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

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

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

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris RANGER 500 2018

Page 1 Publication Printed September 2017 (PN 9928485 R01) © Copyright 2018 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 2 SAFETY WARNINGS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
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. REVISION INDEX DATE CHANGES Preliminary release.
Page 4 2017-2018 RANGER 500 / 570 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10:...
Page 6: Vehicle Information
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 7: Vin / Engine Number Location
GENERAL INFORMATION 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. The VIN can be found stamped on the upper frame rail on the rear LH side of the vehicle below the cargo box.
Page 8: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 9: Publication Numbers
NOTE 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 10: 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 11: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 12 Oil Pressure Gauge Tool Kit PU-50105 PV-43531 PU-50784 Oil Pressure Gauge Adapter Valve Spring Compressor Adapter 570 ONLY PU-50569 PV-43513-A Cylinder Holding & Camshaft Timing Plate PU-50563 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 13 *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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 14 (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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.10 © Copyright Polaris Industries Inc.
Page 15 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.11 © Copyright Polaris Industries Inc.
Page 16 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.12 © Copyright Polaris Industries Inc.
Page 17 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.13 © Copyright Polaris Industries Inc.
Page 18 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.14 © Copyright Polaris Industries Inc.
Page 19: Master Torque Table
Step 1: 18 ft-lbs (25 Nm) Step 2: 30 ft-lbs (40 Nm) 18 in-lbs (2 Nm) IAC Mount Screw Master Cylinder Mount Bolts 17 ft-lbs (23 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.15 © Copyright Polaris Industries Inc.
Page 20 Tie Rod Jamb Nuts TMAP Retaining Bolt 24 in-lbs (3 Nm) TPS Mounting Screws 18 in-lbs (2 Nm) 15 ft-lbs (20 Nm) Transmission Bell Crank Nut 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.16 © Copyright Polaris Industries Inc.
Page 21: Clutching Chart
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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.17 © Copyright Polaris Industries Inc.
Page 22: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.18 © Copyright Polaris Industries Inc.
Page 23 Brake System 4 Wheel Hydraulic Disc Hr / 12 Volt Brake Fluid DOT 4 DC Outlet Standard 12 Volt Parking Brake Transmission - Park Lock 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.19 © Copyright Polaris Industries Inc.
Page 24 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.20 © Copyright Polaris Industries Inc.
Page 25 (0.7 – 0.9 mm) Parking Brake Transmission - Park Lock Battery / Amp Hr Yuasa Conventional 14 Amp Hr / 12 Volt DC Outlet Standard 12 Volt 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.21 © Copyright Polaris Industries Inc.
Page 26 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.22 © Copyright Polaris Industries Inc.
Page 27 Spark Plug / Gap NGK MR7F / 0.0276 − 0.0315″ (0.7 – 0.9 mm) Battery / Amp Hr Yuasa Conventional 14 Amp Hr / 12 Volt 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.23 © Copyright Polaris Industries Inc.
Page 28: 2017 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.24 © Copyright Polaris Industries Inc.
Page 29 (0.7 – 0.9 mm) Parking Brake Transmission - Park Lock Battery / Amp Hr Yuasa Conventional 14 Amp Hr / 12 Volt DC Outlet Standard 12 Volt 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.25 © Copyright Polaris Industries 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.26 © Copyright Polaris Industries Inc.
Page 31 (0.7 – 0.9 mm) Parking Brake Transmission - Park Lock Battery / Amp Hr Yuasa Conventional 14 Amp Hr / 12 Volt DC Outlet Standard 12 Volt 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.27 © Copyright Polaris Industries Inc.
Page 32 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.28 © Copyright Polaris Industries Inc.
Page 33 DC Outlet Standard 12 Volt Instrumentation Multifunction Instrument Cluster Relays EFI / Chassis / Fan / Fuel Pump / Headlight / EPS (EPS model only) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.29 © Copyright Polaris Industries Inc.
Page 34: Misc. Specifications And Charts
π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.30 © Copyright Polaris Industries Inc.
Page 36: Sae Tap / Drill Sizes
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 7/16–14 3–4 2 3/4 7/16–20 25/64 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.32 © Copyright Polaris Industries Inc.
Page 37: Metric Tap / Drill Sizes
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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.33 © Copyright Polaris Industries Inc.
Page 38: Decimal Equivalents
0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.34 © Copyright Polaris Industries Inc.
Page 39 23 mm = 0.9055″ 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″ 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 1.35 © Copyright Polaris Industries Inc.
Page 41 ....... 2.11 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ENGINE ....................2.12 .
Page 43: Periodic Maintenance Chart
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 44: Break-In Period
Do not operate at full throttle or high The break-in period for your new POLARIS vehicle is the speeds during the first three hours of use. first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline.
Page 45: Periodic Maintenance Chart Key
NOTE 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 46 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 47 ▶ = 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 48: Grease Lubrication Points
** Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more often under severe conditions (i.e. operating in water or hauling heavy loads). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 49: 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 50: Storage Tips
Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. 5. If POLARIS fuel system additive is not used, the fuel They do not allow enough ventilation to prevent tank, fuel lines, and injectors should be completely condensation, and may promote corrosion and oxidation.
Page 51: 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 52: Engine
4. Reinstall dipstick completely. NOTE NOTE The dipstick must be screwed completely in to ensure This Polaris 4-Stroke engine is equipped with an accurate measurement. automatic decompressor. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 80-120 psi during a compression test.
Page 53: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.13 © Copyright Polaris Industries Inc.
Page 54: 500 Sohc
NOTE Isolators must be replaced after each use. 4. Remove the PVT cover to access the drive clutch. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.14 © Copyright Polaris Industries Inc.
Page 55 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.15 © Copyright Polaris Industries Inc.
Page 56: Cooling System
If not, perform the following: purged from system. 1. Position the vehicle on a level surface. Polaris recommends the use of Polaris 50/50 Extended 2. The coolant level must be maintained between the Life Antifreeze or a 50/50 mixture of high quality “MAX”...
Page 57 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 58: 50/50 Extended-Life Engine Antifreeze
MAINTENANCE 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE Beginning in the later part of 2014, Polaris began using 50/50 Extended Life antifreeze in some vehicles. All model- year 2015 and newer vehicles will use 50/50 Extended Life antifreeze. Using the 50/50 Extended-life antifreeze extends the service interval from two to five years.
Page 59: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.19 © Copyright Polaris Industries Inc.
Page 60: Radiator Inspection / Cleaning
5. Remove the screws that retain the recovery bottle to effectiveness. Use of a high-pressure washer is not the frame bracket. Set the recovery bottle out of the recommended. way. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.20 © Copyright Polaris Industries Inc.
Page 61 Take care not to damage the cooling fins. 10. Remove the four bolts that retain the fan motor and shroud to the radiator. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.21 © Copyright Polaris Industries Inc.
Page 62: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.22 © Copyright Polaris Industries Inc.
Page 63: Engine Air Intake Inspection
REF. DESCRIP- NOTES TION Cover Filter Seal Clamp 2. Verify there is no debris obstructing the airway. Airbox 3. Reinstall the cover. Boot Installation 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.23 © Copyright Polaris Industries Inc.
Page 64: Transmission And Gearcase
5. Remove the fill plug (refer to “Transmission Lubricant Level Check”). 6. Place a drain pan under the transmission drain plug. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.24 © Copyright Polaris Industries Inc.
Page 65: Front Gearcase Lubrication
Access the drain plug through the skid plate. 11. Check for leaks. Dispose of used lubricant properly. 6. Remove the fill plug (refer to “Front Gearcase Fluid Level Check”). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.25 © Copyright Polaris Industries Inc.
Page 66 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.26 © Copyright Polaris Industries Inc.
Page 67: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.27 © Copyright Polaris Industries Inc.
Page 68: Wheel Installation
Worn tires can cause an accident. Always replace tires when the usable tread depth has worn out. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.28 © Copyright Polaris Industries Inc.
Page 69: Steering
NOTE Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component...
Page 70: Wheel Toe Alignment Inspection
To adjust toe alignment: • Hold tie rod end to keep it from rotating. • Loosen jam nuts at both end of the tie rod. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.30 © Copyright Polaris Industries Inc.
Page 71: Camber And Caster
• 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.31 © Copyright Polaris Industries Inc.
Page 72: Suspension
1. Grease stabilizer bar pivots with a grease gun until old grease is purged from the joint and new grease appears. Inspect link isolators for cracks. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.32 © Copyright Polaris Industries Inc.
Page 73: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.33 © Copyright Polaris Industries Inc.
Page 74: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.34 © Copyright Polaris Industries Inc.
Page 75: Electrical And Ignition System
To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, install the negative cable last. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.35 © Copyright Polaris Industries Inc.
Page 76: Battery Installation
Look for a sharp outer edge with no rounding or NOTE erosion of the electrodes. 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 77: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.37 © Copyright Polaris Industries Inc.
Page 78: Main Frame/Engine Ground
7. Install spark plug and torque to specification. Recommended Spark Plug: NGK MR7F TORQUE Spark Plug: 9 ft-lbs (12 Nm)w/o anti-seize 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 2.38 © Copyright Polaris Industries Inc.
Page 84: General Engine Information
Stator Cover Removal Handles 49317 PV-1253 Valve Spring Compressor Valve Spring Compressor Adapter 43513-A Water Pump Mechanical / Oil Seal Installation 50689 Bosch Automotive Service Solutions: 1-800-345-2233 http://polaris.service-solutions.com/. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 85: Engine Lubrication Specifications
PU-50105 or 2.5″ (64 mm) Oil Type Polaris PS-4 Synthetic Engine Oil Oil Pressure Minimum Specification (using Polaris PS-4 at operating temperature) 10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual...
Page 86: Oil Pressure Test
NOTE Test results are based on the use of the recommended engine oil (Polaris PS-4) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.
Page 88: Engine Specifications
Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.10 © Copyright Polaris Industries Inc.
Page 89 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.11 © Copyright Polaris Industries Inc.
Page 90: Engine Service
1. If vehicle was recently operated, allow it to cool down before attempting to perform any work. 2. Thoroughly clean the engine and chassis. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.12 © Copyright Polaris Industries Inc.
Page 91 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.13 © Copyright Polaris Industries Inc.
Page 92 24. Loosen the (2) bolts and nuts (Item 6) so the engine mount bracket can be slightly tilted away from engine. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.14 © Copyright Polaris Industries Inc.
Page 93: Engine Installation
RZR XP 1000 2013 RANGER 900 2014-16 2015-18 ACE 570 2015-16 RGR ETX 2013–18 RZR 570 2014–18 RANGER 500/570 2015-18 RANGER 570 Full-Size 2014-18 RANGER 900/1000 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.15 © Copyright Polaris Industries Inc.
Page 94 40 ft-lbs (54 Nm) 12. Install the (2) springs (Item 7) securing the muffler to the head pipe. 13. Install the (3) coolant hoses onto the engine. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.16 © Copyright Polaris Industries Inc.
Page 95 / 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 96: Engine Break-In Period
Oil Filter Wrench CAUTION PU-50105 or 2.5” (64 mm) Use only Polaris PS-4 Synthetic Engine Oil. Never substitute or mix oil brands. Oil Type Serious engine damage and voiding of warranty can Polaris PS-4 Synthetic Engine Oil result.
Page 97: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.19 © Copyright Polaris Industries Inc.
Page 98: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.20 © Copyright Polaris Industries Inc.
Page 99 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.21 © Copyright Polaris Industries Inc.
Page 100: Cooling System
REF. DESCRIPTION NOTES Radiator Fan Shroud Cooling Fan Recovery Bottle Radiator Drain Plug Upper Radiator Hose Lower Radiator Hose Bypass Hose Water Pump Hose 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.22 © Copyright Polaris Industries Inc.
Page 101: 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 102: Pressure Cap Test
Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.24 © Copyright Polaris Industries Inc.
Page 103: Coolant Drain / Radiator Removal
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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.25 © Copyright Polaris Industries Inc.
Page 104: Thermostat Replacement
8. Be sure to properly fill and bleed cooling system as outlined in this chapter. 4. Remove the pressure cap (Item 2) and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 5. Remove the cargo box access cover to gain access to the coolant bleed screw that is on top of the thermostat housing.
Page 105: Water Pump Cover And Impeller Service (Stator Cover Remains On Engine)
. Discard the water pump gasket 11. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator 10. Using an 8mm socket, remove the water pump filler neck. impeller 12. Open the bleed screw to allow any trapped air to NOTE escape.
Page 106: Water Pump Mechanical Seal / Oil Seal Replacement
3. Remove all debris and thoroughly clean water pump area and right-hand side of engine block. 4. Open the hood. 5. Remove the pressure cap from the filler neck. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.28 © Copyright Polaris Industries Inc.
Page 107 16. Remove and discard the stator cover gasket. CAUTION Be sure engine coolant does not contaminate the Water Pump Assembly engine oil during stator cover service. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.29 © Copyright Polaris Industries Inc.
Page 108 24. Press in the water pump drive shaft into the bearing using PU-50869 Item #1. 26. Lubricate the new water pump oil seal with clean engine oil. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.30 © Copyright Polaris Industries Inc.
Page 109 30. Align the water pump drive slot as shown below. 33. If needed, install the stator cover removal handles tool PA-49317 to the water cover bolt holes to aid in stator cover installation. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.31 © Copyright Polaris Industries Inc.
Page 110 38. Install a new water pump cover gasket. TORQUE Stator Cover and Water Pump Cover: 9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt threads) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.32 © Copyright Polaris Industries Inc.
Page 111 48. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 49. Check for leaks. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.33 © Copyright Polaris Industries Inc.
Page 112: Troubleshooting
• Cylinder, piston, ring, or valve wear or damage (check compression) • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring • Lack of lubrication 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.34 © Copyright Polaris Industries Inc.
Page 113: Cooling System
• Thermostat missing Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.35 © Copyright Polaris Industries Inc.
Page 114: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.36 © Copyright Polaris Industries Inc.
Page 115 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.37 © Copyright Polaris Industries Inc.
Page 116: Engine Torque Sequences
ENGINE / COOLING SYSTEM ENGINE TORQUE SEQUENCES Cylinder Head Cam Carrier Valve Cover Water pump Cover 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.38 © Copyright Polaris Industries Inc.
Page 122: Crankcase Sealant Path
Alignment Pins MUST be installed prior to assembly CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.44 © Copyright Polaris Industries Inc.
Page 123 WARNING DO NOT EXCEED TORQUE VALUE. Screw Torque: 22 ft-lbs (30 Nm) Replace if loosened or removed. Shoulder Bolt Torque: 88 in-lbs (10 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.45 © Copyright Polaris Industries Inc.
Page 124 Screw Torque: 106 in-lbs (12 Nm) Screw Torque: 22 ft-lbs (30 Nm) Replace if loosened or removed. Shoulder Bolt Torque: 88 in-lbs (10 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.46 © Copyright Polaris Industries Inc.
Page 125: Cylinder / Oil Filter / Oil Pump / Breather
ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.47 © Copyright Polaris Industries Inc.
Page 126 Apply ENGINE OIL to bottom 50 mm of cylinder bore and to piston rings before assembly. Gerotor Inner Gerotor Slot must be visible after assembly Gerotor Outer Gerotor dots must not be visible after assembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.48 © Copyright Polaris Industries Inc.
Page 128 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.50 © Copyright Polaris Industries Inc.
Page 129: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.51 © Copyright Polaris Industries Inc.
Page 130 Torque in Sequence shown in Torque Sequence topic. Replace if loosened of removed. Water Pump Impeller has left hand thread, tighten to finger tight. Impeller Screw Torque: 106 in-lbs (12 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.52 © Copyright Polaris Industries Inc.
Page 132 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.54 © Copyright Polaris Industries Inc.
Page 133: Spark Plugs / Starter / Throttle Body / Valve Cover
ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.55 © Copyright Polaris Industries Inc.
Page 134 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.56 © Copyright Polaris Industries Inc.
Page 136 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.58 © Copyright Polaris Industries Inc.
Page 137: Piston / Crankshaft / Balance Shaft
ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.59 © Copyright Polaris Industries Inc.
Page 138 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.60 © Copyright Polaris Industries Inc.
Page 139 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. “EX” should be nearest the exhaust. IMPORTANT Time balance shaft and crankshaft gears as shown. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.61 © Copyright Polaris Industries Inc.
Page 140 Bearing inner race to be supported during installation. Minimum axial load to be applied to seat the crank in bearings is 13.3 kN. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.62 © Copyright Polaris Industries Inc.
Page 141 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.63 © Copyright Polaris Industries Inc.
Page 143: Engine Disassembly / Inspection - Top End
1. Rotate the engine so the piston is at Top Dead Center (TDC) on the compression stroke. NOTE To verify TDC, see Setting TDC (Top-Dead-Center), page 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.65 © Copyright Polaris Industries Inc.
Page 145: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.67 © Copyright Polaris Industries Inc.
Page 146: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.68 © Copyright Polaris Industries Inc.
Page 147: Cylinder Head Inspection
7. Repeat the previous steps to remove the remaining valve. 8. Clean the combustion chamber and head gasket surface. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.69 © Copyright Polaris Industries Inc.
Page 148 0.2741" - 0.2747" (6.963 - 6.978 mm) 8. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.70 © Copyright Polaris Industries Inc.
Page 149: Combustion Chamber Cleaning
Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.71 © Copyright Polaris Industries Inc.
Page 150 * If the seat is too narrow, widen using the 45° cutter and re-check contact point on the valve face and seat width after each cut. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.72 © Copyright Polaris Industries Inc.
Page 151: Cylinder Removal
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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.73 © Copyright Polaris Industries Inc.
Page 152: Piston Removal
Do not expand the ring more than the amount necessary to remove it from the piston. *By hand: Using both thumbs, spread the ring open and push up on the opposite side. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.74 © Copyright Polaris Industries Inc.
Page 153: Piston-To-Cylinder Clearance
Piston O.D.: 3.6592 - 3.6598″ (92.943 - 92.957 mm) Piston Pin O.D.: Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm) Service Limit: 0.8651″ (21.975 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.75 © Copyright Polaris Industries Inc.
Page 154: Piston Ring Installed Gap
Std.: 0.0007 - 0.0029" (.020 - 0.076 mm) the final bore size, or by rough honing followed by finish Service Limit: 0.0035" (0.89 mm) honing. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.76 © Copyright Polaris Industries Inc.
Page 155: Cylinder Hone Selection / Honing Procedure
Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris A finished cylinder should have a 45 degree cross-hatch recommends using a rigid hone or arbor honing pattern to ensure piston ring seating, aid in oil retention machine which also has the capability of oversizing.
Page 156: Engine Assembly - Top End
Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.78 © Copyright Polaris Industries Inc.
Page 157: Piston / Connecting Rod Assembly
4. Apply clean engine oil to cylinder bore and bottom tapered portion of cylinder sleeve. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.79 © Copyright Polaris Industries Inc.
Page 159: 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. The camshaft lobes should face out. VALVE SEALING TEST 1.
Page 160 .010 ± .002″ (0.254 ± .050 mm) 15. Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification. TORQUE Camshaft Carrier Bolts: 7 ft-lbs (10 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.82 © Copyright Polaris Industries Inc.
Page 161: Intake Valve Lash - Tappet Selection Matrix
0.075-0.099 310 312 315 318 320 322 325 328 330 332 335 338 340 342 345 348 350 352 355 358 360 362 365 368 370 372 375 378 380 382 385 388 390 392 395 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.83 © Copyright Polaris Industries Inc.
Page 162: Camshaft Installation / Timing
0.976-1.000 400 402 405 408 410 412 415 418 420 422 425 428 CAMSHAFT INSTALLATION / TIMING 2. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to NOTE installation. If any valve train components were replaced, refer to “Valve Clearance Adjustment”, page 3.174...
Page 163 Tighten the bolts evenly until snug. Do not torque at freely and returns by spring force after sprocket has this time. been installed. 13. Insure the new sealing washer is in place. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.85 © Copyright Polaris Industries Inc.
Page 164: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.86 © Copyright Polaris Industries Inc.
Page 165: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.87 © Copyright Polaris Industries Inc.
Page 166: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.88 © Copyright Polaris Industries Inc.
Page 167 If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.89 © Copyright Polaris Industries Inc.
Page 168: Starter One-Way Clutch Installation
1. Clean the threads, taper and flat of crankshaft to remove all oil or grease. 7. Align the flywheel keyway with flywheel key on the crankshaft. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.90 © Copyright Polaris Industries Inc.
Page 169: Stator Removal
Test stator wire continuity before removing it from the 2. Clean mounting surfaces of stator and housing. housing. 3. Apply crankcase sealant to edges of rubber stator grommet as shown below. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.91 © Copyright Polaris Industries Inc.
Page 170: Oil Pump Removal
DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.92 © Copyright Polaris Industries Inc.
Page 171 9. Remove the oil pump gerotor that is in the engine case (if needed). 10. Clean the gerotors to remove oil. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.93 © Copyright Polaris Industries Inc.
Page 172: Oil Pump Assembly
4. Slide the gerotor onto the drive shaft and lock them into position on the drive pin. 5. Install the washer onto the drive shaft 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.94 © Copyright Polaris Industries Inc.
Page 173: Crankcase Breather Valve / Hose
Polaris PS-4 Synthetic Engine Oil Oil Pressure Minimum Specification: (using Polaris PS-4 Plus at operating temperature) 10 PSI @ 1200 RPM(Minimum) 40 PSI @ 7000 RPM(Minimum) 12. Prepare Inter (mag) and mag side crank case by clean all mating surfaces.
Page 174: Crankcase Separation
3. Remove the oil filter and the fasteners that secure off PTO case. oil filter adapter to the crankcase. Discard O-rings and thoroughly clean the adaptor for reassembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.96 © Copyright Polaris Industries Inc.
Page 175: Balance Shaft Removal / Inspection
3. Inspect drive gear for broken or damaged teeth. 4. Inspect bearing surfaces for scoring or signs of wear. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.97 © Copyright Polaris Industries Inc.
Page 176: Crankshaft Inspection
4. Remove all special tools from the crankcase. Small End I.D. Standard: 0.8665” - 0.8670” (22.010 - 22.023 mm) Service Limit: 0.08682” (22.053 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.98 © Copyright Polaris Industries Inc.
Page 177 The crankshaft is reusable if it meets specifications and MAG side bearing surface is not groved, pitted, damaged or excessively worn. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.99 © Copyright Polaris Industries Inc.
Page 178: 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. 7. Remove the crankshaft removal / installation tool from the crankcase. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.100 © Copyright Polaris Industries Inc.
Page 179: Balance Shaft Installation / Timing
11. Drive seal until flush with seal bore. 12. Turn PTO crankcase over and support with crankshaft upright. BALANCE SHAFT INSTALLATION / TIMING 1. Position balance shaft in the crankcase. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.101 © Copyright Polaris Industries Inc.
Page 180: Final Crankcase Assembly
1. Prepare MAG side crankcase by cleaning sealing surface. Be sure the oil pickup and oil pressure valve are fully installed. TORQUE Crankcase Bolts: 22 ft-lbs (30 Nm)Torque in Sequence Shown 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.102 © Copyright Polaris Industries Inc.
Page 181 Engine Stand Sleeve Adapter (2.375” Bore Stand): PW-47054 10. Place engine onto the engine stand for final assembly of the engine. Engine Stand: PU-50624-A 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.103 © Copyright Polaris Industries Inc.
Page 182: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.104 © Copyright Polaris Industries Inc.
Page 183 If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.105 © Copyright Polaris Industries Inc.
Page 184: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.106 © Copyright Polaris Industries Inc.
Page 185: Oil Pump Removal
ENGINE / COOLING SYSTEM OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.107 © Copyright Polaris Industries Inc.
Page 186 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.108 © Copyright Polaris Industries Inc.
Page 187: Oil Pump Assembly
Do not use gasket sealer on 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 188: Crankcase Separation
Discard O-rings and through clean the adaptor for reassembly. 3. Remove and discard the fifteen flange bolts from magneto side crankcase evenly in a criss-cross pattern. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.110 © Copyright Polaris Industries Inc.
Page 189: Balance Shaft Removal / Inspection
The inner race should be firm with minimal side to side movement and no detectable up and down (radial) movement. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.111 © Copyright Polaris Industries Inc.
Page 190: Crankshaft Removal
Small End I.D. Standard: 4. Remove all special tools from the crankcase. 0.8665 - 0.8670″ (22.010 - 22.023 mm) Service Limit: 0.08682″ (22.053 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.112 © Copyright Polaris Industries Inc.
Page 191: Pto Side Crankcase Bearing Service
Bearing Spacer 2. If not already performed, remove the screws that secure the bearing retainer to the case. Retaining Ring 3. Remove the retaining ring. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.113 © Copyright Polaris Industries Inc.
Page 192: Mag Side Crankcase Bearing Service
3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.114 © Copyright Polaris Industries Inc.
Page 193: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.115 © Copyright Polaris Industries Inc.
Page 194: 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. 7. Remove the crankshaft removal / installation tool from the crankcase. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.116 © Copyright Polaris Industries Inc.
Page 195 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.117 © Copyright Polaris Industries Inc.
Page 196: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.118 © Copyright Polaris Industries Inc.
Page 197 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.119 © Copyright Polaris Industries Inc.
Page 198: Starter One-Way Clutch Installation
TORQUE One Way Clutch Retaining Bolts: 9 ft-lbs (12 Nm) Apply Loctite® 272™ 4. Rotate crankshaft so the flywheel key is facing upward. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.120 © Copyright Polaris Industries Inc.
Page 199 Fully install the flywheel until seated on the crankshaft taper. 9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.121 © Copyright Polaris Industries Inc.
Page 200: Stator / Stator Cover Installation
8. Install the stator cover screws and torque to specification. TORQUE Stator Mounting Bolts: 9 ft-lbs (12 Nm)Apply Loctite® 242™ TORQUE Stator Wire Retainer: 6 ft-lbs (9 Nm) Apply Loctite® 242™ 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.122 © Copyright Polaris Industries Inc.
Page 201: 570Cc Dohc Engine
37 ft-lbs (50 Nm) ETC Fasteners 7 ft-lbs (10 Nm) Exhaust Manifold Bolts 18 ft-lbs (24 Nm) Exhaust Mounting Fasteners 15 ft-lbs (20 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.123 © Copyright Polaris Industries Inc.
Page 202 Water Pump Cover Fastener 9 ft-lbs (12 Nm) Torque in Sequence NOTE: Refer to the diagrams and procedures within the chapter for fastener identification. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.124 © Copyright Polaris Industries Inc.
Page 203: Torque Sequence
ENGINE / COOLING SYSTEM TORQUE SEQUENCE Cylinder Head Cam Carrier Valve Cover Water pump Cover 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.125 © Copyright Polaris Industries Inc.
Page 204 ENGINE / COOLING SYSTEM Stator Cover Torque Sequence 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.126 © Copyright Polaris Industries Inc.
Page 205 ENGINE / COOLING SYSTEM Intermediate (MAG) Cove Torque Sequencer 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.127 © Copyright Polaris Industries Inc.
Page 206: Crankcase Sealant Path
Clean the case halves with ISOPOPLY ALCHOHOL to remove all sealant before applying new sealant. Alignment Pins MUST be installed prior to assembly IMPORTANT Clean the case deck of all sealant after assembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.128 © Copyright Polaris Industries Inc.
Page 207: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
ENGINE / COOLING SYSTEM CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.129 © Copyright Polaris Industries Inc.
Page 208 Engine oil may be used to aid installation. Torque: 35 in-lbs (6.75 Nm) WARNING DO NOT EXCEED TORQUE VALUE. Screw Torque: 22 ft-lbs (30 Nm) Replace if loosened or removed. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.130 © Copyright Polaris Industries Inc.
Page 209: Cylinder / Oil Filter / Oil Pump / Breather
ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.131 © Copyright Polaris Industries Inc.
Page 210 Apply ENGINE OIL to bore of oil pump cover prior to assembly. Gerotor Outer Gerotor dots must not be visible after assembly. Gerotor Inner Gerotor Slot must be visible after assembly 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.132 © Copyright Polaris Industries Inc.
Page 211: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover - Black Cylinder Head Bolts
ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER - BLACK CYLINDER HEAD BOLTS 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.133 © Copyright Polaris Industries Inc.
Page 212 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.134 © Copyright Polaris Industries Inc.
Page 213: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover - Silver Head Bolts
ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER - SILVER HEAD BOLTS 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.135 © Copyright Polaris Industries Inc.
Page 214 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.136 © Copyright Polaris Industries Inc.
Page 215: Spark Plugs / Starter / Throttle Body / Valve Cover
ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.137 © Copyright Polaris Industries Inc.
Page 216 Starter Motor Apply grease to starter o-ring. Dipstick Apply engine oil to o-ring Hose Clamp Torque: 9 in-lbs (1 Nm) Screw Torque: (22.5 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.138 © Copyright Polaris Industries Inc.
Page 217: Piston / Crankshaft / Balance Shaft
ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.139 © Copyright Polaris Industries Inc.
Page 218 Apply ENGINE OIL or WHITE LITHIUM grease to bearing surfaces and/or bore. Balance Shaft Apply ENGINE OIL or WHITE LITHIUM grease to bearing surfaces and/or bore. Align gears to gear timing marks. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.140 © Copyright Polaris Industries Inc.
Page 219 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. “EX” should be nearest the exhaust. IMPORTANT Time balance shaft and crankshaft gears as shown. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.141 © Copyright Polaris Industries Inc.
Page 220 ENGINE / COOLING SYSTEM 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.142 © Copyright Polaris Industries Inc.
Page 221: Engine Detail, Torques / Sequences
Engine Mount (front) 40 ft-lbs (54 Nm) Engine Coupler (Rear) In Sequence: 55 ft-lb (75 Nm) Exhaust Head Pipe Bolts 18 ft-lb (25 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.143 © Copyright Polaris Industries Inc.
Page 222 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.144 © Copyright Polaris Industries Inc.
Page 223: Torque Sequence
ENGINE / COOLING SYSTEM TORQUE SEQUENCE 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.145 © Copyright Polaris Industries Inc.
Page 224: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
ENGINE / COOLING SYSTEM CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.146 © Copyright Polaris Industries Inc.
Page 225: Cylinder / Oil Filter / Oil Pump / Breather
ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.147 © Copyright Polaris Industries Inc.
Page 226: Camshafts / Cylinder Head / Flywheel / Stator Cover - Black Head Bolts
Apply a drop of Loctite 641 (Yellow) to the crankshaft taper before assembly. Loctite 603 (Green) can be used if 641 is not available. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.148 © Copyright Polaris Industries Inc.
Page 227: Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts
ENGINE / COOLING SYSTEM CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.149 © Copyright Polaris Industries Inc.
Page 228: Spark Plug / Starter / Throttle Body / Valve Cover
Fuel injector O-rings should be replaced if a fuel injector is removed or replaced. Refer to the electronic parts catalog for the latest part number. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.150 © Copyright Polaris Industries Inc.
Page 229 ENGINE / COOLING SYSTEM 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.151 © Copyright Polaris Industries Inc.
Page 230: Piston / Crankshaft / Balance Shaft
ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.152 © Copyright Polaris Industries Inc.
Page 231: Engine Disassembly / Inspection - Top End
. Stuff spark plug hole with a shop towel to prevent anything from falling into the combustion chamber (if further engine disassembly is required). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.153 © Copyright Polaris Industries Inc.
Page 232: Camshaft Sprocket Inspection
6. Mark the intake and exhaust camshafts to ensure proper assembly. TORQUE Camshaft Sprocket Bolt: 14 ft-lb (19 Nm)Replace camshaft sprocket bolt if loosened or removed. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.154 © Copyright Polaris Industries Inc.
Page 233: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.155 © Copyright Polaris Industries Inc.
Page 234: Cam Chain And Guide Service
5. Upon installation, torque all fasteners to specification and reassemble engine and vehicle as outlined in this chapter. TORQUE Upper Cam Chain Guide Fasteners: 7 ft-lb (10 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.156 © Copyright Polaris Industries Inc.
Page 235: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.157 © Copyright Polaris Industries Inc.
Page 236: Cylinder Head Inspection
NOTE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.158 © Copyright Polaris Industries Inc.
Page 237: Combustion Chamber Cleaning
0.2165" - 0.2171" (5.500 - 5.515 mm) 8. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.159 © Copyright Polaris Industries Inc.
Page 238: Valve Seat Reconditioning
The valve may overheat and warp, face resulting in burnt valves. 6. Insert valve into guide and tap valve lightly into place a few times. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.160 © Copyright Polaris Industries Inc.
Page 239 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.161 © Copyright Polaris Industries Inc.
Page 240: Cylinder Removal
(1/2" down from top, in the middle, and 1/2” up from bottom). 6. Remove and discard cylinder base gasket. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.162 © Copyright Polaris Industries Inc.
Page 241: Piston Removal
4. Repeat procedure for second ring. 5. Remove oil control ring top rail first, then bottom rail. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.163 © Copyright Polaris Industries Inc.
Page 242: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.164 © Copyright Polaris Industries Inc.
Page 243: Piston Ring Installed Gap
Do not allow cylinder to heat up during honing. NOTE Always check piston ring installed gap after re-boring a cylinder or when installing new rings. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.165 © Copyright Polaris Industries Inc.
Page 244: Cylinder Hone Selection / Honing Procedure
Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing.
Page 245: Engine Assembly - Top End
Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.167 © Copyright Polaris Industries Inc.
Page 246: Piston / Connecting Rod Assembly
Do not tap on pin or cause any sideways force to connecting rod. Warm piston crown with a heat gun if pin cannot be installed by hand, or use a piston pin installation tool. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.168 © Copyright Polaris Industries Inc.
Page 247: Cylinder Installation
7. Remove support block and ring compressor. 8. Push cylinder downward until fully seated on base gasket. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.169 © Copyright Polaris Industries Inc.
Page 248: Crankcase Identification
2016 To Current Crank Case Identification. NOTE 2015 and Prior Crankcases use dowel in the main crank case. NOTE 2016 to Current Crankcases use dowels. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.170 © Copyright Polaris Industries Inc.
Page 249: Cylinder Head Installation - Black Bolts
4. Carefully set the cylinder head in place on alignment pins. NOTE Install new cylinder head bolts. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.171 © Copyright Polaris Industries Inc.
Page 250: Cylinder Head Installation - Silver Bolts
6. Install and finger tighten the two new outer M6 bolts evenly. 7. Torque the new cylinder head bolts in sequence to specification. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.172 © Copyright Polaris Industries Inc.
Page 251 Step 5: 26 ft-lbs (35 Nm) Step 6: Additional 180° Step 7: Additional 180° Torque The Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.173 © Copyright Polaris Industries Inc.
Page 252: Valve Sealing Test
ENGINE / COOLING SYSTEM VALVE SEALING TEST 3. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 1. Clean and dry the combustion chamber area 4. Carefully install the camshafts into the cylinder head. 2. Pour a small amount of clean solvent into each The camshaft lobes should face out.
Page 253 TORQUE MEASUREMENT Camshaft Carrier Bolts: Exhaust Valve Clearance (cold): 7 ft-lbs (10 Nm) .008 ± .002″ (0.200 ± .050 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.175 © Copyright Polaris Industries Inc.
Page 254 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”. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.176 © Copyright Polaris Industries Inc.
Page 255: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.177 © Copyright Polaris Industries Inc.
Page 256: Exhaust Valve Lash - Tappet Selection Matrix
0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.178 © Copyright Polaris Industries Inc.
Page 257: 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 258 Plate from the end of the camshafts. Cylinder Holding / Camshaft Timing Plate: PU-50563 13. If needed, install the camshaft carrier and bolts. Cylinder Holding / Camshaft Timing Plate: PU-50563 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.180 © Copyright Polaris Industries Inc.
Page 259 30 ft-lb (40 Nm) 15. Insure the new sealing washer is in place. 17. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.181 © Copyright Polaris Industries Inc.
Page 260: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.182 © Copyright Polaris Industries Inc.
Page 261: 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 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.183 © Copyright Polaris Industries Inc.
Page 262: Engine Disassembly / Inspection - Lower End
Discard the flywheel nut and replace for assembly. NOTE The flywheel nut has standard rotation (right hand) threads. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.184 © Copyright Polaris Industries Inc.
Page 263: Starter One-Way Clutch Inspection
If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 6. Remove starter gear from the flywheel assembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.185 © Copyright Polaris Industries Inc.
Page 264: Starter One-Way Clutch Installation
1. Clean the threads, taper and flat of crankshaft to 7. Align the flywheel keyway with flywheel key on the remove all oil or grease. crankshaft. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.186 © Copyright Polaris Industries Inc.
Page 265: Stator Removal
TORQUE Flywheel Retaining Nut: 133 ft-lbs (180 Nm)Torque to specification, back of 180 degrees, retorque to specification. 12. Install starter idler gear and shaft. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.187 © Copyright Polaris Industries Inc.
Page 266: Stator / Stator Cover Installation
DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.188 © Copyright Polaris Industries Inc.
Page 267 The larger oil pump sprocket mounts to the balance installed inward upon assembly shaft extension, the smaller oil pump sprocket mounts to the oil pump shaft. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.189 © Copyright Polaris Industries Inc.
Page 268: Oil Pump Assembly
Oil pump sprockets must be installed in 5. Install the washer (C) onto the drive shaft. the correct position, with the word “OUT” facing out. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.190 © Copyright Polaris Industries Inc.
Page 269: Crankcase Breather Valve / Hose
Polaris PS-4 Synthetic Engine Oil Oil Pressure Minimum Specification: (using Polaris PS-4 Plus at operating temperature) 10 PSI @ 1200 RPM(Minimum) 40 PSI @ 7000 RPM(Minimum) 12. Prepare Inter (mag) and mag side crank case by clean all mating surfaces.
Page 270: Crankcase Separation
2. Remove the oil pan at this time if it has not already been removed. 6. Separate crankcase by tapping with a soft faced hammer in reinforced areas and lift MAG crankcase off PTO case. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.192 © Copyright Polaris Industries Inc.
Page 271: Balance Shaft Removal / Inspection
2. Pull upward on the balance shaft and remove it from the crankcase. 3. Inspect drive gear for broken or damaged teeth. 4. Inspect bearing surfaces for scoring or signs of wear. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.193 © Copyright Polaris Industries Inc.
Page 272: Crankshaft Removal
Small End I.D. Standard: 4. Remove all special tools from the crankcase. 0.8665” - 0.8670” (22.010 - 22.023 mm) Service Limit: 0.08682” (22.053 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.194 © Copyright Polaris Industries Inc.
Page 273: Pto Side Crankcase Bearing Service
The crankshaft is reusable if it meets specifications and MAG side bearing surface is not groved, pitted, damaged or excessively worn. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.195 © Copyright Polaris Industries Inc.
Page 274 NOTE Apply Loctite® 641 to the inner race of each of the crank bearings. 2. Lubricate all bearing bores with clean engine oil. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.196 © Copyright Polaris Industries Inc.
Page 275: Mag Side Crankcase Bearing Service
3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.197 © Copyright Polaris Industries Inc.
Page 276: Oil Pressure Regulator (Bypass) Valve Inspection
2. Be sure alignment pins are in place where used. 3. Be sure oil passages are clean and free of any cleaning solvent. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.198 © Copyright Polaris Industries Inc.
Page 277: 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. 7. Remove the crankshaft removal / installation tool from the crankcase. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.199 © Copyright Polaris Industries Inc.
Page 278 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.200 © Copyright Polaris Industries Inc.
Page 279: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.201 © Copyright Polaris Industries Inc.
Page 280 Engine Stand Sleeve Adapter (2” Bore Stand): PU- 50625 Engine Stand Sleeve Adapter (2.375” Bore Stand): PW-47054 10. Place engine onto the engine stand for service. Engine Stand: PU-50624-A 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.202 © Copyright Polaris Industries Inc.
Page 281: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.203 © Copyright Polaris Industries Inc.
Page 282 If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.204 © Copyright Polaris Industries Inc.
Page 283: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.205 © Copyright Polaris Industries Inc.
Page 284: Oil Pump Removal
ENGINE / COOLING SYSTEM OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.206 © Copyright Polaris Industries Inc.
Page 285 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.207 © Copyright Polaris Industries Inc.
Page 286: Oil Pump Assembly
Do not use gasket sealer on 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 287: Crankcase Separation
Discard O-rings and through clean the adaptor for reassembly. 3. Remove and discard the fifteen flange bolts from magneto side crankcase evenly in a criss-cross pattern. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.209 © Copyright Polaris Industries Inc.
Page 288: Balance Shaft Removal / Inspection
The inner race should be firm with minimal side to side movement and no detectable up and down (radial) movement. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.210 © Copyright Polaris Industries Inc.
Page 289: Crankshaft Removal
Small End I.D. Standard: 4. Remove all special tools from the crankcase. 0.8665 - 0.8670″ (22.010 - 22.023 mm) Service Limit: 0.08682″ (22.053 mm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.211 © Copyright Polaris Industries Inc.
Page 290: Pto Side Crankcase Bearing Service
Bearing Spacer 2. If not already performed, remove the screws that secure the bearing retainer to the case. Retaining Ring 3. Remove the retaining ring. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.212 © Copyright Polaris Industries Inc.
Page 291: Mag Side Crankcase Bearing Service
3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.213 © Copyright Polaris Industries Inc.
Page 292: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.214 © Copyright Polaris Industries Inc.
Page 293: 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. 7. Remove the crankshaft removal / installation tool from the crankcase. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.215 © Copyright Polaris Industries Inc.
Page 294 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.216 © Copyright Polaris Industries Inc.
Page 295: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.217 © Copyright Polaris Industries Inc.
Page 296 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.218 © Copyright Polaris Industries Inc.
Page 297: Starter One-Way Clutch Installation
TORQUE One Way Clutch Retaining Bolts: 9 ft-lbs (12 Nm) Apply Loctite® 272™ 4. Rotate crankshaft so the flywheel key is facing upward. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.219 © Copyright Polaris Industries Inc.
Page 298 Fully install the flywheel until seated on the crankshaft taper. 9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.220 © Copyright Polaris Industries Inc.
Page 299: Stator / Stator Cover Installation
8. Install the stator cover screws and torque to specification. TORQUE Stator Mounting Bolts: 9 ft-lbs (12 Nm)Apply Loctite® 242™ TORQUE Stator Wire Retainer: 6 ft-lbs (9 Nm) Apply Loctite® 242™ 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.221 © Copyright Polaris Industries Inc.
Page 300 ENGINE / COOLING SYSTEM NOTES 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 3.222 © Copyright Polaris Industries Inc.
Page 302 ............4.43 POLARIS MOBILE DIGITAL WRENCH (PMDW) .
Page 303: General Information
• Wire Harness Assembly and should be diagnosed. • Check Engine Light NOTE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 304: 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 305: Fuel Pressure Gauge Kit - Pu-43506-A
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 306: 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 307: Efi Component Locations
REF. COMPONENT Instrument Cluster Ignition Switch Battery Starter Motor Solenoid Regulator / Rectifier Fuse / Relay Box Starter Motor Ignition Coil Engine Temperature Sensor (ECT) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 308: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 309: Line / Hose Routing
The ears on the clip (arrows) will not hold the fitting and give it 5 pumps. The gauge should return properly once it is removed. to 0 immediately or there is an obstruction. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 310: Air Box / Intake System
FUEL SYSTEM AIR BOX / INTAKE SYSTEM AIR BOX / AIR FILTER ASSEMBLY VIEW 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.10 © Copyright Polaris Industries Inc.
Page 311 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.11 © Copyright Polaris Industries Inc.
Page 312: Air Box Removal / Installation
Tighten gear clamps to specification. TORQUE Air Intake Hose Gear Clamps: 24 in-lbs (2.7 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.12 © Copyright Polaris Industries Inc.
Page 313: Electronic Control Unit (Ecu)
The ECU then sends output signals to set the performed. If a problem is encountered, and you injector duration and ignition timing. determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.
Page 314: Ecu Replacement
ECU is transferred to the replacement ECU. 2. Remove seat and ECU cover 3. Remove the 4 screws retaining the ECU. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.14 © Copyright Polaris Industries Inc.
Page 315: Electronic Throttle Body (Etc)
No internal servicing or adjustments may be IMPORTANT performed. If a problem is encountered, and you 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 316: Pedal Position Sensor (Pps)
The Pedal Position Sensor is calibrated to the accelerator pedal. If the PPS is faulty, the accelerator pedal assembly must replaced (see "PPS Replacement"). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.16 © Copyright Polaris Industries Inc.
Page 317: Fuel Tank / Pump / Sendor
7. Remove the fuel cap, push rivets and screws retaining the RH fender panel and remove panel from the vehicle. See Floor and Fenders, page 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.17 © Copyright Polaris Industries Inc.
Page 318: Fuel Tank Installation
6. Reinstall the seat assembly. • Fuel Level Sender (+) • Fuel Level Sender (-) • Fuel Pump Power (+) • Fuel Pump Power Ground (-) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.18 © Copyright Polaris Industries Inc.
Page 319: Fuel Pump Test
2. Cover the fuel line connection at the fuel tank with a shop towel and disconnect the line from the fuel pump outlet. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.19 © Copyright Polaris Industries Inc.
Page 320 Turn on the key switch and listen for the pump to activate. NOTE If the pump starts, repeat steps 3, 4 and 5 to verify correct pressure. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.20 © Copyright Polaris Industries Inc.
Page 321: Fuel Pump Replacement
NOTE A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.21 © Copyright Polaris Industries Inc.
Page 322 The fuel pump will retain some fuel. 10. Inspect the inside of the fuel tank for debris (may require flashlight and mirror). If debris like mud or 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.22 © Copyright Polaris Industries Inc.
Page 323 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.23 © Copyright Polaris Industries Inc.
Page 324: Temperature / Manifold Absolute Pressure (T-Map)
7. Install the retaining bolt and torque to specification. TORQUE T-MAP Retaining Bolt: 24 in-lbs (2.8 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.24 © Copyright Polaris Industries Inc.
Page 325: Crankshaft Position Sensor
9. If resistance of the wires to the ECU are in spec and not shorted to chassis ground, test the shield wire for good continuity to ground (under one ohm). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.25 © Copyright Polaris Industries Inc.
Page 326: Air Gap Test
4. Disconnect the coolant hose at the water pump. encoder flywheel tooth to the mounting surface of the CPS. 5. Remove the fasteners retaining the stator cover. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.26 © Copyright Polaris Industries Inc.
Page 327: Cps Replacement
9. Install a NEW or known good CPS. (see CPS Replacement). 10. Fill and bleed the coolant system (see Engine / Cooling System chapter) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.27 © Copyright Polaris Industries Inc.
Page 328: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.28 © Copyright Polaris Industries Inc.
Page 329: Fuel Injector
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.29 © Copyright Polaris Industries Inc.
Page 330 11. Install the new injector into the fuel rail. Be sure to align boss in the injector with the slot in the fuel rail. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.30 © Copyright Polaris Industries Inc.
Page 331: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.31 © Copyright Polaris Industries Inc.
Page 332: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.32 © Copyright Polaris Industries Inc.
Page 333: Ect Sensor Replacement
5. Torque the sensor to specification. TORQUE ETC Fasteners 7 ft-lbs (10 Nm) 6. Add the required amount of coolant and properly bleed the cooling system (see Engine chapter). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.33 © Copyright Polaris Industries Inc.
Page 334: Efi Diagnosis
• Never disconnect battery while engine is running. • Always unplug ECU from the wire harness before performing any welding on the unit. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.34 © Copyright Polaris Industries Inc.
Page 335: Trouble Code Display (Dtc)
MODE button or turn the ignition key OFF once the codes are recorded. 2. Press and hold the MODE button to enter the diagnostics code menu. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.35 © Copyright Polaris Industries 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.36 © Copyright Polaris Industries 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.37 © Copyright Polaris Industries 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.38 © Copyright Polaris Industries 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.39 © Copyright Polaris Industries Inc.
Page 340 520282 P152B Repeated Adaptation Failed Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.40 © Copyright Polaris Industries Inc.
Page 341 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.41 © Copyright Polaris Industries Inc.
Page 342: Digital Wrench® Operation
Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
Page 343: Polaris Mobile Digital Wrench (Pmdw)
Polaris Mobile Digital Wrench (PMDW) is a diagnostic software application (app) designed specifically for Android™ devices. When paired with the Wireless Vehicle Link (WVL), part number PU-51435, PMDW provides Polaris service technicians with many of the features and functions found in Digital Wrench.
Page 344: Digital Wrench® Updates
NOTE Always operate with the latest update. DIGITAL WRENCH® UPDATES Updates are released for Digital Wrench® via the Internet at: http://polaris.diagsys.com. The Digital Wrench® website can also be accessed through the dealer website at: www.polarisdealers.com. NOTE Only authorized Polaris dealers and distributors can access the dealer website.
Page 345 NOTE Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the install. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.45 © Copyright Polaris Industries Inc.
Page 346 8. When the update is complete, the version shown on the right side of the Digital Wrench® start-up screen should match the update you just downloaded. NOTE Versions and updates are subject to change. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.46 © Copyright Polaris Industries Inc.
Page 347: Digital Wrench® Communication Errors
Diagnostic procedures are added to subsequent versions of Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.47 © Copyright Polaris Industries Inc.
Page 348: Digital Wrench® Serial Number Location
Load the Vehicle Home View information from the Page. main ECU sensors. Open the Software Set up data capture and Configuration Screen. record functions. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.48 © Copyright Polaris Industries Inc.
Page 349: Ecu Replacement
(see Chapter 4 – Digital Wrench® Updates, page 4.44. • CLOSE NON-ESSENTIAL PROGRAMS: Polaris recommends that you DO NOT install non-essential programs on a Service Department laptop. Camera detection software, Virus Scanners, Tool Bars, etc. may clog up memory if running in the background and make it harder for the diagnostic software to operate.
Page 350 FUEL SYSTEM • Proceed to http://polaris.diagsys.com for specific information and FAQs on how to troubleshoot communication problems. • DON’T DISTURB THE PC: While reprogramming is in progress, don’t move the mouse and don’t touch the keyboard. The process only takes a few minutes, and is best left alone until complete.
Page 351 7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.51 © Copyright Polaris Industries Inc.
Page 352 Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop-down menu. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.52 © Copyright Polaris Industries Inc.
Page 353 11. Select the same file type from the list that you selected previously while in Digital Wrench®. Enter the VIN along with the customer’s name and address. When completed, click the Authorize button once to proceed. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.53 © Copyright Polaris Industries Inc.
Page 354 14. At this point the reflash process will begin. Do not touch the vehicle or PC during the process. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.54 © Copyright Polaris Industries Inc.
Page 355: Etc Learn Procedure
3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.55 © Copyright Polaris Industries Inc.
Page 356: Fuel System Troubleshooting
• Failed sensor or disconnected wiring • Fouled spark plug • TPS setting incorrect • Injector failure • Failed sensor or disconnected wiring • Throttle stop screw tampering 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 4.56 © Copyright Polaris Industries Inc.
Page 358: General Information
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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 359: Pvt System Overview
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 Red / 0-1800 10 RHF understands the procedures outlined in this manual.
Page 360: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 361: 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 363: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 364: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 365: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 366: Drive Belt
4. Remove the driven clutch mounting bolt. operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 5. Remove the outer sheave. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.10 © Copyright Polaris Industries Inc.
Page 367: Belt Installation
5. Install the outer clutch cover and (8) screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws: 50 in-lbs (5 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.11 © Copyright Polaris Industries Inc.
Page 368: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.12 © Copyright Polaris Industries Inc.
Page 369: Adjustment
Tool as shown in the inspection process. reassemble the PVT system as outlined in this chapter. Clutch Center Distance Tool PU-50658 TORQUE Rear Trans. Isolator Bolts: 40 ft-lbs (54 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.13 © Copyright Polaris Industries Inc.
Page 370: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.14 © Copyright Polaris Industries Inc.
Page 371: Clutch Disassembly
Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.15 © Copyright Polaris Industries Inc.
Page 372: Shift Weight Inspection
A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.16 © Copyright Polaris Industries Inc.
Page 373: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.17 © Copyright Polaris Industries Inc.
Page 374: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.18 © Copyright Polaris Industries Inc.
Page 375 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.19 © Copyright Polaris Industries Inc.
Page 376: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.20 © Copyright Polaris Industries Inc.
Page 377 30. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 31. Apply Loctite™ 609 evenly to bushing bore in cover. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.21 © Copyright Polaris Industries Inc.
Page 378: Clutch Assembly
To maintain proper clutch balance and belt-to-sheave clearance. be sure to reinstall the original quantity and thickness of washers / spacers beneath the spider during assembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.22 © Copyright Polaris Industries Inc.
Page 379 7. Reinstall cover, aligning “X” mark with other marks. 8. Torque cover bolts evenly to specification. TORQUE Drive Clutch Cover Screw: 8 ft-lbs (10 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.23 © Copyright Polaris Industries Inc.
Page 380: Driven Clutch Service
Plate, Retainer Roller, Clutch Screw Washer, Thrust 9 ft-lbs (12 Nm) Ring, Retaining E-Ring External Label, Clutch Boss Subassembly, Moveable Boss Washer, Thrust Spring, Compression 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.24 © Copyright Polaris Industries Inc.
Page 381: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.25 © Copyright Polaris Industries Inc.
Page 382: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.26 © Copyright Polaris Industries Inc.
Page 383: Pvt System Troubleshooting
-Replace belt. Harsh drive clutch engagement. -Excessive belt / sheave clearance with new -Perform belt / sheave clearance adjustment belt. with shim washers beneath spider. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.27 © Copyright Polaris Industries Inc.
Page 384 -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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 5.28 © Copyright Polaris Industries Inc.
Page 386: 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/ 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 387: 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 388: Transmission Gears
TRANSMISSION TRANSMISSION GEARS LUBRICATION Please refer to the Polaris Parts Catalog for gear tooth FLUID CAPACITY counts and part numbers. Recommended Transmission Lubricant: To access the Polaris Parts catalog please visit: AGL (PN 2878068) (Quart) Capacity: 41 oz. (1200 ml) http://parts.polarisind.com/browse/browse.asp...
Page 390 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 391: Shift Lever
(lever, cable, console, shift knob) cable to the shift lever and disconnect the cable end from the lever. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 392: Shift Cable
7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 393: 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). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 394: Transmission Installation
1. With the help of an assistant, position the transmission into the vehicle frame through the top. 16. Remove the wire ties retaining the main harness harness to transmission and mounts. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.10 © Copyright Polaris Industries Inc.
Page 395 5. In sequence, torque the eight engine coupler bracket fasteners to specification. TORQUE Engine to Trans Coupler Fasteners In Sequence:55 ft-lb (75 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.11 © Copyright Polaris Industries Inc.
Page 396 20. Install the throttle body, air box assembly and 12. Lubricate the transmission splines and mid prop ducting. shaft joint splines with Polaris All Purpose Grease. Install the prop shaft onto the transmission output 21. Reconnect the TPS and IAC harnesses.
Page 397 TRANSMISSION 23. Reinstall the cargo box. 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.13...
Page 398: Transmission Internals Service
An traction. electrical solenoid mounted in the rear portion of the gearcase actuates the shift fork. The solenoid plunger 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.14 © Copyright Polaris Industries Inc.
Page 399: Transmission Disassembly
(G). NOTE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.15 © Copyright Polaris Industries Inc.
Page 401 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). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.17 © Copyright Polaris Industries Inc.
Page 402 (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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.18 © Copyright Polaris Industries Inc.
Page 403 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.19 © Copyright Polaris Industries Inc.
Page 404: Planetary Differential Disassembly
1. Press the old bushing out of the ring gear. 2. Thoroughly clean the bore of the ring gear and check for any unwanted burs. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.20 © Copyright Polaris Industries Inc.
Page 405 5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.21 © Copyright Polaris Industries Inc.
Page 406: Planetary Differential Assembly
4. Apply Loctite® 2760™ to cover screws. 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.22 © Copyright Polaris Industries Inc.
Page 407: Gear / Shaft / Bearing Inspection
5. Install screws hand tight. Place assembly in soft jaw TORQUE vise and torque to specification. Differential Cover Screws: 22 ft-lbs (30 Nm) GEAR / SHAFT / BEARING INSPECTION 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.23 © Copyright Polaris Industries Inc.
Page 408: Snorkel Gear Backlash Procedure
8. Apply Loctite® 242™ to the threads of the bearing cover retaining screws. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.24 © Copyright Polaris Industries Inc.
Page 409 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.25 © Copyright Polaris Industries Inc.
Page 410 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.26 © Copyright Polaris Industries Inc.
Page 411 23. Install the rear output shaft assembly (C). Rotate output shaft assembly to align slots with engagement dog. Ensure bearing is fully seated upon assembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.27 © Copyright Polaris Industries Inc.
Page 412 Sealant (PN 2871557) to the left hand transmission mating surface. NOTE Shift fork pins should be offset towards the input shaft as shown above. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.28 © Copyright Polaris Industries Inc.
Page 413 Seals should be installed just past the case lead-in chamfer (.070" or 1.8 mm from outer face of bore). 33. Install the spacer onto the shift drum shaft. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.29 © Copyright Polaris Industries Inc.
Page 414 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.30 © Copyright Polaris Industries Inc.
Page 415: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 6.31 © Copyright Polaris Industries Inc.
Page 419: General Information
35 in-lbs (4 Nm) Screws Wheel Lug Nuts (Steel 36 ft-lbs (49 Nm) Wheels) Wheel Lug Nuts 30 ft-lbs + 90º (41 Nm + (Aluminum Wheels) 90º) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 420: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 421: Hub Installation
NOTE 8. Install hub cap. Use care to not allow any of the Loctite compound to get in the bearing. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 422 11. Install wheel, washers, wheel nuts, and tighten evenly in a cross pattern to specified torque. Refer to “Torque Specifications”. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 423: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 425: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 426: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.10 © Copyright Polaris Industries Inc.
Page 427 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). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.11 © Copyright Polaris Industries Inc.
Page 428: Front Gearcase Assembly View
Fill / Check Plug Roller Cage 10 ft-lbs (14 Nm) Roller Pinion Gear Spring Retainer Snap Ring Cover Plate Screws O-ring 11 ft-lbs (15 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.12 © Copyright Polaris Industries Inc.
Page 430: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.14 © Copyright Polaris Industries Inc.
Page 432: 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 7.14 for detailed inspection process. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.16 © Copyright Polaris Industries Inc.
Page 433 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.17 © Copyright Polaris Industries Inc.
Page 434 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.18 © Copyright Polaris Industries Inc.
Page 436 11. Install a new O-ring on the cover plate assembly. NOTE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.20 © Copyright Polaris Industries Inc.
Page 437 13. Install the output cover assembly onto the gearcase housing. Install the seven cover plate screws and torque to specification. TORQUE Cover Plate Screws: 11 ft-lbs (15 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.21 © Copyright Polaris Industries Inc.
Page 439 Torque: 11 ft-lbs (15 Nm) PLUG, OIL FILL Torque: 8-10 ft-lbs (11-14 Nm) RING, RETAINING, INTERNAL KIT, SPRING RING, RETAINING, EXTERNAL ASM., GEAR HOUSING AND PINION GEAR 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.23 © Copyright Polaris Industries Inc.
Page 440: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.24 © Copyright Polaris Industries Inc.
Page 441: Disassembly / Inspection, Front Gearcase (Adc)
6. Remove and inspect the armature plates . Refer to “AWD Diagnosis” for detailed inspection process. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.25 © Copyright Polaris Industries Inc.
Page 442 Inspect the roll cage for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.26 © Copyright Polaris Industries Inc.
Page 443 Inspect the input shaft bearing for signs of wear. Replace the input shaft cover O-ring prior to reassembly. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.27 © Copyright Polaris Industries Inc.
Page 444: Reassembly, Front Gearcase (Adc)
5. Press the pinion shaft seal into the gearcase, until the seal is flush. 6. Install the LH output hub into the gearcase housing. The output hub should spin freely. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.28 © Copyright Polaris Industries Inc.
Page 445 The output hub should spin freely. 10. Align the spring retainer dowel pin with the ring gear dowel pin and install the retainer on top of the torsion spring. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.29 © Copyright Polaris Industries Inc.
Page 446 16. Fill the gearcase with fluid. FLUID CAPACITY Demand Drive Hub Fluid 8.97 oz. (265 ml) 17. Install the drain plug. Torque to specification. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.30 © Copyright Polaris Industries Inc.
Page 447: Troubleshooting, Front Gearcase (Adc)
If it locks vehicle. to the drive train in only one direction, ADC is not indexing cage in both directions 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.31 © Copyright Polaris Industries Inc.
Page 448 If pole faces are severely problem has been fixed. If worn and damaged, not, continue onto replace output cover. additional problems listed. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.32 © Copyright Polaris Industries Inc.
Page 449 Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.33 © Copyright Polaris Industries Inc.
Page 450: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.34 © Copyright Polaris Industries Inc.
Page 451: Disassembly
4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. 5. Replace the bearing carrier bushings if worn or damaged. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.35 © Copyright Polaris Industries Inc.
Page 452: Installation
5. Install the wheel hub assembly onto the rear drive shaft. 6. Install the washers (domed side out) and the wheel hub castle nut 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.36 © Copyright Polaris Industries Inc.
Page 453 8. Carefully lower the vehicle. Torque the rear hub castle nut to specification. Install a new cotter pin TORQUE Rear Hub Castle Nut: 110 ft-lbs (150 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.37 © Copyright Polaris Industries Inc.
Page 454: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.38 © Copyright Polaris Industries Inc.
Page 455: Drive Shaft Service
OUTER CV JOINT / BOOT REPLACEMENT 1. Using side cutters, cut away and discard the boot clamps. NOTE Tap on inner race only! 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.39 © Copyright Polaris Industries Inc.
Page 456 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.40 © Copyright Polaris Industries Inc.
Page 457 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.41 © Copyright Polaris Industries Inc.
Page 458: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.42 © Copyright Polaris Industries Inc.
Page 459 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.43 © Copyright Polaris Industries Inc.
Page 460: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.44 © Copyright Polaris Industries Inc.
Page 462: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.46 © Copyright Polaris Industries Inc.
Page 463: Support Bearing Replacement (Crew)
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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.47 © Copyright Polaris Industries Inc.
Page 464: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.48 © Copyright Polaris Industries Inc.
Page 465: Assembly
If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 7.49 © Copyright Polaris Industries Inc.
Page 468: General Information
30 ft-lbs + 90º (41 Nm + (Aluminum Wheels) 90º) NOTE Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 469: Special Tools
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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 471 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 473 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 474: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 475: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 476: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.10 © Copyright Polaris Industries Inc.
Page 477: Power Steering Unit Removal
WARNING Electronic Power Steering (EPS) units are not interchangeable between ATV and RANGER product lines. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.11 © Copyright Polaris Industries Inc.
Page 478 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.12 © Copyright Polaris Industries Inc.
Page 479: Front Strut
2. Compress spring using strut spring compressor tools. REPLACEMENT 1. Hold strut rod and remove top nut. Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.13 © Copyright Polaris Industries Inc.
Page 480: Ball Joint Replacement
• Apply heat to ease installation. • Drive new joint into strut housing until fully seated. 5. Remove castle nut and separate A-arm from ball joint stud 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.14 © Copyright Polaris Industries Inc.
Page 481 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.15 © Copyright Polaris Industries Inc.
Page 482: Rear A-Arms
A-arm to new A-arm. the bearing carrier. Lower A-arm Removal 8. Remove the fastener attaching the lower A-arm to the bearing carrier. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.16 © Copyright Polaris Industries Inc.
Page 483: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.17 © Copyright Polaris Industries Inc.
Page 484: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.18 © Copyright Polaris Industries Inc.
Page 485: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.19 © Copyright Polaris Industries Inc.
Page 486: Assembly View
3. Reverse the procedure to reinstall the shock. Torque NEW fasteners to specification. TORQUE Shock Fasteners: 40 ft-lbs (54 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 8.20 © Copyright Polaris Industries Inc.
Page 489: General Information
Master Cylinder Mount 17 ft-lbs (23 Nm) Bolts 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 490: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 491: 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 492: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 493: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 494: Master Cylinder
6. Dispose of brake fluid properly and do not re-use. INSTALLATION Reverse Steps 1-5 for master cylinder installation. Refer to the torque specifications in the illustration. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 495: Brake Pressure Switch
TORQUE Brake Pressure Switch / Banjo Bolt: 15 ft-lbs (20 Nm) NOTE Always replace banjo washers if fastener is loosened or removed. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual © Copyright Polaris Industries Inc.
Page 496: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.10 © Copyright Polaris Industries Inc.
Page 497: Brake Service Procedures
Between the MIN and MAX line CAUTION Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir to prevent air from entering the master Polaris DOT 4 Brake Fluid cylinder. (P/N 2872189) 13. Tighten bleeder screw and remove bleeder hose.
Page 498: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.12 © Copyright Polaris Industries Inc.
Page 499: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.13 © Copyright Polaris Industries Inc.
Page 500: Pad Assembly / Installation- Ranger
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.14 © Copyright Polaris Industries Inc.
Page 501: Pad Inspection
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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.15 © Copyright Polaris Industries Inc.
Page 502: Pad Assembly / Installation- Crew
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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.16 © Copyright Polaris Industries Inc.
Page 503: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.17...
Page 504: Front Caliper Removal- Ranger
5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE Be sure to clean seal grooves in caliper body. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.18 © Copyright Polaris Industries Inc.
Page 505: 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 506: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.20 © Copyright Polaris Industries Inc.
Page 507: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.21...
Page 508: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.22 © Copyright Polaris Industries Inc.
Page 509: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.23 © Copyright Polaris Industries Inc.
Page 510: 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 511 5. Install wheel and torque wheel nuts to specification (see Chapter 2). NOTE If new brake pads are installed, brake burnishing is required. SeeBrake Burnishing Procedure, page 9.12. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.25 © Copyright Polaris Industries Inc.
Page 512: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.26 © Copyright Polaris Industries Inc.
Page 513: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.27 © Copyright Polaris Industries Inc.
Page 514: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.28 © Copyright Polaris Industries Inc.
Page 515: Rear Pad Installation
5. Fill master cylinder to Max level. 6. Burnish brakes as outlined in this chapter. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.29 © Copyright Polaris Industries Inc.
Page 516: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.30...
Page 517: Caliper Removal
NOTE Be sure to clean seal grooves in caliper body. 4. Clean disc, caliper body, and pistons with brake cleaner or alcohol. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.31 © Copyright Polaris Industries Inc.
Page 518: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.32 © Copyright Polaris Industries Inc.
Page 519: Rear Caliper Installation
If the brake drags, re-check assembly and installation. NOTE If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE PADS - Brake Burnishing Procedure”). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.33 © Copyright Polaris Industries Inc.
Page 520: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.34 © Copyright Polaris Industries Inc.
Page 521: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.35 © Copyright Polaris Industries Inc.
Page 522: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 9.36 © Copyright Polaris Industries Inc.
Page 524: General Information
Wheel Lug Nuts 36 ft-lbs (49 Nm) NOTE Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.2 © Copyright Polaris Industries Inc.
Page 525: Chassis / Body Assembly Views
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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.3 © Copyright Polaris Industries Inc.
Page 526: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.4 © Copyright Polaris Industries Inc.
Page 527: Cab Frame Assembly View
Nut - M10 1.5 (QTY.10) Nut - M8 x 1.25 (QTY.8) Nut - M10 x 1.25 (QTY.4) Used with part on 2017–2018 cab frames 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.5 © Copyright Polaris Industries Inc.
Page 528 Net Rod Mounts (Not Shown) Screw (Used to fasten Net Rod Mounts) Torque to 8 ft-lbs (11 Nm) 2017 CREW CAB FRAME ASSEMBLY VIEW 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.6 © Copyright Polaris Industries Inc.
Page 529 BODY / FRAME NOTE Image for reference only. 2016 cab frame shown. Refer to E-cat for an image of the 2017 cab frame. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.7 © Copyright Polaris Industries Inc.
Page 530 2017 cab frames Nets - Door Net Rod Mounts (Not Shown) Screw (Used to fasten Net Rod Mounts) Torque to 8 ft-lbs (11 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.8 © Copyright Polaris Industries Inc.
Page 531: Dash Instruments / Controls
BODY / FRAME DASH INSTRUMENTS / CONTROLS REF. DESCRIPTION NOTES Instrument Cluster Bezel Key Switch 12V Accessory Plug Turf Switch Dash Panel 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.9 © Copyright Polaris Industries Inc.
Page 532: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.10 © Copyright Polaris Industries Inc.
Page 533: Floor / Rear Fenders
FLOOR / REAR FENDERS REF. DESCRIPTION NOTES Front Floor Main Floor Floor Cover Cup Holder Push Rivet Screws Torque to 5 ft-lbs (7 Nm) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.11 © Copyright Polaris Industries Inc.
Page 534: 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.12 © Copyright Polaris Industries Inc.
Page 535: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.13 © Copyright Polaris Industries Inc.
Page 536: Crew Seat Mounting / Seat Belts
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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.14 © Copyright Polaris Industries Inc.
Page 537: Rear Cargo Box
BODY / FRAME REAR CARGO BOX CARGO BOX - TAILGATE / BOX SUPPORT 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.15 © Copyright Polaris Industries Inc.
Page 538 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) 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.16 © Copyright Polaris Industries Inc.
Page 539: Box Removal
CAUTION Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.17 © Copyright Polaris Industries Inc.
Page 540: Body Component Removal
3. Remove the two fasteners from each side of the upper portion of the bumper. 4. Carefully remove the bumper from the vehicle. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.18 © Copyright Polaris Industries Inc.
Page 541: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.19 © Copyright Polaris Industries Inc.
Page 542: Floors
3. Remove the seven Torx-head screws retaining the adequate clearance to remove the front floor section. center floor. 4. Remove the Torx-head screws retaining the front floor cover. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.20 © Copyright Polaris Industries Inc.
Page 543: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.21 © Copyright Polaris Industries Inc.
Page 544 BODY / FRAME NOTES 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 10.22 © Copyright Polaris Industries Inc.
Page 547: General Information
Battery Hydrometer 2870836 Authorized Polaris dealers/distributors are required to 2460761 Hall Sensor Probe Harness use the conductance analyzer when testing 12V Polaris Static Timing Light Harness 2871745 batteries. Digital Wrench™ Diagnostic Software PU-47063 Digital Wrench™ SmartLink Module Kit...
Page 548: Components Under Hood
• AWD/2WD/TURF Switch • 12 VDC Accessory Power Point • Ignition Switch • Instrument Cluster • Cooling Fan • TRS Connector • Brake Switch • Headlights 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.4 © Copyright Polaris Industries Inc.
Page 549: Switches / Controls
A and B; C and D; E • When the switch is in position #3 (TURF), there should and F. be continuity between terminals 1 (White/Green) and 2 (Orange/White). 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.5 © Copyright Polaris Industries Inc.
Page 550: Differential Solenoid
Check for power at the ECU and Rear Differential Solenoid Relay. • Check the switch wires for loose connections. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.6 © Copyright Polaris Industries Inc.
Page 551: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.7 © Copyright Polaris Industries Inc.
Page 552: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.8 © Copyright Polaris Industries Inc.
Page 553: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.9 © Copyright Polaris Industries Inc.
Page 554: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.10 © Copyright Polaris Industries Inc.
Page 555: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.11 © Copyright Polaris Industries Inc.
Page 556 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.12 © Copyright Polaris Industries Inc.
Page 557: Diagnostic Mode
MIL to illuminate. Diagnostic trouble codes 5. If more than one code exists, press the MODE button to advance to the next trouble code. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.13 © Copyright Polaris Industries Inc.
Page 558: Instrument Cluster Pinouts
Apply pressure on the bezel while pressing down on the instrument cluster. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.14 © Copyright Polaris Industries Inc.
Page 559: Headlights
(see illustration). Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.15 © Copyright Polaris Industries Inc.
Page 560: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.16 © Copyright Polaris Industries Inc.
Page 561: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.17 © Copyright Polaris Industries Inc.
Page 562: Cooling System
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.18 © Copyright Polaris Industries Inc.
Page 563: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.19 © Copyright Polaris Industries Inc.
Page 564: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.20 © Copyright Polaris Industries Inc.
Page 565: Relays
High side 12v from Start Orange 12v output to EPS unit Solenoid 12v output to Splice, Chassis Brown Chassis ground #2 Gray ECU controlled ground 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.21 © Copyright Polaris Industries Inc.
Page 566 ELECTRICAL • Rear Differential Solenoid Relay, controlled by the AWD/2WD/TURF switch and ECM, operates the differential solenoid to unlock the rear end. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.22 © Copyright Polaris Industries Inc.
Page 567: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.23 © Copyright Polaris Industries Inc.
Page 568: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.24 © Copyright Polaris Industries Inc.
Page 569: Charging System
(lights, etc.) and begins to charge the battery. Depending on battery condition and system load, the break even point may vary slightly. The battery should be fully charged before performing this test. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.25 © Copyright Polaris Industries Inc.
Page 570 Any measurement other than Infinity (open) will indicate a failed or shorted stator leg. TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.26 © Copyright Polaris Industries Inc.
Page 571: 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. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.27 © Copyright Polaris Industries Inc.
Page 572: 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 573: Battery Inspection
5. Check the vent tube. Make sure it’s not kinked, pinched or otherwise obstructed. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.29 © Copyright Polaris Industries Inc.
Page 574: Battery Removal / Installation
YuMicron™ Type 100% Charged 12.70 V 75% Charged 12.50 V 50% Charged 12.20 V 25% Charged 12.0 V 0% Charged 11.9 V or less 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.30 © Copyright Polaris Industries Inc.
Page 575: Specific Gravity Test
If electrolyte contacts the vehicle frame, corrosion will occur. 7. Route cables so they are tucked away in front and behind battery. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.31 © Copyright Polaris Industries Inc.
Page 576: Off Season Storage
ELECTRICAL OFF SEASON STORAGE See Chapter 2 “Maintenance” for battery service procedures. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.32 © Copyright Polaris Industries Inc.
Page 577: 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 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.33...
Page 578: Starter Solenoid Bench Test
5 seconds. With the solenoid energized, there should be continuity between terminals (A) and (B). If there is no continuity or high resistance, replace the starter solenoid. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.34 © Copyright Polaris Industries Inc.
Page 579: Starter Solenoid Operation
• The brake must be applied to provide a ground path provides a current path for 12V power to reach the via the Brown / Yellow wire. starter motor. 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.35 © Copyright Polaris Industries Inc.
Page 580: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual 11.36 © Copyright Polaris Industries Inc.
Page 581 Test ..............4.25 Breather Current Draw - Key Off ..........11.25 Hose ..............2.13 CV Shaft Boot Valve Inspection.............2.13 Inspection.............2.27 Cylinder Head Combustion Chamber Cleaning......3.71, 3.159 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual IX.1 © Copyright Polaris Industries Inc.
Page 582 EFI System Engine Coolant Temperature (ECT) Sensor Operation Overview ..........4.3 Overview ..............4.32 Electrical Sensor Test............4.32 Break Even Test........... 11.25 Engine Fastener Torque Specifications 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual IX.2 © Copyright Polaris Industries Inc.
Page 583 Assembly View ............4.17 Removal..............9.8 Installation ............4.18 Master Special Tools Table ........... 1.7 Removal...............4.17 Master Torque Table ..........1.15 Fuses ............11.23–11.24 Model Number Designation .......... 1.2 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual IX.3 © Copyright Polaris Industries Inc.
Page 584 Special Tools ..........1.6, 4.4, 6.3 Periodic Maintenance Chart.......... 2.5 Body/Steering/Suspension ......... 8.3, 10.2 Periodic Maintenance Chart Key........2.5 Brakes ..............9.3 Polaris Mobile Digital Wrench (PMDW) ......4.43 Electrical .............. 11.3 Power Steering Unit (EPS) Engine ..............3.6 Installation ............8.11 Final Drive .............
Page 585 Mechanical Seal / Oil Seal........3.28 Piston / Crank / Balance Shaft ......... 3.152 Wheel and Hub ............2.27 Removal / Installation ..........3.27 Torque Specifications Wheel 9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual IX.5 © Copyright Polaris Industries Inc.

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Ranger 570 2017 Ranger 500 2017 Ranger 570 2018

Polaris RANGER 500 2018 Service Manual

Chapter 1 1 General Information

Chapter 2 Maintenance

Chapter 3 Engine / Cooling System

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Chapters

Troubleshooting

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Summary of Contents for Polaris RANGER 500 2018