page 190 Crankshaft Runout Limit See Service Procedure (PTO and MAG) Listed In This Chapter Bearing Journal O.D. 1.1798” - 1.1802" Balance Shaft (Standard) (29.969 - 29.979 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.34 © Copyright Polaris Inc.
Page 191: Engine Torque Sequences
ENGINE / COOLING SYSTEM ENGINE TORQUE SEQUENCES CAM CARRIER CYLINDER HEAD WATER PUMP COVER VALVE COVER 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.35 © Copyright Polaris Inc.
Page 193: Crankcase Sealant Path
Alignment Pins MUST be installed prior to assembly IMPORTANT Clean the case deck of all sealant after assembly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.37 © Copyright Polaris Inc.
Page 194: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
Engine oil may be used to aid installation. Oil Pressure Regulator Assembly Torque: 20 ft-lbs (12 Nm) Piston Oil Jet Torque: 35–in-lbs (4 Nm) Oil Pump Cover Torque: 106 in-lbs (12 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.38 © Copyright Polaris Inc.
Page 195: Cylinder / Oil Filter / Oil Pump / Breather
ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.39 © Copyright Polaris Inc.
Page 196 Gerotor dots must not be visible after assembly. Piston Assembly Apply ENGINE OIL to bottom 50 mm of cylinder bore and to piston rings before assembly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.40 © Copyright Polaris Inc.
Page 197: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.41 © Copyright Polaris Inc.
Page 198 Torque in Sequence shown in Torque Sequence topic. Replace if loosened of removed. Water Pump Impeller Impeller has left hand thread, tighten to finger tight. Screw Torque: 106 in-lbs (12 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.42 © Copyright Polaris Inc.
Page 199: Spark Plugs / Starter / Throttle Body / Valve Cover
ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.43 © Copyright Polaris Inc.
Page 200 Screw Torque: 89 in-lbs (10 Nm) Screw Torque: 89 in-lbs (10 Nm) Starter Motor Apply grease to starter o-ring. Dipstick Apply engine oil to o-ring 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.44 © Copyright Polaris Inc.
Page 202 Apply load to outer race only. Balance Shaft Apply ENGINE OIL or WHITE LITHIUM grease to bearing surfaces and/or bore. Align gears to gear timing marks. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.46 © Copyright Polaris Inc.
Page 203 Orient cir-clip as shown below. The gap should be located at the 6 o’clock or 12 o’clock locations. IMPORTANT Orient Piston as shown. Arrow should be pointing to the exhaust valve side. IMPORTANT Time balance shaft and crankshaft gears as shown. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.47 © Copyright Polaris Inc.
Page 204: Engine Disassembly / Inspection - Top End
1. Rotate the engine so the piston is at Top Dead Center (TDC) on the compression stroke. NOTICE To verify TDC, see “Setting TDC (Top-Dead-Center)”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.48 © Copyright Polaris Inc.
Page 206: Exhaust Camshaft Decompression Mechanism
3. Remove the fasteners that secure the lower cam chain guide to the crankcase. 4. Inspect the cam chain guides and replace if excessive wear is evident. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.50 © Copyright Polaris Inc.
Page 207: Cylinder Head Removal
4. Tap cylinder head lightly with a soft faced hammer until loose. Tap only in reinforced areas or on thick parts of the cylinder head casting. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.51 © Copyright Polaris Inc.
Page 208: Cylinder Head Inspection
2. Check valve face for excessive runout, pitting, and keeping it in order for reassembly in the same valve burnt spots. guide. 7. Repeat the previous steps to remove the remaining valve. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.52 © Copyright Polaris Inc.
Page 209 0.2741" - 0.2747" (6.963 - 6.978 mm) 8. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.53 © Copyright Polaris Inc.
Page 210: Combustion Chamber Cleaning
The valve may overheat and warp, resulting in burnt valves. IMPORTANT Polaris Premium Carbon Clean can be used to help remove carbon deposits. Do not use a metal scraper, a coarse wire brush or abrasive cleaners to clean the cylinder head. Damage may result.
Page 211: Cylinder Removal
12. Thoroughly clean cylinder head and valves. CYLINDER REMOVAL 1. Remove and discard the head gasket. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.55 © Copyright Polaris Inc.
Page 212: Cylinder Inspection
If necessary, heat the crown of the piston slightly with a heat gun. IMPORTANT Do not apply heat to the piston rings, they may lose radial tension. Cylinder Warpage: .00098” (.025 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.56 © Copyright Polaris Inc.
Page 213: Piston-To-Cylinder Clearance
Piston Pin O.D.: Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm) Service Limit: 0.8651″ (21.975 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.57 © Copyright Polaris Inc.
Page 214: Piston Ring Installed Gap
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm) Service Limit: 0.0042" (0.108 mm) Second Ring: Std.: 0.0007 - 0.0029" (.020 - 0.076 mm) Service Limit: 0.0035" (0.89 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.58 © Copyright Polaris Inc.
Page 215: Engine Assembly - Top End
Second Ring Gap Position Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.59 © Copyright Polaris Inc.
Page 216: Piston / Connecting Rod Assembly
2. Install a new base gasket. NOTICE Base gasket and surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.60 © Copyright Polaris Inc.
Page 217: Cylinder Head Installation
If cam chain and flywheel are installed (top end work only is being performed) hold cam chain tight while rotating the engine to avoid damage to the chain, drive sprocket teeth, or tensioner blade. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.61 © Copyright Polaris Inc.
Page 218: Valve Sealing Test
(if removed) as outlined in this chapter. 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. VALVE SEALING TEST The camshaft lobes should face out.
Page 219 Lubricate the outer portion of the valve bucket upon installation. MEASUREMENT Exhaust Valve Clearance (cold): 14. Repeat steps until all necessary valves have been .010 ± .002″ (0.254 ± .050 mm) adjusted. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.63 © Copyright Polaris Inc.
Page 220: Valve Lash - Tappet Selection Matrix
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.64 © Copyright Polaris Inc.
Page 221: Camshaft Installation / Timing
(TDC). NOTICE To verify TDC, see “Setting TDC (Top-Dead-Center)”. 2. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 Synthetic Engine Oil prior to installation. 6. Carefully install the camshaft carrier onto the camshafts. 7. Install the four bolts that retain the camshaft carrier.
Page 222 Ensure exhaust decompression mechanism still moves freely and returns by spring force after sprocket has been installed. 13. Insure the new sealing washer is in place. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.66 © Copyright Polaris Inc.
Page 223: Camshaft Timing - Quick Reference
1/4” drive socket extension through flywheel is aligned with the CPS mounting hole. the crankcase and into the crankshaft locating hole 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.67 © Copyright Polaris Inc.
Page 224: Valve Cover Installation
2. Install a new valve cover seal 3. Install the four valve cover bolts 4. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 9 ft-lbs (12 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.68 © Copyright Polaris Inc.
Page 225: Engine Disassembly / Inspection - Lower End
2. Place flywheel on work bench. Grasp gear and rotate clockwise. It should turn smoothly without binding. 3. Rotate gear counterclockwise. The gear should immediately lock in position and not slip. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.69 © Copyright Polaris Inc.
Page 227: Stator Removal
4. Remove the two bolts that secure the stator wire routing bracket to the stator cover. 5. Remove the stator from the stator cover. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.71 © Copyright Polaris Inc.
Page 228: Oil Pump Removal
ENGINE / COOLING SYSTEM OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.72 © Copyright Polaris Inc.
Page 229 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.73 © Copyright Polaris Inc.
Page 230: Oil Pump Assembly
Do not use gasket sealer on Oil Pressure the pump cover mating surfaces. Minimum Specification (using Polaris PS-4 at operating temperature) 2. Align the gerotor according to the orientation dots. 10 PSI @ 1200 RPM (Minimum) 3. Place the drive pin...
Page 231: Crankcase Breather Service
Crankcase Breather Cover Bolts: 9 ft-lbs (12 Nm) 3. Remove and discard the fifteen flange bolts from magneto side crankcase evenly in a criss-cross pattern. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.75 © Copyright Polaris Inc.
Page 232: Balance Shaft Removal / Inspection
The inner race should be firm with minimal side to side movement and no detectable up and down (radial) movement. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.76 © Copyright Polaris Inc.
Page 233: Crankshaft Removal
0.8665 - 0.8670″ (22.010 - 22.023 mm) 4. Remove all special tools from the crankcase. Service Limit: 0.08682″ (22.053 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.77 © Copyright Polaris Inc.
Page 234: Pto Side Crankcase Bearing Service
2. If not already performed, remove the screws that Bearing Spacer secure the bearing retainer to the case. Retaining Ring 3. Remove the retaining ring. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.78 © Copyright Polaris Inc.
Page 235: Mag Side Crankcase Bearing Service
2. Clean all bearing bores and inspect for excessive wear. 3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.79 © Copyright Polaris Inc.
Page 236: Oil Pickup Assembly Inspection
4. Thoroughly clean the valve. 5. Replace the o-ring and lubricate with clean engine oil. 6. Press the oil pressure valve into the crankcase until fully seated. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.80 © Copyright Polaris Inc.
Page 237: Engine Assembly - Lower End
6. With the help of an assistant, slowly tighten the nut until the crankshaft is completely seated into the crankcase bearings. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.81 © Copyright Polaris Inc.
Page 238 Be sure seal lip does not fold back when moving over the crankshaft flange. 11. Drive seal until flush with seal bore. 12. Turn PTO crankcase over and support with crankshaft upright. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.82 © Copyright Polaris Inc.
Page 239: Balance Shaft Installation / Timing
4. Tap crankcase evenly until fully seated with a soft sided hammer. 5. Install the new crankcase bolts finger tight in MAG side crankcase. 6. Tighten all bolts evenly until snug. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.83 © Copyright Polaris Inc.
Page 240 Sleeve adapter for a 2.375″ bore engine stand: PW-47054 10. Place engine onto the engine stand for top end engine assembly as outlined in this chapter. Engine Stand: PU-50624-A 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.84 © Copyright Polaris Inc.
Page 241: Starter One-Way Clutch Installation
One Way Clutch Retaining Bolts: 1st: 6 ft-lbs (8 Nm)2nd: 9 ft-lbs (12 Nm) Apply Loctite® 272™ 4. Rotate crankshaft so the flywheel key is facing upward. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.85 © Copyright Polaris Inc.
Page 242 The flywheel nut has standard rotation (right hand) threads. 12. Install starter idler gear and shaft 9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.86 © Copyright Polaris Inc.
Page 243: Stator / Stator Cover Installation
The flywheel contains powerful magnets. Use caution when installing the stator cover. DO NOT place fingers between cover and crankcase at any time during the installation process or injury could result. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.87 © Copyright Polaris Inc.
Page 244: 570Cc Dohc Engine
Torque the Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) ETC Fasteners 7 ft-lbs (10 N·m) Engine Mount (front) 40 ft-lbs (54 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.88 © Copyright Polaris Inc.
Page 245 75 in-lb (6 Nm) Water Pump Cover Bolts 9 ft-lbs (12 Nm) (Apply Loctite® 204™ to bolt threads) Water Pump Impeller Finger Tight *LH threads 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.89 © Copyright Polaris Inc.
Page 246: Torque Sequence
Step 6: Additional 180° Step 7: Additional 180° Torque the Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) 7 ft-lbs (10 Nm) M6 Bolts: 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.90 © Copyright Polaris Inc.
Page 247 Stator Cover Bolts Water Cover Bolts bolt threads) CAM CARRIER VALVE COVER 7 ft-lbs (10 N·m) 7 ft-lbs (10 N·m) Camshaft Carrier Bolts Valve Cover Bolts 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.91 © Copyright Polaris Inc.
Page 248: Crankcase - Timing / Sealing Path
ENGINE / COOLING SYSTEM CRANKCASE - TIMING / SEALING PATH TIMING MARKS CRANKCASE SEALING PATH 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.92 © Copyright Polaris Inc.
Page 249: Engine Disassembly / Inspection - Top End
7. Remove the spark plug . Stuff spark plug hole with a shop towel to prevent anything from falling into the combustion chamber (if further engine disassembly is required). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.93 © Copyright Polaris Inc.
Page 250: Camshaft Sprocket Inspection
6. Mark the intake and exhaust camshafts to ensure proper assembly. TORQUE Camshaft Sprocket Bolt: 14 ft-lbs (19 N·m) Replace camshaft sprocket bolt if loosened or removed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.94 © Copyright Polaris Inc.
Page 251: Camshaft Inspection
MEASUREMENT Camshaft Lobe Height: Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm) Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.95 © Copyright Polaris Inc.
Page 252: Cam Chain And Guide Service
TORQUE Lower Cam Chain Guide Fasteners: 9 ft-lbs (12 Nm) Upper Cam Chain Guide Fasteners: 7 ft-lbs (10 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.96 © Copyright Polaris Inc.
Page 253: Cylinder Head Disassembly
7. Repeat the previous steps to remove the remaining spring compressor adapter. valves. 8. Clean the combustion chamber and head gasket surface. Valve Spring Compressor Adapter PV-43513-A 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.97 © Copyright Polaris Inc.
Page 254: Cylinder Head Inspection
NOTICE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.98 © Copyright Polaris Inc.
Page 255: Combustion Chamber Cleaning
NOTICE gauge and a micrometer. Measure in two directions. Polaris Premium Carbon Clean can be used to help remove carbon deposits. Do not use a metal scraper, a coarse wire brush or abrasive cleaners to clean the cylinder head.
Page 256: Valve Seat Reconditioning
6. Insert valve into guide and tap valve lightly into place a few times. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.100 © Copyright Polaris Inc.
Page 257 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.101 © Copyright Polaris Inc.
Page 258: Cylinder Removal
(1/2" down from top, in the middle, and 1/2” up from bottom). 6. Remove and discard cylinder base gasket. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.102 © Copyright Polaris Inc.
Page 259: Piston Removal
4. Repeat steps for the second ring. 5. Remove oil control ring top rail first, then remove the bottom rail. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.103 © Copyright Polaris Inc.
Page 260: Piston / Rod Inspection
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm) Service Limit: 0.0042" (0.108 mm) Second Ring: Std.: 0.0007 - 0.0029" (.020 - 0.076 mm) Service Limit: 0.0035" (0.89 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.104 © Copyright Polaris Inc.
Page 261: Piston Ring Installed Gap
Std: 0.0098” - 0.0401" (0.25 - 1.02 mm) Limit: 0.0480" (1.22 mm) NOTICE Always check piston ring installed gap after re-boring a cylinder or when installing new rings. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.105 © Copyright Polaris Inc.
Page 262: Engine Assembly - Top End
Second Ring Gap Position Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.106 © Copyright Polaris Inc.
Page 263: Piston / Connecting Rod Assembly
(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. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.107 © Copyright Polaris Inc.
Page 264: Cylinder Installation
7. Remove support block and ring compressor. 8. Push cylinder downward until fully seated on base gasket. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.108 © Copyright Polaris Inc.
Page 265: Crankcase Identification
CRANKCASE IDENTIFICATION The first image displays (1) crankcase dowel for 2015 and earlier models. The second image displays (2) crankcase dowels for 2016 and later models. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.109 © Copyright Polaris Inc.
Page 266: Cylinder Head Installation - Black Bolts
4. Carefully set the cylinder head in place on alignment pins. NOTICE Install NEW cylinder head bolts. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.110 © Copyright Polaris Inc.
Page 267: Cylinder Head Installation - Silver Bolts
Step 7: Additional 180° Do not touch sealing surfaces of the new head gasket. Torque The Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.111 © Copyright Polaris Inc.
Page 268: Valve Sealing Test
3. Repeat for exhaust valves by pouring fluid into each exhaust port 3. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head. The camshaft lobes should face out.
Page 269 NOTICE If all valve clearance measurements are within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.113 © Copyright Polaris Inc.
Page 270 19. If valve clearance is not within specification, repeat this procedure. 20. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.114 © Copyright Polaris Inc.
Page 271: Valve Lash - Tappet Selection
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.115 © Copyright Polaris Inc.
Page 272: Camshaft Installation / Timing
3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Place the exhaust cam into the cylinder head and align the timing marks as shown below.
Page 273 Plate from the end of the camshafts. Cylinder Holding / Camshaft Timing Plate: Cylinder Holding / Camshaft Timing Plate: PU-50563 PU-50563 13. If needed, install the camshaft carrier and bolts. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.117 © Copyright Polaris Inc.
Page 274 18. Check the valve lash after tensioner installation and two engine revolutions. NOTICE Verify the valve lash after rotating the engine. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.118 © Copyright Polaris Inc.
Page 275: Camshaft Timing - Quick Reference
1/4” drive socket extension through flywheel is aligned with the CPS mounting hole. the crankcase and into the crankshaft locating hole 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.119 © Copyright Polaris Inc.
Page 276: Valve Cover Installation
5. Install the three valve cover shoulder bolts new isolators Around each T40 fastener. 6. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 N·m) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.120 © Copyright Polaris Inc.
Page 277: Engine Disassembly / Inspection - Lower End
2. Place flywheel on work bench. Grasp gear and rotate clockwise. It should turn smoothly without binding. 3. Rotate gear counterclockwise. The gear should immediately lock in position and not slip. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.121 © Copyright Polaris Inc.
Page 278 If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.122 © Copyright Polaris Inc.
Page 279: Stator Removal
4. Remove the two bolts that secure the stator wire routing bracket to the stator cover. 5. Remove the stator from the stator cover. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.123 © Copyright Polaris Inc.
Page 280: Oil Pump Removal
ENGINE / COOLING SYSTEM OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.124 © Copyright Polaris Inc.
Page 281 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.125 © Copyright Polaris Inc.
Page 282: Oil Pump Assembly
Do not use gasket sealer on Oil Pressure the pump cover mating surfaces. Minimum Specification (using Polaris PS-4 at operating temperature) 2. Align the gerotor according to the orientation dots. 10 PSI @ 1200 RPM (Minimum) 3. Place the drive pin...
Page 283: Crankcase Breather Service
Crankcase Breather Cover Bolts: 9 ft-lbs (12 Nm) 3. Remove and discard the fifteen flange bolts from magneto side crankcase evenly in a criss-cross pattern. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.127 © Copyright Polaris Inc.
Page 284: Balance Shaft Removal / Inspection
The inner race should be firm with minimal side to side movement and no detectable up and down (radial) movement. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.128 © Copyright Polaris Inc.
Page 285: Crankshaft Removal
0.8665 - 0.8670″ (22.010 - 22.023 mm) 4. Remove all special tools from the crankcase. Service Limit: 0.08682″ (22.053 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.129 © Copyright Polaris Inc.
Page 286: Pto Side Crankcase Bearing Service
2. If not already performed, remove the screws that Bearing Spacer secure the bearing retainer to the case. Retaining Ring 3. Remove the retaining ring. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.130 © Copyright Polaris Inc.
Page 287: Mag Side Crankcase Bearing Service
2. Clean all bearing bores and inspect for excessive wear. 3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.131 © Copyright Polaris Inc.
Page 288: Oil Pickup Assembly Inspection
4. Thoroughly clean the valve. 5. Replace the o-ring and lubricate with clean engine oil. 6. Press the oil pressure valve into the crankcase until fully seated. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.132 © Copyright Polaris Inc.
Page 289: Engine Assembly - Lower End
6. With the help of an assistant, slowly tighten the nut until the crankshaft is completely seated into the crankcase bearings. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.133 © Copyright Polaris Inc.
Page 290 Be sure seal lip does not fold back when moving over the crankshaft flange. 11. Drive seal until flush with seal bore. 12. Turn PTO crankcase over and support with crankshaft upright. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.134 © Copyright Polaris Inc.
Page 291: Balance Shaft Installation / Timing
4. Tap crankcase evenly until fully seated with a soft sided hammer. 5. Install the new crankcase bolts finger tight in MAG side crankcase. 6. Tighten all bolts evenly until snug. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.135 © Copyright Polaris Inc.
Page 292: Starter One-Way Clutch Installation
Sleeve adapter for a 2.375″ bore engine stand: Loctite® 272™ PW-47054 10. Place engine onto the engine stand for top end engine assembly as outlined in this chapter. Engine Stand: PU-50624-A 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.136 © Copyright Polaris Inc.
Page 293: Flywheel Installation
9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 4. Rotate crankshaft so the flywheel key is facing upward. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.137 © Copyright Polaris Inc.
Page 294: Stator / Stator Cover Installation
The flywheel contains powerful magnets. Use caution when installing the stator cover. DO NOT place fingers between cover and crankcase at any time during the installation process or injury could result. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.138 © Copyright Polaris Inc.
Page 295 ENGINE / COOLING SYSTEM 8. Install the stator cover screws and torque in sequence to specification. TORQUE Stator Mounting Bolts: 9 ft-lbs (12 Nm) Apply Loctite® 242™ 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.139 © Copyright Polaris Inc.
Page 296 ENGINE / COOLING SYSTEM NOTES 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 3.140 © Copyright Polaris Inc.
Page 298: Electronic Control Unit (Ecu)
No internal servicing or readjustment may be injector duration and ignition timing. performed. If a problem is encountered, and you determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.
Page 299: Ecu Replacement
ECU is transferred to the replacement ECU. 2. Remove seat and ECU cover 3. Remove the 4 screws retaining the ECU. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 300: Electronic Throttle Body (Etc)
No internal servicing or adjustments may be performed. If a problem is encountered, and you IMPORTANT determine the ETC to be faulty, contact the Polaris This procedure MUST be performed on the vehicle Service Department for specific handling instructions. Do...
Page 301: Temperature / Manifold Absolute Pressure (T-Map)
The T-MAP sensor is a non-serviceable item. If it is faulty, it must be replaced. 7. Install the retaining bolt and torque to specification. TORQUE T-MAP Retaining Bolt: 24 in-lbs (2.8 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 302: Pedal Position Sensor (Pps)
The Pedal Position Sensor is calibrated to the accelerator pedal. If the PPS is faulty, the accelerator pedal assembly must be replaced (see "PPS Replacement"). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 303: Crankshaft Position Sensor
Check both wires in this matter. engine will stop running. They should both read OL, indicating no shorts to ground. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 304 CPS. 6. Subtract the sensor length from the sensor mounting point to encoder flywheel measurement. Verify that the calculated air gap is within specification. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 305: Cps Replacement
9. Install a NEW or known good CPS (see the “CPS Replacement” procedure). 10. Fill and bleed the coolant system (see Engine / Cooling System chapter). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 306: Engine Coolant Temperature Sensor (Etc)
5. Place the sensor / tip of a thermometer in the water, ensure the display is legible as you will reference the thermometer throughout the test. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 4.10 © Copyright Polaris Inc.
Page 307: Ect Sensor Replacement
5. Torque the sensor to specification. TORQUE ETC Fasteners 7 ft-lbs (10 N·m) 6. Add the required amount of coolant and properly bleed the cooling system (see Engine chapter). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 4.11 © Copyright Polaris Inc.
Page 311: General Information
During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 312: Principal Components
• Temperature and Manifold Absolute Pressure Sensor utilizing the Digital Wrench® Diagnostic Software (T-MAP) (dealer only). • Electronic Throttle Control (ETC) • Wire Harness Assembly • Check Engine Light 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 313: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 314: Digital Wrench® - Diagnostic Connector
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 315: Digital Wrench® Diagnostic Softwarepu-47063-B
PU-47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench® diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470.
Page 316: Efi Component Locations
EFI COMPONENT LOCATIONS – LEFT VIEW REF. COMPONENT Instrument Cluster Ignition Switch Battery Starter Motor Solenoid Regulator / Rectifier Fuse / Relay Box Starter Motor Ignition Coil Engine Temperature Sensor (ECT) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 317: Efi Component Locations - Right View
EFI COMPONENT LOCATIONS - RIGHT VIEW REF. COMPONENT Fuel Pump / Sender High Tension Wire / Spark Plug Throttle Body (ETC) Speed Sensor (Mounted to Transmission) Stator (Magneto) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 318: Line / Hose Routing
• The fuel vent line is routed as shown below and terminates at the fuel vent connector that is inserted in the frame. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.10 © Copyright Polaris Inc.
Page 319: Vent Line Termination Fitting
If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.11 © Copyright Polaris Inc.
Page 321 Pre-Filter Box, Intake Plug, Drain Screw Torque to 8 ft-lbs (11 Nm) Seal, Engine, Inlet Screw Torque to 18 ft-lbs (27 Nm) Hose - Breather 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.13 © Copyright Polaris Inc.
Page 322: Air Box Removal / Installation
Tighten gear clamps to specification. TORQUE Air Intake Hose Gear Clamps: 24 in-lbs (2.7 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.14 © Copyright Polaris Inc.
Page 323: Fuel Tank / Pump / Sending Unit
7. Remove the fuel cap, push rivets and screws retaining the RH fender panel and remove panel from the vehicle. See Floor / Rear Fenders page 11.9. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.15 © Copyright Polaris Inc.
Page 324: Fuel Tank Installation
Check for leaks. 6. Reinstall the seat assembly. • Fuel Level Sender (+) • Fuel Level Sender (-) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.16 © Copyright Polaris Inc.
Page 325: Fuel Pump Test
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.17 © Copyright Polaris Inc.
Page 326: Fuel Pump Replacement
“3” and “4”' at the white fuel pump connector to check for continuity within the fuel pump. NOTICE If there was no continuity between the pump terminals, replace the fuel pump assembly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.18 © Copyright Polaris Inc.
Page 327 PFA nut. NOTICE Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 5. Disconnect the fuel pump electrical harness 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.19 © Copyright Polaris Inc.
Page 328 Use care not to bend float arm 19. Verify alignment of fuel pump and tank orientation when unpacking. Do not lift or carry fuel pump marks. assembly by the float arm. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.20 © Copyright Polaris Inc.
Page 329 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 and check for leaks. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.21 © Copyright Polaris Inc.
Page 330: Ignition Coil Overview
Coil Pack – and 6.6kΩ +/- 10% Spark Plug Wire Terminal Spark Plug Wire Wire Connector 7.0kΩ +/- 10% Terminal and Spark Boot Terminal COIL PACK CONNECTIONS 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.22 © Copyright Polaris Inc.
Page 331: Fuel Injector
“injection duration” or “pulse width”. It may vary in length depending on the speed and load requirements of the engine. Fuel Injector Resistance Specification: 11.4 - 12.6 Ω 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.23 © Copyright Polaris Inc.
Page 332: 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. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.24 © Copyright Polaris Inc.
Page 333: Fuel Injector Troubleshooting
Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.25 © Copyright Polaris Inc.
Page 334: Efi Diagnosis
• Always unplug ECU from the wire harness before inspection of the ECU connector for contamination or performing any welding on the unit. damage). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.26 © Copyright Polaris Inc.
Page 335: Trouble Code Display (Dtc)
MODE button or turn the ignition key OFF once the 2. Press and hold the MODE button to enter the codes are recorded. diagnostics code menu. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.27 © Copyright Polaris Inc.
Page 336 Voltage Too Low P0112 MAP) Abnormal rate of Change P0114 Valid But Above Normal P0127 (least severe) Engine Temperature Sensor Engine Overheat Shutdown P1217 (ECT) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.28 © Copyright Polaris Inc.
Page 337 Driver Circuit Grounded P1262 Driver Circuit Open P0261 P0265 Driver Circuit Short to B+ Injector 2 (PTO) Driver Circuit Grounded P1265 Driver Circuit Open P0264 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.29 © Copyright Polaris Inc.
Page 338 ECU Output Supply Voltage 3 3599 Valid But Above Normal P17AD (least severe) Valid But Below Normal P17AF (least severe) Cylinder Not Identified Misfire Detected 65590 P0314 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.30 © Copyright Polaris Inc.
Page 339 EPS Power Save Condition 520231 C1071 Power Save/Timeout Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520268 P1519 M17; IAC Stepper Pin 3 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.31 © Copyright Polaris Inc.
Page 340 Condition Exists 520282 P152B Repeated Adaptation Failed Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.32 © Copyright Polaris Inc.
Page 341 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.33 © Copyright Polaris Inc.
Page 342: Fuel System Troubleshooting
• Injector failure • Throttle stop screw tampering • Failed sensor or disconnected wiring • Failed sensor or disconnected wiring • Throttle stop screw tampering 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 5.34 © Copyright Polaris Inc.
Page 344: General Information
2871025 Replacement Tool Kit Standard Clutch Alignment Tool 2870654 PART SPECIAL SUPPLIES NUM- Loctite™ 680 8560054 RTV Silicone Sealer Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 345: Pvt System Overview
DRIVE SHIFT All PVT maintenance or repairs should be performed by ALTITUDE WEIGHT SPRING a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and 0-1800 25–52G Black understands the procedures outlined in this manual. (0-6000)
Page 346: Drive Clutch Operation
Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 347: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift transmission to Low during loading of the vehicle to Clutch malfunction.
Page 348: Pvt System Service
PVT Exhaust Duct Drain Plug Clamp Torque to 10 ft-lbs (14 Nm) Screw Torque to 60 in-lbs (7 Nm) Bolt Torque to 24 in-lbs (3 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 349: Pvt Disassembly
Make note of cable and hose routings 8. Remove the driven clutch retaining bolt and driven for assembly. clutch assembly. 9. Install the Drive Clutch Holder. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 350: Pvt Assembly
Driven Clutch Retaining Bolt: 38 ft-lbs (51 Nm) 10. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 351: Drive Belt
PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 5. Remove the outer sheave. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 352: Belt Installation
5-7 times to properly seat the belt in the driven clutch. 5. Install the outer clutch cover and (8) screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws: 50 in-lbs (5 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.10 © Copyright Polaris Inc.
Page 353: Clutch Alignment / Offset / 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. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.11 © Copyright Polaris Inc.
Page 354: Adjustment
Tool as shown in the inspection process. reassemble the PVT system as outlined in this Clutch Center Distance Tool chapter. PU-50658 TORQUE Rear Trans. Isolator Bolts: 40 ft-lbs (54 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.12 © Copyright Polaris Inc.
Page 355: Drive Clutch Service
Shift Weight 100 in-lbs (12 Nm) Spring 25 in-lbs (2.8 Nm) Limiter Spacer Button Spider Washer 210 ft-lbs (284 Nm) Sheave Bushing Roller Bushing Spacer 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.13 © Copyright Polaris Inc.
Page 356: Clutch Disassembly
. 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. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.14 © Copyright Polaris Inc.
Page 357: Shift Weight Inspection
NOTICE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.15 © Copyright Polaris Inc.
Page 358: Spider Removal
Roller Pin Tool to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation. Roller Pin Tool: PN 2870910 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.16 © Copyright Polaris Inc.
Page 359: Button To Tower Clearance Inspection
1. Remove the moveable sheave spacer sleeve Inspect for damage and wear. Button to Tower Clearance: .000-.010” 2. Inspect sheave surfaces. Replace the entire clutch if worn, damaged or cracked. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.17 © Copyright Polaris Inc.
Page 360 Measure the thickness and compare to specification. Replace if worn or damaged. MEASUREMENT PTFE Washer Thickness Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.18 © Copyright Polaris Inc.
Page 361: Bushing Service
Main Puller Adapter 5010- Adapter Reducer 5020- Number Two Puller Adapter #10 1 4. Install puller adapter (Item 10 from kit). Puller Adapter: PN 2871226 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.19 © Copyright Polaris Inc.
Page 362 29. Remove nut from puller rod and set aside. 30. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 31. Apply Loctite™ 609 evenly to bushing bore in cover. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.20 © Copyright Polaris Inc.
Page 363 35. Turn clutch cover counterclockwise on puller rod until bushing is seated. 36. Remove nut from puller rod. Take installation tool and clutch cover off rod. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.21 © Copyright Polaris Inc.
Page 364: Clutch Assembly
Drive Clutch Cover Screw: clearance. be sure to reinstall the original quantity and 8 ft-lbs (10 Nm) thickness of washers / spacers beneath the spider during assembly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.22 © Copyright Polaris Inc.
Page 365: Driven Clutch Service
Roller, Clutch Plate, Retainer Screw Washer, Thrust 9 ft-lbs (12 Nm) Ring, Retaining E-Ring External Label, Clutch Boss Subassembly, Moveable Boss Washer, Thrust Spring, Compression 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.23 © Copyright Polaris Inc.
Page 366: Clutch Disassembly / Inspection
7. Turn the compression tool handle counter-clockwise to relieve spring pressure and allow the spring cup and retaining ring to move out from the moveable sheave. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.24 © Copyright Polaris Inc.
Page 367: Clutch Assembly
Torque the retaining ring bolts to specification. TORQUE Clutch Spring Retaining Ring Bolts: 12 ft-lbs (16 Nm) 5. Install driven clutch assembly and drive belt. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.25 © Copyright Polaris Inc.
Page 368: Pvt System Troubleshooting
Belt burnt, thin -Dragging brake -Vehicle operated with park brake on. Inspect spots brake system. -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.26 © Copyright Polaris Inc.
Page 369 -Replace belt. Refer to belt burnt troubleshooting Engagement -Thin spots on belt, worn belt and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 6.27 © Copyright Polaris Inc.
Page 372: General Information
Rear Driveshaft Seal Guide 2871702 Kit) Bearing Seal Driver (50 mm) 2871282 PU-50566 Transmission Nut Socket PU-50658 Clutch Center Distance Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 373: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Page 374: Transmission Gears
TRANSMISSION TRANSMISSION GEARS Refer to the Polaris Electronic Parts Catalog for gear tooth counts and part numbers. To access the Polaris Electronic Parts Catalog, visit: http://parts.polarisind.com/browse/browse.asp LUBRICATION FLUID CAPACITY Recommended Transmission Lubricant: AGL (PN 2878068) (Quart) Capacity: 41 oz. (1200 ml) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual ©...
Page 375: Transmission Mounting And Torque Values
TRANSMISSION MOUNTING AND TORQUE VALUES REF. DESCRIPTION NOTES Bolt Torque to 55 ft-lbs (75 Nm) Bolt Torque to 40 ft-lbs (54 Nm) Bolt Torque to 25 ft-lbs (34 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 377 Gear, 48T 102. Bearing, Needle Subassembly, Shift Fork Screw, Cap M8 - 1.25 x 25 104. Bearing, Ball Sprocket, 48T Bracket, Wire Harness 105. Bearing, Ball 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 378: Shift Lever
4. Remove the retaining ring and slide the shift lever off the mounting bracket and out from the frame. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 379: Shift Cable
6. Perform any cable adjustments needed at this time. 5. Remove the shift cable from the retainers. Refer toAdjustment page 7.10 for the cable adjustment procedure. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 380: Adjustment
Replace if worn or damaged. 3. If adjustment is required, loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.10 © Copyright Polaris Inc.
Page 381: Transmission Service
Be sure to use the correct Drive Clutch Puller (PA- 48595) to prevent damage to crankshaft. 12. Remove driveshaft from both sides (see Chapter 7). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.11 © Copyright Polaris Inc.
Page 382 19. Using an overhead lift or an assistant, lift the transmission up and out of the chassis. 16. Remove the wire ties retaining the main harness harness to transmission and mounts. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.12 © Copyright Polaris Inc.
Page 383: Transmission Installation
5. In sequence, torque the eight engine coupler bracket fasteners at this time. fasteners to specification. TORQUE Engine to Trans Coupler Fasteners In Sequence:55 ft-lb (75 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.13 © Copyright Polaris Inc.
Page 384 21. Reconnect the TPS and IAC harnesses. 12. Lubricate the transmission splines and mid prop 22. Connect the (-) negative battery cable and reinstall shaft joint splines with Polaris All Purpose Grease. the seat base. Install the prop shaft onto the transmission output 23.
Page 385 TRANSMISSION 24. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris AGL (see Chapter 2 “Transmission Lubrication”). FLUID CAPACITY Recommended Transmission Lubricant: AGL (PN 2878068) (Quart) Capacity : 41 oz. (1200 ml) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.15...
Page 386: Transmission Internals Service
This locks the rear differential as a solid rear axle, increasing traction. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.16 © Copyright Polaris Inc.
Page 387: Transmission Disassembly
(G). NOTICE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.17 © Copyright Polaris Inc.
Page 389 53T gear and needle bearing off the housing. reverse shaft (see Figure 8-1). 22. Remove the retaining ring and engagement dog from the reverse shaft (see Figure 8-1). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.19 © Copyright Polaris Inc.
Page 390 (X) from the end of the shift rail on either side. CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.20 © Copyright Polaris Inc.
Page 391 31. Use an arbor press to remove the snorkel tube from the snorkel shaft. 32. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.21 © Copyright Polaris Inc.
Page 392: Planetary Differential Disassembly
If bushing replacement is required, proceed to Planetary Differential Bushing Replacement”. 2. Remove the (6) screws retaining the differential cover and remove the cover. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.22 © Copyright Polaris Inc.
Page 393: Planetary Differential Bushing Replacement
8. Press the old bushing out of the differential cover. 9. Thoroughly clean the bore of the differential cover and check for any unwanted burs. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.23 © Copyright Polaris Inc.
Page 394 14. Press the new bushing into the side gear until it bottoms out. 11. Install the bushing to the specified depth as shown. Female Side Gear Bushing Replacement 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.24 © Copyright Polaris Inc.
Page 395: Planetary Differential Assembly
4. Apply Loctite® 2760™ to cover screws. 5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification. TORQUE Differential Cover Screws: 22 ft-lbs (30 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.25 © Copyright Polaris Inc.
Page 397: Snorkel Gear Backlash Procedure
Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.27 © Copyright Polaris Inc.
Page 398 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.28 © Copyright Polaris Inc.
Page 399 Inspect case half mating surfaces for damage. 18. Install shift fork (S) and torsion spring into transmission housing as an assembly. Load spring as shown in image below 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.29 © Copyright Polaris Inc.
Page 400 (see specification. illustrations). TORQUE Shift Fork Screws: 10 ft-lbs (14 Nm) 20. Slide engagement dog (U) onto retaining pins of shift fork. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.30 © Copyright Polaris Inc.
Page 401 Be sure the shift forks are engaged into the engagement dogs. NOTICE Shift fork pins should be offset towards the input shaft as shown above. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.31 © Copyright Polaris Inc.
Page 402 (.070" or 1.8 mm from outer face of bore). 28. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to the left hand transmission mating surface. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.32 © Copyright Polaris Inc.
Page 403 39. Install the sector cover and align the transmission case dowel with the alignment hole. Install and torque the bolts to specification. TORQUE Sector Cover Bolts: 11 ft-lbs (15 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.33 © Copyright Polaris Inc.
Page 404 Install the nut and torque to specification. TORQUE Bell Crank Nut: 15 ft-lbs (20 Nm) 42. Refer to “Transmission Installation” to complete the repair. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.34 © Copyright Polaris Inc.
Page 405: Troubleshooting
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 7.35 © Copyright Polaris Inc.
Page 409: General Information
GENERAL INFORMATION SPECIAL TOOLS PART TOOL DESCRIPTION NUMBER 2872608 Roll Pin Removal Tool PU-48951 CV Boot Clamp Tool or 8700226 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 410: Front Hub / Bearing
2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown in Step 3. 5. Remove hub cap, cotter pin , front spindle nut and washer. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 411: Hub Installation
NOTICE different directions. Use care to not allow any of the Loctite compound to 8. Install hub cap. get in the bearing. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 412 11. Install wheel, washers, wheel nuts, and tighten evenly in a cross pattern to specified torque. Refer to “Torque Specifications”. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 413: Front Hub/Wheel Exploded View
Steel Wheel Nuts: 36 ft-lbs (49 Nm) Aluminum Wheel Nuts: 30 ft-lbs + 90º (41 Nm + 90º) Washer Tire Front Hub Stud Brake Disc Bolt 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 414: Front Drive Shaft
Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line. 5. Remove and discard the cotter pin, then remove the front hub castle nut. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 415: Front Drive Shaft Installation
Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer. 2. Install drive shaft into strut housing. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 416: Front Gearcase
Use a NEW spring pin in the front propshaft. 3. Install the (4) bolts that secure the front gearcase to the frame and torque to specification. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.10 © Copyright Polaris Inc.
Page 417 Front Housing Capacity 6.7–7.6 fl. oz. (200–225 ml) TORQUE Front Gearcase Mounting Bolts: 33 ft-lbs (56 Nm) 5. Connect the AWD wire harness (Item 4). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.11 © Copyright Polaris Inc.
Page 418: Front Gearcase (Non-Adc)
10 ft-lbs (14 N·m) Fill / Check Plug Roller Cage 10 ft-lbs (14 N·m) Roller Pinion Gear Spring Retainer Snap Ring O-ring Cover Plate Screws 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.12 © Copyright Polaris Inc.
Page 419: All Wheel Drive Operation
“over-running” condition. The vehicle is now back to rear wheel drive until the next loss of rear wheel traction occurs. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.13 © Copyright Polaris Inc.
Page 420: Awd Diagnosis
8. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.14 © Copyright Polaris Inc.
Page 421: Front Gearcase Disassembly / Inspection
Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate . Refer to AWD Diagnosis page 8.14 for detailed inspection process. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.15 © Copyright Polaris Inc.
Page 422 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. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.16 © Copyright Polaris Inc.
Page 423 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.17 © Copyright Polaris Inc.
Page 425 11. Install a new O-ring on the cover plate assembly. NOTICE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.19 © Copyright Polaris Inc.
Page 426 13. Install the output cover assembly onto the gearcase housing. Install the seven cover plate screws and torque to specification. TORQUE Cover Plate Screws: 9 ft-lbs (12 N·m) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.20 © Copyright Polaris Inc.
Page 428 11 ft-lbs (15 Nm) PLUG, OIL FILL 8-10 ft-lbs (11-14 Nm) RING, RETAINING, INTERNAL KIT, SPRING RING, RETAINING, EXTERNAL ASM., GEAR HOUSING AND PINION GEAR 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.22 © Copyright Polaris Inc.
Page 429: Operation, Front Gearcase (4Wdc)
During engine braking the front drive can also speed differentiate across the axle when turning. Also, if the outer wheel slips or loses traction the inner wheel will then begin to slow the vehicle as well. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.23 © Copyright Polaris Inc.
Page 430: Disassembly / Inspection, Front Gearcase (Adc)
5. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.24 © Copyright Polaris Inc.
Page 431 11. Inspect the bearing and contact surfaces of the output gear hub for signs of wear or damage. Replace component if found to be worn or damaged. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.25 © Copyright Polaris Inc.
Page 432 16. Drill a hole in the input shaft seal and remove the Inspect the H-springs, but do not remove them seal using a pry bar or seal puller. from the roll cage. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.26 © Copyright Polaris Inc.
Page 433 O-ring prior to reassembly. 19. Inspect the input shaft bushing for wear. 20. Thoroughly clean the gearcase components before beginning reassembly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.27 © Copyright Polaris Inc.
Page 434: Reassembly, Front Gearcase (Adc)
5. Press the pinion shaft seal into the gearcase, until the seal is flush. 9. Install the pins , roll cage , and ring gear assembly into the gearcase housing. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.28 © Copyright Polaris Inc.
Page 435 AWD Cover Screws: 8 ft-lbs (11 Nm) 16. Fill the gearcase with fluid. FLUID CAPACITY Polaris Demand Drive Fluid 8.97 oz. (265 ml) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.29 © Copyright Polaris Inc.
Page 436 FINAL DRIVE 17. Install the drain plug. Torque to specification. TORQUE Fill Plug: 8-10 ft-lbs (11-14 Nm) Drain Plug: 11 ft-lbs (15 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.30 © Copyright Polaris Inc.
Page 437: Troubleshooting, Front Gearcase (Adc)
If it locks vehicle. to the drive train in only one direction, ADC is not indexing cage in both directions 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.31 © Copyright Polaris Inc.
Page 438 If pole faces are severely problem has been fixed. If worn and damaged, not, continue onto replace output cover. additional problems listed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.32 © Copyright Polaris Inc.
Page 439 If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.33 © Copyright Polaris Inc.
Page 440 5. Inspect the rollers for nicks, scratches, and flat spots. Also inspect the roll cage for cracks and ensure the rollers are able to slide up and down and in and out freely within the roll cage sliding surfaces. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.34 © Copyright Polaris Inc.
Page 441: Rear Bearing Carrier
6. Remove the upper and lower A-arm fasteners from the bearing carrier 7. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.35 © Copyright Polaris Inc.
Page 442: Disassembly
4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. 5. Replace the bearing carrier bushings if worn or damaged. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.36 © Copyright Polaris Inc.
Page 443: Installation
Rear Hub Castle Nut: 110 ft-lbs (150 Nm) NOTICE The lower shock bolt may need to be removed to allow the upper A-arm to move freely. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.37 © Copyright Polaris Inc.
Page 444: Rear Drive Shaft
3. Install the drive shaft into the rear bearing carrier. 4. Perform “REAR BEARING CARRIER Installation” procedure to properly reassemble the vehicle. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.38 © Copyright Polaris Inc.
Page 445: Drive Shaft Service
CV joints and CV joint boots. OUTER CV JOINT / BOOT REPLACEMENT 1. Using side cutters, cut away and discard the boot clamps. NOTICE Tap on inner race only! 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.39 © Copyright Polaris Inc.
Page 446 8. 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. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.40 © Copyright Polaris Inc.
Page 447 19. Install and tighten the large clamp using the Axle Boot Clamp Tool (PU-48951 or 8700226). Axle Boot Clamp Tool PU-48951 or 8700226 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.41 © Copyright Polaris Inc.
Page 448: Inner Plunging Joint / Boot Replacement
3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.42 © Copyright Polaris Inc.
Page 449 19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.43 © Copyright Polaris Inc.
Page 450: Drive Shaft Assembly View
22. Position the boot lip in its groove. Install and tighten the large clamp using the Axle Boot Clamp Tool. Axle Boot Clamp Tool PU-48951 or 8700226 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.44 © Copyright Polaris Inc.
Page 451: Propshaft U-Joint Service
(Item 1). shaft. 8. Use a NEW roll pin upon installation. FRONT PROP SHAFT COMPONENTS DESCRIPTION Grease Zerk Rear Yoke U-Joint Front Yoke 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.45 © Copyright Polaris Inc.
Page 452: Support Bearing Replacement (Crew)
11. Torque bearing support fasteners to specification. TORQUE Prop Shaft Bearing Support Fasteners: 36 ft-lbs (49 Nm) 12. If front prop shaft was removed, use a NEW roll pin upon installation. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.46 © Copyright Polaris Inc.
Page 453: Disassembly
Prop Shaft Support Bearing Fasteners: 36 ft-lbs (49 Nm) 9. Grease the prop shaft yoke(s). 10. Reinstall the large storage container and front seat base. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.47 © Copyright Polaris Inc.
Page 454: Assembly
If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 8.48 © Copyright Polaris Inc.
Page 456: General Information
Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ Included in this machine’s tool kit, the multi-function pliers is designed to remove the plastic push rivets used to fasten body components. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 457: Shock Analysis
(weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 459 40 ft-lbs (54 Nm) SCREW BOLT 16 ft-lbs (22 Nm) 40 ft-lbs (54 Nm) 36 ft-lbs (49 Nm) 65 ft-lbs (88 Nm) BUSHING, STEERING PIN, COTTER LOCTITE® 271 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 461 SCREW BOLT SCREW BOLT 15 ft-lbs (21 Nm) 40 ft-lbs (54 Nm) 49 ft-lbs (66 Nm) 65 ft-lbs (88 Nm) BUSHING, STEERING PIN, COTTER LOCTITE 271 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 462: Steering Wheel Removal (Non-Eps Models)
9. Install the steering wheel and hand tighten the nut. 4. Note the order and location of the spacers between the pivot tube and steering shaft. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 463: Steering Shaft / Steering Rack Removal (Non-Eps Models)
6. Remove the five fasteners retaining the steering rack to the frame. 2. Remove upper and lower dash panels. 3. Remove the steering wheel tilt assembly fasteners. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual © Copyright Polaris Inc.
Page 464: Steering Wheel / Upper Steering Shaft Removal (Eps)
10. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.10 © Copyright Polaris Inc.
Page 465: Power Steering Unit Removal
WARNING Electronic Power Steering (EPS) units are not interchangeable between ATV and RANGER product lines. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.11 © Copyright Polaris Inc.
Page 466 11. Reinstall the upper and lower dash panels making sure to reconnect the instrument cluster, both 12V outlets and all the switches. 12. Turn the key switch on and test EPS operation. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.12 © Copyright Polaris Inc.
Page 467: Steering Rack Removal / Installation (Eps)
IMPORTANT Pay close attention to the location of the washers to ensure they are installed in the correct location during assembly. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.13 © Copyright Polaris Inc.
Page 468 40 ft-lbs (54 N·m) 6. Install cotter pins in both tie rod end fasteners. 7. Verify that steering alignment is within specifications. If not, perform steering alignment. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.14 © Copyright Polaris Inc.
Page 469: Front Strut
15 ft-lbs ( 20 Nm) Wheel Bearing Lower Pivot Ball Spring Retainer Hubstrut Spring Cam Adjuster Bumper Washer Spacer Front Strut Bolts 20 ft-lbs (27 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.15 © Copyright Polaris Inc.
Page 470: Front Strut Cartridge Replacement
Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. 3. Remove wheel nuts and wheels. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.16 © Copyright Polaris Inc.
Page 471 10. Install A-arm on ball joint and torque castle nut to specification. TORQUE Ball Joint Nut: 30 ft-lbs (41 Nm) 11. Install new cotter pin with open ends toward rear of machine. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.17 © Copyright Polaris Inc.
Page 472: Rear A-Arms
7. Insert new A-arm bushings and pivot tubes into the the bearing carrier. new A-arm. Lower A-arm Removal 8. Remove the fastener attaching the lower A-arm to the bearing carrier. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.18 © Copyright Polaris Inc.
Page 473: Installation
30 ft-lbs + 90º (41 Nm + 90º) Bearing Carrier Fasteners: 40 ft-lbs (54 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.19 © Copyright Polaris Inc.
Page 474: Assembly View
STEERING / SUSPENSION ASSEMBLY VIEW DESCRIPTION DESCRIPTION Bushing Lower A-Arm Upper A-Arm Bearing Carrier Grease Zerk Nuts Wheel Bearing 40 ft-lbs (54 Nm) Snap Ring 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.20 © Copyright Polaris Inc.
Page 475: Rear Stabalizer Bar / Linkage
8. Torque the stabilizer retaining bolts and upper rubber bushing nuts to specification. 9. If the stabilizer linkage was removed, torque the lower shock retaining bolt to specification. ASSEMBLY VIEW 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.21 © Copyright Polaris Inc.
Page 476: Assembly View
3. Reverse the procedure to reinstall the shock. Torque NEW fasteners to specification. TORQUE Shock Fasteners: 40 ft-lbs (54 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 9.22 © Copyright Polaris Inc.
Page 479: General Information
Rear Brake Disc Runout 0.010" (.254 mm) SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION Mity Vac™ Pressure Test 2870975 Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.3 © Copyright Polaris Inc.
Page 480: Brake System 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 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.4 © Copyright Polaris Inc.
Page 481: Hydraulic Brake System Operation
Never overfill the reservoir! Do not fill the reservoir beyond the 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.
Page 482: Brake System Assembly Views
Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm) Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm) Screw Torque to 12–15 ft-lbs (16–20 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.6 © Copyright Polaris Inc.
Page 483: Ranger Crew
Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm) Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm) Screw Torque to 12–15 ft-lbs (16–20 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.7 © Copyright Polaris Inc.
Page 484: Master Cylinder
Torque to 15 ft-lbs (20 Nm) CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.8 © Copyright Polaris Inc.
Page 485: Brake Pedal
PEDAL INSTALLATION 1. Reverse steps for foot brake installation. 2. Tighten pivot bolt sufficiently. Refer to the general torque specifications in Chapter 1. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.9 © Copyright Polaris Inc.
Page 486: Brake Service Procedures
Master Cylinder Fluid Level Between the MIN and MAX line CAUTION Maintain at least 1/2"(1.27 cm) of brake fluid in the Polaris DOT 4 Brake Fluid reservoir to prevent air from entering the master cylinder. (P/N 2872189) 13. Tighten bleeder screw and remove bleeder hose.
Page 487: Brake Burnishing Procedure
Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times to maximize pad service life. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.11 © Copyright Polaris Inc.
Page 488: Front Brake Pads
Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.12 © Copyright Polaris Inc.
Page 489: Pad Assembly / Installation- Ranger
4. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2"(12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.13 © Copyright Polaris Inc.
Page 490: Crew
NOTICE When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.14 © Copyright Polaris Inc.
Page 491: Pad Inspection
7. Install wheel and torque wheel nuts to specification liquid soaked do not use the pads. (see “Chapter 2 - Maintenance”). Use only new, clean pads. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.15 © Copyright Polaris Inc.
Page 492: Front Caliper
NOTES Adjuster Screw Finger Tighten Bleeder Screw 30–60 in-lbs (3.4–6.8 Nm) Caliper Body Square O-Rings Apply Polaris Dot 4 Brake Fluid Piston Apply Polaris Dot 4 Brake Fluid Dust Boots Caliper Bracket Caliper Pins Apply Brake Disc Caliper Lube Pads 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.16...
Page 493: Front Caliper Removal- Ranger
4. Remove brake caliper mounting bolts and caliper. 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTICE Be sure to clean seal grooves in caliper body. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.17 © Copyright Polaris Inc.
Page 494: Front Caliper Inspection- Ranger
Replace if damage is evident or if worn beyond brakes may drag. service limit. 2. Coat the piston with clean Polaris DOT 4 Brake Fluid (P/N 2872189). Install piston with a twisting MEASUREMENT motion while pushing inward.
Page 495: Front Caliper Installation
2. Install brake line and tighten securely with a flare nut wrench. 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.19 © Copyright Polaris Inc.
Page 496: Crew
Bleeder Screw 47 in-lbs (5.3 Nm) Socket Set Screw Caliper Assembly Dust Boots Square O-Rings Apply Polaris DOT 4 Brake Fluid Piston Caliper Mount Caliper Pins Apply Disc Brake Caliper Lube Brake Pads 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.20...
Page 497: Front Caliper Removal- Crew
5. Loosen brake pad adjustment set screw (Item 2) 2-3 turns to allow brake pad removal after the caliper is removed. 2. Remove both brake pads from the caliper. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.21 © Copyright Polaris Inc.
Page 498: Front Caliper Inspection - Crew
O-rings from the caliper. O-rings should be replaced during caliper service. MEASUREMENT Caliper Piston Bore I.D.: Std: 1.373” (34.87 mm) Service Limit: 1.375” (34.93 mm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.22 © Copyright Polaris Inc.
Page 499: Front Caliper Assembly - Crew
TORQUE Front Caliper Mount Bolt: 46 ft-lbs (62 Nm) 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 500 5. Install wheel and torque wheel nuts to specification (see Chapter 2). NOTICE If new brake pads are installed, brake burnishing is required. SeeBrake Burnishing Procedure page 10.11. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.24 © Copyright Polaris Inc.
Page 501: Front Brake Disc
Brake Disc Thickness: New .150-.165” (3.81 - 4.19 mm) Service Limit .140”/3.56 mm MEASUREMENT Brake Disc Thickness Variance: Service Limit .002” (.051 mm) difference between measurements 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.25 © Copyright Polaris Inc.
Page 502: Disc Removal / Replacement
CAUTION When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.26 © Copyright Polaris Inc.
Page 503: Brake Pad Inspection
6. Remove the brake pads. MEASUREMENT Brake Pad .030″ (0.762 mm) 3. If any one pad is less than the service limit then all pads should be replaced. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.27 © Copyright Polaris Inc.
Page 504: Rear Pad Installation
5. Fill master cylinder to Max level. 6. Burnish brakes as outlined in this chapter. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.28 © Copyright Polaris Inc.
Page 505: Rear Calipers
NOTES Socket Set Screw Bleeder Screw 47 in-lbs (5.3 Nm) Caliper Assembly Dust Boots Square O-Rings Apply Polaris DOT 4 Brake Fluid Piston Apply Polaris DOT 4 Brake Fluid Caliper Pins Apply Disc Brake Caliper Lube Caliper Mount Brake Pads 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.29...
Page 506: Caliper Removal
NOTICE Be sure to clean seal grooves in caliper body. 4. Clean disc, caliper body, and pistons with brake cleaner or alcohol. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.30 © Copyright Polaris Inc.
Page 507: Rear Caliper Inspection
Std: 1.500” (38.10 mm) Service Limit: 1.498” (38.05 mm) 3. Inspect the brake disc and pads as outlined for brake pad replacement in this chapter. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.31 © Copyright Polaris Inc.
Page 508: Rear Caliper Installation
If the brake drags, re-check assembly and installation. NOTICE If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE PADS - Brake Burnishing Procedure”). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.32 © Copyright Polaris Inc.
Page 509: Rear Brake Disc
Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.33 © Copyright Polaris Inc.
Page 510: Disc Removal / Replacement
Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.34 © Copyright Polaris Inc.
Page 511: 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 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.35 © Copyright Polaris Inc.
Page 512: Brake Warning System Inspection (Intl Models)
If a circuit concern is found, repair or replace as necessary. 9. If the concern is still present after previous testing has passed, suspect there is a fault within the ECU. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 10.36 © Copyright Polaris Inc.
Page 514: General Information
Wheel Lug Nuts 36 ft-lbs (49 Nm) NOTICE Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.2 © Copyright Polaris Inc.
Page 515: Chassis / Body Assembly Views
Dash Support Left Floor Support Right Floor Support Skid Plate Bumper Screen Screws Torque to 22 ft-lbs (30 Nm) Screws Torque to 8 ft-lbs (11 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.3 © Copyright Polaris Inc.
Page 516: Crew Frame Assembly View
Front Skid Plate Rear Skid Plate Seat Base Frame Bumper Screen Screws Torque to 22 ft-lbs Screws Torque to 8 ft-lbs Screws Torque to 40 ft-lbs 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.4 © Copyright Polaris Inc.
Page 517 Used with part on 2017–2018 cab frames Net Rod Mounts (Not Shown) Screw (Used to fasten Net Rod Mounts) Torque to 8 ft-lbs (11 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.5 © Copyright Polaris Inc.
Page 518 2017 cab frames Nets - Door Net Rod Mounts (Not Shown) Screw (Used to fasten Net Rod Mounts) Torque to 8 ft-lbs (11 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.6 © Copyright Polaris Inc.
Page 519: Dash Instruments / Controls
BODY / FRAME DASH INSTRUMENTS / CONTROLS REF. DESCRIPTION NOTES Instrument Cluster Bezel Key Switch 12V Accessory Plug Turf Switch Dash Panel 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.7 © Copyright Polaris Inc.
Page 520: Hood / Dash / Front Fascia
HOOD / DASH / FRONT FASCIA REF. DESCRIPTION NOTES Hood Front Fascia Dash Panel Glove Box Lid Hood Strap Hood Hinge Pins Push Rivet Hood Latch 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.8 © Copyright Polaris Inc.
Page 521: Floor / Rear Fenders
BODY / FRAME FLOOR / REAR FENDERS REF. DESCRIPTION NOTES Front Floor Main Floor Floor Cover Cup Holder Push Rivet Screws Torque to 5 ft-lbs (7 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.9 © Copyright Polaris Inc.
Page 522: Seat Mounting / Seat Belts
Seat Back Seat Base LH Seat Belt Assm RH Seat Belt Assm Seat Base Frame Screw 24 in-lbs (3 Nm) Bolt 40 ft-lbs (54 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.10 © Copyright Polaris Inc.
Page 523: Crew Floor / Rear Fenders
CREW FLOOR / REAR FENDERS REF. DESCRIPTION NOTES Front Floor Main Floor Front Seat Panel Rear Main Floor Storage Box Front Inner Fender Cup Holder Floor Cover Push Rivet 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.11 © Copyright Polaris Inc.
Page 524: Crew Seat Mounting / Seat Belts
REF. DESCRIPTION NOTES Front Seat Base Frame Rear Seat Base Frame Seat Base Seat Back Screw 24 in-lbs (3 Nm) Bolt 40 ft-lbs (54 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.12 © Copyright Polaris Inc.
Page 525: Rear Cargo Box
BODY / FRAME REAR CARGO BOX CARGO BOX - TAILGATE / BOX SUPPORT 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.13 © Copyright Polaris Inc.
Page 526 Box Tilt Latch Heat Shield Tailgate Tube Tailgate Mount Bracket Bushing Tailgate Latch Screw Torque to 8 ft-lbs (11 Nm) Screw Torque to 5 ft-lbs (7 Nm) 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.14 © Copyright Polaris Inc.
Page 527: Box Removal
CAUTION Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.15 © Copyright Polaris Inc.
Page 528: Body Component Removal
6. Repeat this procedure to remove the other rear fender. 3. Remove the two fasteners from each side of the upper portion of the bumper. 4. Carefully remove the bumper from the vehicle. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.16 © Copyright Polaris Inc.
Page 529: Hood / Dash
7. Remove the five push rivets from under the dash panel. Unhook all electrical components to allow the panel to be completely removed. 8. Carefully remove the dash assembly from the vehicle. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.17 © Copyright Polaris Inc.
Page 530: Floors
7. Remove the accelerator and brake pedals for center floor. adequate clearance to remove the front floor section. 4. Remove the Torx-head screws retaining the front floor cover. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.18 © Copyright Polaris Inc.
Page 531: Decals
2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 11.19 © Copyright Polaris Inc.
Page 535: General Information
2870836 2460761 Hall Sensor Probe Harness Authorized Polaris dealers/distributors are required to Static Timing Light Harness 2871745 use the conductance analyzer when testing 12V Polaris batteries. Digital Wrench™ Diagnostic Software PU-47063 Digital Wrench™ SmartLink Module Kit PU-47471 Battery Conductance Analyzer...
Page 536: Components Under Hood
• AWD/2WD/TURF Switch • 12 VDC Accessory Power Point • Ignition Switch • Instrument Cluster • Cooling Fan • TRS Connector • Brake Switch • Headlights 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.4 © Copyright Polaris Inc.
Page 537: Switches / Controls
• When the switch is in position #3 (TURF), there should continuity between switch pins A and B; C and D; E be continuity between terminals 1 (White/Green) and 2 and F. (Orange/White). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.5 © Copyright Polaris Inc.
Page 538: Differential Solenoid
If there is no continuity or greater than .5 ohms resistance when the brake is applied with slight pressure, first clean the switch contacts and re-test. Replace switch if necessary. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.6 © Copyright Polaris Inc.
Page 539: All Wheel Drive (Awd) Coil
• Verify the wiring harness, wiring, connectors, connector pins and grounds are undamaged, clean and connected properly. • Verify continuity of wire connections with a volt/ohm meter. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.7 © Copyright Polaris Inc.
Page 540: Vehicle Speed Sensor
Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness (PN 2460761). 3. Pass a screwdriver back and forth in front of the sensor tip. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.8 © Copyright Polaris Inc.
Page 541: Instrument Cluster
Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.9 © Copyright Polaris Inc.
Page 542: Rider Information Display
11. TURF Indicator - Illuminated when the AWD / TURF switch is in the TURF position. 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.10 © Copyright Polaris Inc.
Page 543: Information Display Area
To reset the trip meter: 1. Toggle the MODE button to TRIP 1. Engine hours are logged anytime the engine is running. Total hours can not be reset. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.11 © Copyright Polaris Inc.
Page 544 7. Toggle the MODE button until the odometer is displayed. 8. Press and hold the MODE button until the hour segment flashes. Release the button. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.12 © Copyright Polaris Inc.
Page 545: Diagnostic Mode
The diagnostic mode is accessible only when the check engine MIL has been activated. 4. Use the trouble code reference table in the EFI Chapter for a description of each code. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.13 © Copyright Polaris Inc.
Page 546: Instrument Cluster Pinouts
2. Disconnect the wire connectors from the back side of properly seat the instrument cluster. Apply pressure the instrument cluster. on the bezel while pressing down on the instrument cluster. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.14 © Copyright Polaris Inc.
Page 547: Headlights
(see illustration). Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.15 © Copyright Polaris Inc.
Page 548: Headlight Bulb Replacement
3. Reinstall the bulb into the housing and rotate it clockwise 90° to lock it in place. 4. Close the hood and adjust headlights using the “Headlight Adjustment” procedure. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.16 © Copyright Polaris Inc.
Page 549: Tail Light / Brake Light
4. Reinstall the assembly by reversing this procedure. 5. Test after installation to verify proper function of tail, brake, and turn signal lamps. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.17 © Copyright Polaris Inc.
Page 551: Ignition Coil
Between Coil (-) and Primary (+) at the Coil 0.5 Ω Test Connection Between High Tension Secondary 7.0 k Ω ± 5% Lead Caps Test 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.19 © Copyright Polaris Inc.
Page 552: Ignition Coil And Ht Lead Replacement
Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 6. Connect harness connection to the ignition coil. 7. Reconnect battery cable and install the drivers seat. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.20 © Copyright Polaris Inc.
Page 553: Relays
OPERATION Red / Blue Relay coil 12v from EFI Splice High side 12v from Start Solenoid 12v output to Splice, Chassis Gray ECU controlled ground 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.21 © Copyright Polaris Inc.
Page 554 Brown Chassis ground #2 • Rear Differential Solenoid Relay, controlled by the AWD/2WD/TURF switch and ECM, operates the differential solenoid to unlock the rear end. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.22 © Copyright Polaris Inc.
Page 555: Fuses / Circuit Breaker
FUSE SIZE FEATURE SUPPORTED Brake Light 10 A Drive System, Fuel Pump 20 A EFI, Power Steering (if equipped), Lights, Accessories 20 A Circuit Breaker 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.23 © Copyright Polaris Inc.
Page 556: Operation (Intl.)
FUSE SIZE FEATURE SUPPORTED 10 A Brake Light, Drive System, Fuel Pump 20 A EFI, Power Steering (if equipped), Lights, Accessories 20 A Circuit Breaker 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.24 © Copyright Polaris Inc.
Page 557: Charging System
Maximum of .01 DCA (10 mA) Charging system damage will occur if incompatible components are installed. Always reference the Polaris 9. If over 10 milliamps, go to the fuse block and start Electronic Parts Catalog for the proper part numbers.
Page 558: Charging System Alternator Tests
TEST 2: Resistance Value of Each Stator Leg to Ground 3. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.26 © Copyright Polaris Inc.
Page 559 80 VAC ± 25 % the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3). 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.27 © Copyright Polaris Inc.
Page 560: Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.28 © Copyright Polaris Inc.
Page 561: Battery Service
ELECTRICAL BATTERY SERVICE BATTERY TERMINALS / BOLTS BATTERY ACTIVATION Use Polaris corrosion resistant Nyogel™ grease (PN WARNING 2871329) on battery terminal bolts. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
Page 562: Battery Inspection
Don’t add acid, use distilled water only! 5. Check the vent tube. Make sure it’s not kinked, pinched or otherwise obstructed. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.30 © Copyright Polaris Inc.
Page 563: Battery Removal / Installation
100% Charged 1.275 50% Charged 12.20 V 75% Charged 1.225 25% Charged 12.0 V 50% Charged 1.175 0% Charged 11.9 V or less 25% Charged 1.135 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.31 © Copyright Polaris Inc.
Page 564: Load Test
(+) cable first and negative (-) cable last. 5. After connecting the battery cables, install the cover on the battery and attach the hold down strap. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.32 © Copyright Polaris Inc.
Page 565: Starter System
Make sure the end washer is positioned properly so that it will hold the lock ring in its groove. Polaris Premium Starter Drive Grease PN 2871460 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.33...
Page 566: Starter Solenoid Bench Test
12V power via the White / Red wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.34 © Copyright Polaris Inc.
Page 567: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual 12.35 © Copyright Polaris Inc.
Page 569 Test ..............4.7 Break Even Test............12.25 CV Shaft Boot Break-In Inspection.............2.27 Brake System ............2.4 Cylinder Engine and Drivetrain..........2.4 Misfire..............1.87 PVT..............2.4 Cylinder Head 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual IX.1 © Copyright Polaris Inc.
Page 570 Feature Map............1.73 Troubleshooting - EPS Non-Functional MIL Off .....1.99 Guided Diagnostics ..........1.70 Troubleshooting - EPS Non-Functional MIL On .....1.98 Polaris Mobile Digital Wrench® (PMDW) .....1.74 Troubleshooting - Using Digital Wrench® ....1.100 Serial Number Location ...........1.72 Electronic Throttle Body Software Installation and Updates ......1.71 Learn Procedure .............
Page 571 Lower Seat Base............. 11.16 Front Gearcase Lubrication .........2.25 Lubrication Front Strut Front Gearcase............2.25 Assembly View ............9.15 Grease Points............2.8 Cartridge Replacement..........9.16 Stabilizer Bar Pivot ..........2.32 Fuel Suspension............2.33 Filter..............2.22 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual IX.3 © Copyright Polaris Inc.
Page 572 Pedal Position Sensor ..........4.6 Spark Plug Test ..............4.6 Service - 570 ..........2.38-2.39 Periodic Maintenance Chart.......... 2.5 Special Tools ..........1.8, 5.5, 7.3 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual IX.4 © Copyright Polaris Inc.
Page 573 Pivot Lubrication ............2.33 Shock Analysis ........1.101, 2.34, 9.3 Fuel System ............1.89 Spring Adjustment ..........2.32 Misfire Detection ............1.87 Switch PVT System ............1.91 AWD/2WD/TURF ...........12.5 Brake............10.8, 12.6 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual IX.5 © Copyright Polaris Inc.
Page 574 VIN Location ............. 1.4 Voltage Drop Test ............ 12.31 Water Pump Mechanical Seal / Oil Seal........3.25 Removal / Installation ..........3.25 Wheel Installation ............2.28 Removal...............2.27 Wheel Alignment ............2.30 9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual IX.6 © Copyright Polaris Inc.

This manual is also suitable for:

Ranger 500 2018 Ranger 500 2019 Ranger 500 2020 Ranger 500 2021 Ranger 570 2017 Ranger 570 2018 ... Show all

Polaris RANGER 500 2017 Service Manual

Chapter 1 1 General Information

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling System

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris RANGER 500 2017

Summary of Contents for Polaris RANGER 500 2017