Polaris RANGER ETX 2015 Owner's Manual

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2015 - 2016 RANGER ETX / 570 2-SEAT

2015 - 2016 RANGER 570 CREW

FOREWORD

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

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

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

technicians in a properly

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

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

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

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

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

tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service

Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful.

Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask

Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

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

2100 Hwy 55, Medina, MN 55340.

Publication Printed October 2015 (PN 9926806 R03)

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 ETX 2015

Page 1 Publication Printed October 2015 (PN 9926806 R03) © Copyright 2015 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 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: 2015 - 2016 RANGER 4X4...
Page 4 2015-2016 RANGERETX/5702-SEAT 2015- 2016RANGER570CREW 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW 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: General Specifications
Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 9 Brake Fluid DOT 4 12 Volt Parking Brake Transmission - Park Lock DC Outlet Standard 12 Volt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 10: Model: 2015 Ranger 570
Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 11 Yuasa Conventional 14 Amp Hr / Parking Brake Transmission - Park Lock 12 Volt DC Outlet Standard 12 Volt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 12: Model: 2015 Ranger 570 Crew
Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 13 Battery / Amp Hr Yuasa Conventional 14 Amp Hr / 12 Volt DC Outlet Standard 12 Volt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 14: Model: 2016 Ranger Etx
Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.10 © Copyright Polaris Industries Inc.
Page 15 DOT 4 12 Volt Parking Brake Transmission - Park Lock DC Outlet Standard 12 Volt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.11 © Copyright Polaris Industries Inc.
Page 16: Model: 2016 Ranger 570 4X4
Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.12 © Copyright Polaris Industries Inc.
Page 17 Yuasa Conventional 14 Amp Hr / Parking Brake Transmission - Park Lock 12 Volt DC Outlet Standard 12 Volt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.13 © Copyright Polaris Industries Inc.
Page 18: Model: 2016 Ranger 570 2X4 (Intl.)
Towing Capacity 1500 lbs. / 680.4kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.14 © Copyright Polaris Industries Inc.
Page 19: 2016 Ranger 2X4 (Intl.)
Yuasa Conventional 14 Amp Hr / Parking Brake Transmission - Park Lock 12 Volt DC Outlet Standard 12 Volt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.15 © Copyright Polaris Industries Inc.
Page 20: Model: 2016 Ranger 570 Crew
Domestic Single Cyl., Liquid Platform Cooled, 4–Stroke, DOHC Engine Idle Speed 1200 +/- 100 RPM Engine Displacement 567cc 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.16 © Copyright Polaris Industries Inc.
Page 21 1/8 − 1/4″ (3.20 − 6.35 mm) Front Suspension Strut / A-arm Front Travel 8″ (20.3 cm) Rear Suspension Independent (IRS) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.17 © Copyright Polaris Industries Inc.
Page 22: Misc. Specifications And Charts
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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.18...
Page 23: 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 24: Replacement Keys
SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.20 © Copyright Polaris Industries Inc.
Page 25: Master Special Tools Table
Stator Cover Removal Handles Valve Spring Compressor Water Pump Seal Installation Tool PA-49317 PV-1253 PU-50869 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.21 © Copyright Polaris Industries Inc.
Page 26 PU-51038 (0-10 PSI / .69 - 69 KPa) Commercially Available Water Pump Seal Puller 2872105-A 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.22 © Copyright Polaris Industries Inc.
Page 27 PU-50784 Oil Pressure Gauge Oil Pressure Gauge Adapter Valve Spring Compressor Adapter PV-43531 PU-50569 PV-43513-A 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.23 © Copyright Polaris Industries Inc.
Page 28 Digital Wrench® Wireless Fuel Pressure Gauge Kit Fuel Pressure Gauge Adapter Vehicle Link PU-43506-A PV-48656 PU-51435 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.24 © Copyright Polaris Industries Inc.
Page 29 Serial Adaptor: Saelig RS-232 Commercially Available (refer to diagnostic software user manual or HELP section for minimum requirements) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.25 © Copyright Polaris Industries Inc.
Page 30 Universal Clutch Compressor Tool Standard Clutch Alignment Tool Clutch Center Distance Tool PU-50518-A 2870654 PU-50658-A 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.26 © Copyright Polaris Industries Inc.
Page 31 CV Boot Clamp Pliers 2870772 Installation Tool 8700226 or PU-48951 PA-48542 Roller Pin Removal Tool 2872608 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.27 © Copyright Polaris Industries Inc.
Page 32 Compression Tool 2870623 BRAKES Mity Vac® Pressure Test Tool 2870975 BODY / FRAME Multi-Function Pliers 2876389 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.28 © Copyright Polaris Industries Inc.
Page 33 PU-50296 PV-43568 Hall Sensor Probe Harness Static Timing Light Harness Timing Light 2460761 2871745 2870630 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.29 © Copyright Polaris Industries Inc.
Page 34: Master Torque Table
Step 2: 26 ft-lb (35 Nm) Front Bumper / Fender 5 ft-lbs (7 Nm) Screws Step 3: Additional 135° 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.30 © Copyright Polaris Industries Inc.
Page 35 Starter One-Way Clutch threads) 9 ft-lbs (12 Nm) Bolts 9 ft-lbs (12 Nm) Stator Cover Screws 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.31 © Copyright Polaris Industries Inc.
Page 36 36 ft-lbs (49 Nm) Wheels) Wheel Lug Nuts (Aluminum 30 ft-lbs + 90º (41 Nm + 90º) Wheels) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.32 © Copyright Polaris Industries Inc.
Page 37: Clutching Chart
25-52G Black (0-6000) (5632409) (7043594) Meters (Feet) 1800-3700 25-48 Black (6000 - 12000) (5633217) (7043594) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.33 © Copyright Polaris Industries Inc.
Page 38: Conversion Table
9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.34 © Copyright Polaris Industries Inc.
Page 39: Standard Bolt Torque Specification
159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.35 © Copyright Polaris Industries Inc.
Page 40: Sae Tap / Drill Sizes
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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.36 © Copyright Polaris Industries Inc.
Page 41: Metric Tap / Drill Sizes
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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.37 © Copyright Polaris Industries Inc.
Page 42: Decimal Equivalents
37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.38 © Copyright Polaris Industries Inc.
Page 43 24 mm = 0.9449″ 61/64 0.9531″ 31/32 0.9688″ 25 mm = 0.9843″ 63/64 0.9844″ 1.000″ 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 1.39 © Copyright Polaris Industries Inc.
Page 45 .......2.14 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS GENERAL MAINTENANCE................2.15 .
Page 48: Maintenance
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 49: Break-In Period
BREAK-IN PERIOD VEHICLE BREAK-IN PERIOD NOTE The break-in period for your new POLARIS vehicle is the Excessive heat build-up during the first three hours of first 25 hours of operation, or the time it takes to use the operation will damage close-fitted engine parts and first two tanks full of gasoline.
Page 50: Inspection / Maintenance Intervals
Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 51: 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 52 ▶ Engine mounts Inspect 100 H 12 M Exhaust muffler /pipe Inspect 100 H 12 M 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 53 ▶ = 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 54: 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). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.10 © Copyright Polaris Industries Inc.
Page 55 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 56: Component Quick Reference
*More often Under severe use, such as operated in water or under severe loads. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.12 © Copyright Polaris Industries Inc.
Page 57 4. Front Gearcase Fill Plug: 10–14 ft. lbs. (14–19 Nm) Drain Plub: 10–14 ft. lbs. (14–19 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.13 © Copyright Polaris Industries Inc.
Page 58: Service Products And Lubricants
MAINTENANCE SERVICE PRODUCTS AND LUBRICANTS 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 60: 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 61: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.17 © Copyright Polaris Industries Inc.
Page 62: Engine Air Intake Inspection
2. Verify there is no debris obstructing the airway. Airbox 3. Reinstall the cover. Boot Installation 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.18 © Copyright Polaris Industries Inc.
Page 63: Engine Common
MAINTENANCE ENGINE COMMON COMPRESSION AND LEAKDOWN TEST NOTE This Polaris 4-Stroke engine is equipped with an 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 64: Engine Oil Level Check - 325
If the oil level is over the full mark, change the oil. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.20 © Copyright Polaris Industries Inc.
Page 65 9. Place shop towels beneath the filter cover to catch oil drips. Remove the cover screws (item 3). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.21 © Copyright Polaris Industries Inc.
Page 67 (see PVT System). Torque to Compare results to the specifications. specification. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.23 © Copyright Polaris Industries Inc.
Page 68 4. Check the hoses for cracks, deterioration, abrasions or leaks. Replace as needed. 5. Reinstall the hoses and clamps. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.24 © Copyright Polaris Industries Inc.
Page 69: Engine Oil Level
If the oil level is over the full mark, change the oil. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.25 © Copyright Polaris Industries Inc.
Page 70: Valve Clearance - Dohc
23. Dispose of used filter and oil properly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.26 © Copyright Polaris Industries Inc.
Page 71: Breather Hose
Be sure breather line is routed properly and secured in place. CAUTION Make sure line(s) are not kinked or pinched. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.27 © Copyright Polaris Industries Inc.
Page 72: Transmission And Gearcases
11. Check for leaks. Dispose of used lubricant properly. 6. Place a drain pan under the transmission drain plug. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.28 © Copyright Polaris Industries Inc.
Page 73: Front Gearcase Lubrication
(refer to “Front Gearcase Fluid Level Check”). 7. Place a drain pan under the front gearcase drain plug 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.29 © Copyright Polaris Industries Inc.
Page 74: Cooling System
If not, perform the following: 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 75 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 76: 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 77: Coolant Strength / Type
Do not over-tighten hose clamps at radiator, or radiator fitting may distort. TORQUE Radiator Hose Clamp: 36 in-lbs (0.4 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.33 © Copyright Polaris Industries Inc.
Page 78: Radiator Inspection / Cleaning
Use of a high-pressure washer is not the frame bracket. Set the recovery bottle out of the recommended. way. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.34 © Copyright Polaris Industries Inc.
Page 79 10. Remove the four bolts that retain the fan motor and shroud to the radiator. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.35 © Copyright Polaris Industries Inc.
Page 80: Final Drive / Wheel And Tire
4. Remove the wheel nuts and washers and remove the wheel. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.36 © Copyright Polaris Industries Inc.
Page 81: Wheel Installation
Worn tires can cause an accident. Always replace tires when the usable tread depth has worn out. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.37 © Copyright Polaris Industries Inc.
Page 82: Electrical And Ignition System
(black) cable first. When reinstalling the battery, install the negative cable last. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.38 © Copyright Polaris Industries Inc.
Page 83: Battery Installation
NOTE 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 tenders can be left connected during the storage 4.
Page 84: 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.40 © Copyright Polaris Industries Inc.
Page 85: 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 86: Wheel Toe Alignment Inspection
• Hold tie rod end to keep it from rotating. • Loosen jam nuts at both end of the tie rod. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.42 © Copyright Polaris Industries Inc.
Page 87: Camber And Caster
Tie Rod Jam Nut: 14 ft-lbs (19 Nm) CAMBER AND CASTER The camber and caster are non-adjustable. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.43 © Copyright Polaris Industries Inc.
Page 89: Brake System
Tighten any loose fittings and replace any worn or damaged parts. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.45 © Copyright Polaris Industries Inc.
Page 90: Brake Disc Inspection
5. Adjust cable outward to tighten brake. protects the park brake pads from excessive wear. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.46 © Copyright Polaris Industries Inc.
Page 91 Service Limit: 0.31 in (7.87 mm) MEASUREMENT Parking Brake Disc Thickness: 0.150-0.164 in (3.81-4.16 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 2.47 © Copyright Polaris Industries Inc.
Page 98: General Information
Oil Pressure Gauge (0–10 psi / 6.9–69 kPa) Commercially Available Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 99: Engine Lubrication Specifications
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 100: Engine Oil Flow Chart
ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 101: Engine Specifications
Valve Seat - Contacting Width - Exhaust Valve Seat 17° ± 1.5° Valve Seat Angles 45° ± 0.5° 70° ± 1.5° 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 102 Bearing Journal O.D. (Oil Pump End) damage or wear is found. Rotor tip clearance .0059 in. / 0.150 mm 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.10 © Copyright Polaris Industries Inc.
Page 103: Engine Detail - Torque Values - Sequences
Flywheel Retaining Nut 133 ft-lbs (180 Nm) Torque to specification, back of 180 degrees, retorque to specification. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.11 © Copyright Polaris Industries Inc.
Page 104 44 ft-lbs (59 Nm) Engine Screws (In sequence) Rear Engine Mount to 23 ft-lbs (31 Nm) Frame Fasteners 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.12 © Copyright Polaris Industries Inc.
Page 105: Spark Plug / Throttle Body / Thermostat
ENGINE / COOLING SYSTEM SPARK PLUG / THROTTLE BODY / THERMOSTAT 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.13 © Copyright Polaris Industries Inc.
Page 106: Stator Cover / Valve Cover / Oil Sump Cover
Loctite 603 (Green) can be used if 641 is not available. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.14 © Copyright Polaris Industries Inc.
Page 107: Camshafts / Cam Carrier / Cam Chain Tensioner
ENGINE / COOLING SYSTEM CAMSHAFTS / CAM CARRIER / CAM CHAIN TENSIONER 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.15 © Copyright Polaris Industries Inc.
Page 108: Cylinder Head / Crankcase
ENGINE / COOLING SYSTEM CYLINDER HEAD / CRANKCASE 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.16 © Copyright Polaris Industries Inc.
Page 109: Crankshaft / Balance Shaft / Cam Chain Guides
ENGINE / COOLING SYSTEM CRANKSHAFT / BALANCE SHAFT / CAM CHAIN GUIDES 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.17 © Copyright Polaris Industries Inc.
Page 110: Engine Mounting Torque Specifications
ENGINE / COOLING SYSTEM ENGINE MOUNTING TORQUE SPECIFICATIONS 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.18 © Copyright Polaris Industries Inc.
Page 111: Engine / Transmission Coupler Bracket Torque Sequence
ENGINE / COOLING SYSTEM ENGINE / TRANSMISSION COUPLER BRACKET TORQUE SEQUENCE 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.19 © Copyright Polaris Industries Inc.
Page 112: Cylinder Head Torque Specification / Sequence
ENGINE / COOLING SYSTEM CYLINDER HEAD TORQUE SPECIFICATION / SEQUENCE 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.20 © Copyright Polaris Industries Inc.
Page 113: Stator Cover Torque Sequence
Turn the engine by rotating the drive clutch or similar method to turn balance shaft. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.21 © Copyright Polaris Industries Inc.
Page 114: Oil Sump Cover Torque Sequence
OIL SUMP COVER TORQUE SEQUENCE NOTE Install new sump cover gasket whenever the sump is removed from the crankcase. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.22 © Copyright Polaris Industries Inc.
Page 115: Lower Crankcase Sealant Pattern
ENGINE / COOLING SYSTEM LOWER CRANKCASE SEALANT PATTERN 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.23 © Copyright Polaris Industries Inc.
Page 116: 325 Exhaust System
Exhaust Manifold Bolts 18 ft-lbs (24 Nm) Hex Nuts 18 ft-lbs (24 Nm) Washers Lock Washers 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.24 © Copyright Polaris Industries Inc.
Page 117: Engine Cooling System
ENGINE / COOLING SYSTEM ENGINE COOLING SYSTEM COOLING SYSTEM FLOW 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.25 © Copyright Polaris Industries Inc.
Page 118: Cooling System Assembly View
Recovery Tank Tube Radiator Lower Mount Bushing Radiator Clamp Springband Coolant Tube In Coolant Tube Out 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.26 © Copyright Polaris Industries Inc.
Page 119: 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 120: Radiator
8. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.28 © Copyright Polaris Industries Inc.
Page 121: Thermostat Inspection / Replacement
7.3 ft–lbs (10 Nm) 6. Refill and bleed the cooling system. (Refer to “Cooling System Bleeding Procedure”). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.29 © Copyright Polaris Industries Inc.
Page 123: Water Pump Service
Continue prying around the outer surface circumference until the seal body is removed from the bore. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.31 © Copyright Polaris Industries Inc.
Page 124 Torque screws to specification. TORQUE Water Pump Cover Screw: 7 ft-lbs (10 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.32 © Copyright Polaris Industries Inc.
Page 125: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.33 © Copyright Polaris Industries Inc.
Page 126 19. Disconnect the upper engine coolant hose, bypass hose and ECT harness connector. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.34 © Copyright Polaris Industries Inc.
Page 127 26. Using a 12 mm hex drive, turn the take-up nuts (3) clockwise to release the transmission ears from the mount. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.35 © Copyright Polaris Industries Inc.
Page 129 2015-18 RANGER 570 Full-Size duct, intake boot and air box. 2014-18 RANGER 900/1000 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.37 © Copyright Polaris Industries Inc.
Page 130 / coolant. 25. If the engine oil was completely drained, add approximately 1.75 quarts (1.65 L) of Polaris PS-4 Synthetic Engine Oil into the crankcase. 26. Install a new oil filter. 27. Connect the (-) negative battery cable to the battery.
Page 131: Engine Break-In Period
Polaris PS-4 Synthetic Engine Oil CAUTION Oil Pressure Minimum Specifications (using Polaris PS-4 at operating temperature) Use only Polaris PS-4 Synthetic Engine Oil. 1.0 PSI @ 1200 RPM (Minimum) 5.0 PSI @ 7000 RPM (Minimum) Never substitute or mix oil brands.
Page 132: Engine To Transmission Coupler Service
Remove the lock nuts and washers from the engine to transmission adapter mounting bolts (3) and discard. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.40 © Copyright Polaris Industries Inc.
Page 134: Setting Tdc (Top-Dead-Center)
TDC of the compression stroke. 3. See Camshaft Timing - Quick Reference, page 3.67 for additional information. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.42 © Copyright Polaris Industries Inc.
Page 135: Engine Disassembly / Inspection - Top End
After cleaning valve cover, reinstall breather plate and torque screws to specification. TORQUE Valve Cover Breather Plate Screws: 3 ft-lbs (4 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.43 © Copyright Polaris Industries Inc.
Page 136: Camshaft / Carrier Removal
4. Install PA-51430 Camshaft Sprocket Tool on the intake camshaft sprocket and remove the intake camshaft sprocket bolt. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.44 © Copyright Polaris Industries Inc.
Page 137: Camshaft Carrier Disassembly
Snap Ring Decompression Spring Bearing Decompression Shaft Intake Camshaft Decompression Disc Bearing Support Screw Bearing 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.45 © Copyright Polaris Industries Inc.
Page 138 MAG side bearing support. 8. Reverse disassembly procedure for reassembly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.46 © Copyright Polaris Industries Inc.
Page 139: Camshaft Sprocket Inspection
1. Visually inspect each cam lobe for wear or damage. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.47 © Copyright Polaris Industries Inc.
Page 140 The cam on the flyweight rotates into recess on the camshaft and no longer makes contact with the tappet. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.48 © Copyright Polaris Industries Inc.
Page 141: Camshaft Oil Jet
2. Remove and discard the nuts that retain the cylinder head and the cylinder. 3. Remove the cylinder head bolts. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.49 © Copyright Polaris Industries Inc.
Page 142: Cylinder Head Inspection
Do not touch sealing surfaces of the new head gasket. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.50 © Copyright Polaris Industries Inc.
Page 143: Cylinder Head Warp Inspection
Intake Valve Stem Diameter: .1958–.196 in. / 4.975-4.990 mm Exhaust Valve Stem Diameter: .1950–.1956 / 4.955-4.970 mm 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.51 © Copyright Polaris Industries Inc.
Page 144: Valve Sealing Test
The valve seats should hold fluid with no seepage. 3. Repeat for exhaust valves by pouring fluid into each exhaust port 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.52 © Copyright Polaris Industries Inc.
Page 145: Valve Seat Reconditioning
6. Insert valve into guide and tap valve lightly into place a few times. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.53 © Copyright Polaris Industries Inc.
Page 146 * 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.54 © Copyright Polaris Industries Inc.
Page 147: Cylinder Removal
*Using a piston ring pliers: Carefully expand ring 3. Inspect cylinder for wear, scratches, or damage. and lift it off the piston. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.55 © Copyright Polaris Industries Inc.
Page 148: Piston-To-Cylinder Clearance
.0003 - .002″ (.008 - .062 mm) Piston O.D.: 3.068 - 3.07″ (77.946 – 77.984 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.56 © Copyright Polaris Industries Inc.
Page 149: Piston Ring Installed Gap
Always check piston ring installed gap after re-boring a cylinder or when installing new rings. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.57 © Copyright Polaris Industries Inc.
Page 150: Engine Assembly - Top End
6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.58 © Copyright Polaris Industries Inc.
Page 151: Piston / Connecting Rod Assembly
4. Verify all ring end gaps are correctly located on the piston. Place cam chain and guides in alignment with chain tunnel. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.59 © Copyright Polaris Industries Inc.
Page 152: Cylinder Installation - Piston In Cylinder
Orientate band tool so that open end is opposite the MAG side of the piston. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.60 © Copyright Polaris Industries Inc.
Page 154: Cylinder Head Assembly
13. After the piston pin and circlip are installed, slide the engine oil. cylinder down onto the crankcase. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.62 © Copyright Polaris Industries Inc.
Page 155: Cylinder Head Installation
5. Install and finger tighten the new cylinder head bolts evenly. 6. Install and finger tighten the cylinder head nuts evenly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.63 © Copyright Polaris Industries Inc.
Page 156: Camshaft Installation / Timing
7. Torque the cylinder head nuts in sequence to 3. Lubricate all camshaft lobes and bearing journal specifications. surfaces with Polaris PS-4 engine oil prior to installation. 4. Wrap the cam chain around the exhaust cam sprocket and hold the exhaust cam in its current position.
Page 157 8. Verify cam timing is correct and the piston is at TDC TORQUE Camshaft Carrier Bolts: 7 ft-lbs (10 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.65 © Copyright Polaris Industries Inc.
Page 158 6 ft-lbs (8 Nm) 14. Push the detent down and push the ram into the housing. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.66 © Copyright Polaris Industries Inc.
Page 159: Camshaft Timing - Quick Reference
ENGINE / COOLING SYSTEM CAMSHAFT TIMING - QUICK REFERENCE 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.67 © Copyright Polaris Industries Inc.
Page 160: Valve Clearance Adjustment
This engine features one-piece tappets / shims. The shims are not removable from the tappets. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.68 © Copyright Polaris Industries Inc.
Page 161: Valve Cover Installation
4. Install the spark plug and torque to specification. TORQUE Spark Plug: 9 ft-lbs (12 Nm)Do Not Apply Anti-seize 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.69 © Copyright Polaris Industries Inc.
Page 162: 325 Intake Valve Lash - Tappet Selection Matrix
0.926-0.950 535 538 540 542 545 548 550 0.951-0.975 538 540 542 545 548 550 0.976-1.000 540 542 545 548 550 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.70 © Copyright Polaris Industries Inc.
Page 163: 325 Exhaust Valve Lash - Tappet Selection Matrix
0.526-0.550 0.551-0.575 0.576-0.600 0.601-0.625 0.626-0.650 0.651-0.675 0.676-0.700 0.701-0.725 0.726-0.750 0.751-0.775 0.776-0.800 0.801-0.825 0.826-0.850 0.851-0.875 0.876-0.900 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.71 © Copyright Polaris Industries Inc.
Page 164: Engine Disassembly / Inspection - Lower End
Inspect shaft and shaft bearing surfaces in case and stator housing for wear. 9. Tighten center bolt of tool PA-49316 and remove flywheel. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.72 © Copyright Polaris Industries Inc.
Page 165: Stator Removal
4. Remove starter gear from the flywheel assembly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.73 © Copyright Polaris Industries Inc.
Page 166: Oil Pump Removal
Retaining Ring Gerotor Washer Pin, Solid Piston / Spring Shaft, Oil Pump Oil Seal Gerotor 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.74 © Copyright Polaris Industries Inc.
Page 167: Oil Pressure Regulator (Bypass) Valve Inspection
4. Thoroughly clean the piston and bore. towards cover. Press until seal is fully seated in bore 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.75 © Copyright Polaris Industries Inc.
Page 168: Balance Shaft Removal / Inspection
1. Support the engine so oil sump cover side is facing upward. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.76 © Copyright Polaris Industries Inc.
Page 169: Crankshaft Removal
Small End I.D. Standard: .7086 - .709″ (18.000 - 18.018 mm) Service Limit: .710″ (18.036 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.77 © Copyright Polaris Industries Inc.
Page 171: Oil Pickup Assembly Inspection
2. Be sure alignment pins are in place where used. 3. Be sure oil passages are clean and free of any cleaning solvent. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.79 © Copyright Polaris Industries Inc.
Page 172: Engine Assembly - Lower End
Once the crankcases are mated and the retainer plate secured, the cam chain will be held in place on the crankshaft. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.80 © Copyright Polaris Industries Inc.
Page 173: Balance Shaft Installation / Timing
13 ft-lbs (17 Nm) (Replacement required) 14. Proceed with installing the top-end of the engine. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.81 © Copyright Polaris Industries Inc.
Page 174: Starter One-Way Clutch Installation
3. Apply Loctite® 272™ on the one way clutch retaining bolts threads . Place hub on flywheel and install bolts. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.82 © Copyright Polaris Industries Inc.
Page 175 Flywheel Retaining Nut: 133 ft-lbs (180 Nm)Torque to specification, back of 180 degrees, retorque to specification. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.83 © Copyright Polaris Industries Inc.
Page 176: Oil Pump Assembly
#105 or equivalent). Stator Cover BoltsStator to Cover Retaining Bolts: 9 ft-lbs (12 Nm)Apply Loctite® 242™ 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.84 © Copyright Polaris Industries Inc.
Page 177 ENGINE / COOLING SYSTEM TORQUE Stator Wire Bracket Bolts: 6 ft-lbs (9 Nm)Apply Loctite® 242™ 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.85 © Copyright Polaris Industries Inc.
Page 178: Engine / Cooling System Troubleshooting
• Ignition or kill switch circuit faulty • Poor connections in ignition system • Ignition timing incorrect • Sheared flywheel key 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.86 © Copyright Polaris Industries Inc.
Page 179: Cooling System Troubleshooting
• Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.87 © Copyright Polaris Industries Inc.
Page 180: General Information
43513-A Water Pump Mechanical / Oil Seal Installation 50689 Bosch Automotive Service Solutions: 1-800-345-2233 http://polaris.service-solutions.com/. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.88 © Copyright Polaris Industries Inc.
Page 181: Engine Lubrication Specifications
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 182: Engine Oil Flow Chart
ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.90 © Copyright Polaris Industries Inc.
Page 183: Engine Specifications
Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.91 © Copyright Polaris Industries Inc.
Page 184 See Service Procedure Listed In This Chapter Bearing Journal O.D. (Standard) 1.1798 - 1.1802″ (29.969 - 29.979 mm) Balance Shaft 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.92 © Copyright Polaris Industries Inc.
Page 185: Engine Detail
Engine Coupler (Rear) In Sequence: 55 ft-lb (75 Nm) Exhaust Head Pipe Bolts 18 ft-lb (25 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.93 © Copyright Polaris Industries Inc.
Page 186 9 ft-lbs (12 Nm) (Apply Loctite® 204™ to bolt threads) Water Pump Impeller Finger Tight *LH threads 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.94 © Copyright Polaris Industries Inc.
Page 188: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
ENGINE / COOLING SYSTEM CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.96 © Copyright Polaris Industries Inc.
Page 189: Cylinder / Oil Filter / Oil Pump / Breather
Apply a drop of Loctite 641 (Yellow) to the crankshaft taper before assembly. Loctite 603 (Green) can be used if 641 is not available. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.97 © Copyright Polaris Industries Inc.
Page 191: Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts
ENGINE / COOLING SYSTEM CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.99 © Copyright Polaris Industries Inc.
Page 192: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.100 © Copyright Polaris Industries Inc.
Page 193: Piston / Crankshaft / Balance Shaft
ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.101 © Copyright Polaris Industries Inc.
Page 194: Engine Cooling System
Recovery Bottle Radiator Drain Plug Upper Radiator Hose Lower Radiator Hose Bypass Hose Water Pump Hose 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.102 © Copyright Polaris Industries Inc.
Page 195: 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 196: Pressure Cap Test
Use of a high-pressure washer is not recommended. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.104 © Copyright Polaris Industries Inc.
Page 197: Coolant Drain / Radiator Removal
8. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.105 © Copyright Polaris Industries Inc.
Page 198: 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 199: Water Pump Cover And Impeller Service (Stator Cover Remains On Engine)
11. Remove the pressure cap. Add the necessary cover gasket . Discard the water pump gasket amount of Polaris Premium Antifreeze to the radiator filler neck. 10. Using an 8mm socket, remove the water pump impeller 12. Open the bleed screw to allow any trapped air to escape.
Page 200: Water Pump Mechanical Seal / Oil Seal Replacement
. Discard the water pump gasket. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.108 © Copyright Polaris Industries Inc.
Page 201 Be sure engine coolant does not contaminate the engine oil during stator cover service. Water Pump Assembly 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.109 © Copyright Polaris Industries Inc.
Page 202 PU-50869 Item #1. 26. Lubricate the new water pump oil seal with clean engine oil. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.110 © Copyright Polaris Industries Inc.
Page 203 33. If needed, install the stator cover removal handles tool PA-49317 to the water cover bolt holes to aid in stator cover installation. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.111 © Copyright Polaris Industries Inc.
Page 204 Stator Cover and Water Pump Cover: 9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt threads) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.112 © Copyright Polaris Industries Inc.
Page 205 48. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 49. Check for leaks. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.113 © Copyright Polaris Industries Inc.
Page 206: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.114 © Copyright Polaris Industries Inc.
Page 207 Plug CPS hole with clean shop towel. Inspect CPS O-ring and replace if needed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.115 © Copyright Polaris Industries Inc.
Page 208 24. Loosen the (2) bolts and nuts (Item 6) so the engine mount bracket can be slightly tilted away from engine. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.116 © Copyright Polaris Industries Inc.
Page 209: Engine Installation
RGR ETX 2013–18 RZR 570 2014–18 RANGER 500/570 2015-18 RANGER 570 Full-Size 2014-18 RANGER 900/1000 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.117 © Copyright Polaris Industries Inc.
Page 211 / 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 212: Engine Break-In Period
Oil Filter Wrench CAUTION PU-50105 or 2.5” (64 mm) Use only Polaris PS-4 Synthetic Engine Oil. Oil Type Never substitute or mix oil brands. Polaris PS-4 Synthetic Engine Oil Serious engine damage and voiding of warranty can result.
Page 213: Engine Mounting And Torque Values
Torque to 40 ft-lbs (54 Nm) Torque to 25 ft-lbs (34 Nm) Bolt Torque to 18 ft-lbs (25 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.121 © Copyright Polaris Industries Inc.
Page 214: Setting Tdc (Top-Dead-Center)
TDC by aligning the timing hole in crank case with a timing hole in the crankshaft. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.122 © Copyright Polaris Industries Inc.
Page 215 View the timing marks on the cam shaft sprockets to ensure the engine is at TDC of the compression stroke. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.123 © Copyright Polaris Industries Inc.
Page 216: Engine Disassembly / Inspection - Top End
(if further engine disassembly is required). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.124 © Copyright Polaris Industries Inc.
Page 217: Camshaft Sprocket Inspection
TORQUE Camshaft Sprocket Bolt: 14 ft-lb (19 Nm)Replace camshaft sprocket bolt if loosened or removed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.125 © Copyright Polaris Industries Inc.
Page 218: Camshaft Inspection
Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm) Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.126 © Copyright Polaris Industries Inc.
Page 219: Cam Chain And Guide Service
TORQUE Upper Cam Chain Guide Fasteners: 7 ft-lb (10 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.127 © Copyright Polaris Industries Inc.
Page 220: Cylinder Head Disassembly
8. Clean the combustion chamber and head gasket surface. Valve Spring Compressor Adapter PV-43513-A 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.128 © Copyright Polaris Industries Inc.
Page 221: Cylinder Head Identification
NOTE NOTE 2016 to Current Cylinder Head 2016 to Current Crankcases use dowels. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.129 © Copyright Polaris Industries Inc.
Page 222: Cylinder Head Inspection
The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.130 © Copyright Polaris Industries Inc.
Page 223: Combustion Chamber Cleaning
8. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.131 © Copyright Polaris Industries Inc.
Page 224: Valve Seat Reconditioning
6. Insert valve into guide and tap valve lightly into place a few times. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.132 © Copyright Polaris Industries Inc.
Page 226: Cylinder Removal
(1/2" down from top, in the middle, and 1/2” up from bottom). 6. Remove and discard cylinder base gasket. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.134 © Copyright Polaris Industries Inc.
Page 227: Piston Removal
5. Remove oil control ring top rail first, then bottom rail. 6. Remove oil control ring expander. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.135 © Copyright Polaris Industries Inc.
Page 228: Piston / Rod Inspection
1” (25.4 mm) down from the cylinder head gasket surface. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.136 © Copyright Polaris Industries Inc.
Page 229: Honing To Oversize
NOTE Do not allow cylinder to heat up during honing. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.137 © Copyright Polaris Industries Inc.
Page 230: Cylinder Hone Selection / Honing Procedure
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 231 “E” marks aligned with gasket surface. 7. Carefully install the camshaft carrier onto the camshafts. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.139 © Copyright Polaris Industries Inc.
Page 232 30 ft-lb (40 Nm) 17. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.140 © Copyright Polaris Industries Inc.
Page 233: Camshaft Timing - Quick Reference
CPS mounting hole. the crankcase and into the crankshaft locating hole 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.141 © Copyright Polaris Industries Inc.
Page 234: Engine Assembly - Top End
6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.142 © Copyright Polaris Industries Inc.
Page 235: Piston / Connecting Rod Assembly
Warm piston crown with a heat gun if pin cannot be installed by hand, or use a piston pin installation tool. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.143 © Copyright Polaris Industries Inc.
Page 236: Cylinder Installation
5. Dip the seat , valve spring and retainer clean engine oil. 6. Install the valve spring seat 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.144 © Copyright Polaris Industries Inc.
Page 237: Valve Sealing Test
12. Exercise each valve through its travel to ensure the valve keepers are seated correctly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.145 © Copyright Polaris Industries Inc.
Page 238: Cylinder Head Identification
NOTE NOTE 2016 to Current Cylinder Head 2016 to Current Crankcases use dowels. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.146 © Copyright Polaris Industries Inc.
Page 239: Cylinder Head Installation - Black Bolts
4. Carefully set the cylinder head in place on alignment pins. NOTE Install new cylinder head bolts. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.147 © Copyright Polaris Industries Inc.
Page 240: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.148 © Copyright Polaris Industries Inc.
Page 241: Valve Clearance Check / Adjustment
Torque The Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) 3. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head. The camshaft lobes should face out.
Page 242 If all valve clearance measurements are within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.150 © Copyright Polaris Industries Inc.
Page 243 20. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.151 © Copyright Polaris Industries Inc.
Page 244: 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.152 © Copyright Polaris Industries Inc.
Page 245: 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.153 © Copyright Polaris Industries Inc.
Page 246: Valve Cover Installation
6. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.154 © Copyright Polaris Industries Inc.
Page 247: Engine Disassembly / Inspection - Lower End
It should turn smoothly without binding. 3. Rotate gear counterclockwise. The gear should immediately lock in position and not slip. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.155 © Copyright Polaris Industries Inc.
Page 249: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.157 © Copyright Polaris Industries Inc.
Page 250: Oil Pump Removal
OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.158 © Copyright Polaris Industries Inc.
Page 251 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.159 © Copyright Polaris Industries Inc.
Page 252: Oil Pump Assembly
Oil Pressure Minimum Specification 2. Align the gerotor according to the orientation dots. (using Polaris PS-4 at operating temperature) 3. Place the drive pin through the oil pump drive 10 PSI @ 1200 RPM (Minimum) shaft.
Page 253: Crankcase Separation
3. Remove and discard the fifteen flange bolts from magneto side crankcase evenly in a criss-cross pattern. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.161 © Copyright Polaris Industries Inc.
Page 254: Balance Shaft Removal / Inspection
The inner race should be firm with minimal side to side movement and no detectable up and down (radial) movement. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.162 © Copyright Polaris Industries Inc.
Page 255: Crankshaft Removal
4. Remove all special tools from the crankcase. 0.8665 - 0.8670″ (22.010 - 22.023 mm) Service Limit: 0.08682″ (22.053 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.163 © Copyright Polaris Industries Inc.
Page 256: Pto Side Crankcase Bearing Service
Bearing Spacer secure the bearing retainer to the case. 3. Remove the retaining ring. Retaining Ring 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.164 © Copyright Polaris Industries Inc.
Page 257: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.165 © Copyright Polaris Industries Inc.
Page 258: Oil Pickup Assembly Inspection
5. Replace the o-ring and lubricate with clean engine oil. 6. Press the oil pressure valve into the crankcase until fully seated. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.166 © Copyright Polaris Industries Inc.
Page 259: Engine Assembly - Lower End
7. Remove the crankshaft removal / installation tool from the crankcase. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.167 © Copyright Polaris Industries Inc.
Page 260 11. Drive seal until flush with seal bore. 12. Turn PTO crankcase over and support with crankshaft upright. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.168 © Copyright Polaris Industries Inc.
Page 261: Balance Shaft Installation / Timing
5. Install the new crankcase bolts finger tight in MAG side crankcase. 6. Tighten all bolts evenly until snug. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.169 © Copyright Polaris Industries Inc.
Page 262 10. Place engine onto the engine stand for top end engine assembly as outlined in this chapter. Engine Stand: PU-50624-A 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.170 © Copyright Polaris Industries Inc.
Page 263: Starter One-Way Clutch Installation
9 ft-lbs (12 Nm) Apply Loctite® 272™ 4. Rotate crankshaft so the flywheel key is facing upward. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.171 © Copyright Polaris Industries Inc.
Page 264 9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.172 © Copyright Polaris Industries Inc.
Page 265: Stator / Stator Cover Installation
9 ft-lbs (12 Nm)Apply Loctite® 242™ TORQUE Stator Wire Retainer: 6 ft-lbs (9 Nm) Apply Loctite® 242™ 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.173 © Copyright Polaris Industries Inc.
Page 266: Troubleshooting
• Restricted exhaust muffler • Cam worn excessively Piston Failure - Scoring • Lack of lubrication 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.174 © Copyright Polaris Industries Inc.
Page 267 • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 3.175 © Copyright Polaris Industries Inc.
Page 270 ............4.45 POLARIS MOBILE DIGITAL WRENCH (PMDW) .
Page 272: General Information
NOTE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 273: 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 274: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 275: 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 276: Efi Component Locations
High Tension Wire / Spark Plug Throttle Body (ETC) Speed Sensor (Mounted to Transmission) Stator (Magneto) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 277: Efi Component Locations - Left View
Starter Motor Solenoid Regulator / Rectifier Fuse / Relay Box Starter Motor Ignition Coil Engine Temperature Sensor (ECT) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 279: Air Box / Intake System
FUEL SYSTEM AIR BOX / INTAKE SYSTEM AIR BOX / AIR FILTER ASSEMBLY VIEW - 325 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.11 © Copyright Polaris Industries Inc.
Page 280: Air Box / Air Filter Assembly View - 325
Asm - Breather Valve Springband - Clamp Hose - Vent, Eng Clamp - Hose, Spring 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.12 © Copyright Polaris Industries Inc.
Page 282: Air Box / Air Filter Assembly View - 570
Torque to 8 ft-lbs (11 Nm) Seal, Engine, Inlet Screw Torque to 18 ft-lbs (27 Nm) Hose - Breather 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.14 © Copyright Polaris Industries Inc.
Page 283: Air Box Removal / Installation
Tighten gear clamps to specification. TORQUE Air Intake Hose Gear Clamps: 24 in-lbs (2.7 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.15 © Copyright Polaris Industries Inc.
Page 284: 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 285: Ecu Replacement
ECU. 2. Remove seat and ECU cover 3. Remove the 4 screws retaining the ECU. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.17 © Copyright Polaris Industries Inc.
Page 286: 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 287: Pedal Position Sensor (Pps)
If the PPS is faulty, the accelerator pedal assembly must replaced (see "PPS Replacement"). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.19 © Copyright Polaris Industries Inc.
Page 288: Fuel Tank / Pump / Sendor
RH fender panel and remove panel from the vehicle. See Floor and Fenders, page 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.20 © Copyright Polaris Industries Inc.
Page 289: Fuel Tank Installation
Fuel Level Sender (-) • Fuel Pump Power (+) • Fuel Pump Power Ground (-) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.21 © Copyright Polaris Industries Inc.
Page 290: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.22 © Copyright Polaris Industries Inc.
Page 291: Fuel Pump Replacement
NOTE If the pump still does not operate, replace the fuel pump assembly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.23 © Copyright Polaris Industries Inc.
Page 292 10. Inspect the inside of the fuel tank for debris (may require flashlight and mirror). If debris like mud or 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.24 © Copyright Polaris Industries Inc.
Page 293 Cycle the key several times to prime the system and check for leaks. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.25 © Copyright Polaris Industries Inc.
Page 294: 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) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.26 © Copyright Polaris Industries Inc.
Page 296: Air Gap Test
CPS. 5. Remove the fasteners retaining the stator cover. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.28 © Copyright Polaris Industries Inc.
Page 297: 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) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.29 © Copyright Polaris Industries Inc.
Page 298: Ignition Coil Overview
Spark Plug Wire Wire Connector 7.0kΩ +/- 10% Terminal and Spark Boot Terminal COIL PACK CONNECTIONS 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.30 © Copyright Polaris Industries Inc.
Page 299: Fuel Injector
Failure to do so could result in serious injury or complications. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.31 © Copyright Polaris Industries Inc.
Page 300 11. Install the new injector into the fuel rail. Be sure to align boss in the injector with the slot in the fuel rail. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.32 © Copyright Polaris Industries Inc.
Page 301: Fuel Injector Troubleshooting
Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.33 © Copyright Polaris Industries Inc.
Page 302: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.34 © Copyright Polaris Industries Inc.
Page 303: Ect Sensor Replacement
6. Add the required amount of coolant and properly bleed the cooling system (see Engine chapter). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.35 © Copyright Polaris Industries Inc.
Page 304: Efi Diagnosis
• Always unplug ECU from the wire harness before performing any welding on the unit. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.36 © Copyright Polaris Industries Inc.
Page 305: Trouble Code Display (Dtc)
2. Press and hold the MODE button to enter the diagnostics code menu. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.37 © Copyright Polaris Industries Inc.
Page 306 Valid But Above Normal P0127 (least severe) Engine Temperature Sensor Engine Overheat Shutdown P1217 (ECT) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.38 © Copyright Polaris Industries Inc.
Page 307 Driver Circuit Short to B+ Injector 2 (PTO) Driver Circuit Grounded P1265 Driver Circuit Open P0264 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.39 © Copyright Polaris Industries Inc.
Page 308 (least severe) Valid But Below Normal P17AF (least severe) Cylinder Not Identified Misfire Detected 65590 P0314 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.40 © Copyright Polaris Industries Inc.
Page 309 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520268 P1519 M17; IAC Stepper Pin 3 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.41 © Copyright Polaris Industries Inc.
Page 310 Outside of Pedal Range (Level 1) P152F Throttle Body Control Voltage Above Normal 520283 P152C Voltage Below Normal P152D 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.42 © Copyright Polaris Industries Inc.
Page 311 Valid But Above Normal P0170 Adaptive Fuel Correction Bank 520344 Valid But Below Normal P1170 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.43 © Copyright Polaris Industries Inc.
Page 312: 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 313: 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 314: 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 315 Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the install. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.47 © Copyright Polaris Industries Inc.
Page 316 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.48 © Copyright Polaris Industries Inc.
Page 318: Digital Wrench® Serial Number Location
ECU sensors. Open the Software Set up data capture and Configuration Screen. record functions. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.50 © Copyright Polaris Industries Inc.
Page 319: Ecu Replacement
(see Chapter 4 – Digital Wrench® Updates, page 4.46. • 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 320 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 321 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.53 © Copyright Polaris Industries Inc.
Page 322 9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop-down menu. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.54 © Copyright Polaris Industries Inc.
Page 323 When completed, click the Authorize button once to proceed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.55 © Copyright Polaris Industries Inc.
Page 324 14. At this point the reflash process will begin. Do not touch the vehicle or PC during the process. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.56 © Copyright Polaris Industries Inc.
Page 325: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.57 © Copyright Polaris Industries Inc.
Page 326: Fuel System Troubleshooting
• TPS setting incorrect • Injector failure • Failed sensor or disconnected wiring • Throttle stop screw tampering 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 4.58 © Copyright Polaris Industries Inc.
Page 328: General Information
SPECIAL SUPPLIES NUM- Loctite™ 680 8560054 RTV Silicone Sealer Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 329: 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 330: Drive Clutch Operation
PVT system changes engine load requirements by either upshifting or backshifting. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 331: 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 332: Pvt System Service
Torque to 10 ft-lbs (14 Nm) Screw Torque to 60 in-lbs (7 Nm) Bolt Torque to 24 in-lbs (3 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 333: Pvt Disassembly
8. Remove the driven clutch retaining bolt and driven for assembly. clutch assembly. 9. Install the Drive Clutch Holder. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 334: Pvt Assembly
10. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 335: Drive Belt
See the Troubleshooting Chart at the end of this chapter for possible causes. 5. Remove the outer sheave. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 336: 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) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.10 © Copyright Polaris Industries Inc.
Page 337: Clutch Alignment / Offset / Center Distance
4. If the tool does not fit as shown above, adjustment is needed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.11 © Copyright Polaris Industries Inc.
Page 338: Adjustment
Clutch Center Distance Tool PU-50658 TORQUE Rear Trans. Isolator Bolts: 40 ft-lbs (54 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.12 © Copyright Polaris Industries Inc.
Page 339: Engine To Transmission Coupler Service
Remove the lock nuts and washers from the engine to transmission adapter mounting bolts (3) and discard. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.13 © Copyright Polaris Industries Inc.
Page 341 88 ft-lbs (119 Nm) 6. Reinstall PVT Inner Cover, Driven Clutch, Drive Clutch and PVT Outer Cover. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.15 © Copyright Polaris Industries Inc.
Page 342: Drive Clutch Service
25 in-lbs (2.8 Nm) Limiter Spacer Button Spider Washer 210 ft-lbs (284 Nm) Sheave Bushing Roller Bushing Spacer 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.16 © Copyright Polaris Industries Inc.
Page 343: Clutch Disassembly
Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.17 © Copyright Polaris Industries Inc.
Page 344: Shift Weight Inspection
See “Roller, Pin and Thrust Washer Inspection”. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.18 © Copyright Polaris Industries Inc.
Page 346: Button To Tower Clearance Inspection
Button to Tower Clearance: .000-.010” 2. Inspect sheave surfaces. Replace the entire clutch if worn, damaged or cracked. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.20 © Copyright Polaris Industries Inc.
Page 347 Replace if worn or damaged. MEASUREMENT PTFE Washer Thickness Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.21 © Copyright Polaris Industries Inc.
Page 348: Bushing Service
Number Two Puller Adapter #10 1 4. Install puller adapter (Item 10 from kit). Puller Adapter: PN 2871226 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.22 © Copyright Polaris Industries Inc.
Page 349 Discard bushing. Cover Bushing Installation 31. Apply Loctite™ 609 evenly to bushing bore in cover. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.23 © Copyright Polaris Industries Inc.
Page 350: Clutch Assembly
/ spacers beneath the spider during assembly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.24 © Copyright Polaris Industries Inc.
Page 351 8. Torque cover bolts evenly to specification. TORQUE Drive Clutch Cover Screw: 8 ft-lbs (10 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.25 © Copyright Polaris Industries Inc.
Page 352: Driven Clutch Service
9 ft-lbs (12 Nm) Ring, Retaining E-Ring External Label, Clutch Boss Subassembly, Moveable Boss Washer, Thrust Spring, Compression 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.26 © Copyright Polaris Industries Inc.
Page 354: Clutch Assembly
Clutch Spring Retaining Ring Bolts: 12 ft-lbs (16 Nm) 5. Install driven clutch assembly and drive belt. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.28 © Copyright Polaris Industries Inc.
Page 355: Troubleshooting
-Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.29 © Copyright Polaris Industries Inc.
Page 356 -Thin spots on belt, worn belt and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 5.30 © Copyright Polaris Industries Inc.
Page 358: General Information
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/ 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 359: 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 360: 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 361: Shift Lever
(lever, cable, console, shift knob) cable to the shift lever and disconnect the cable end from the lever. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 362: Shift Cable
If transmission still ratchets after cable adjustment, the transmission will require service. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 363: Transmission Removal
(Item 3), remove the duct mounting bolt (Item 4) and remove the intake duct (Item 5). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 364 12. Place a spacer or support between the vehicle frame and engine to hold the engine up in position. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 365 20. Using an overhead lift or an assistant, lift the transmission up and out of the chassis. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 366 48595) to prevent damage to crankshaft. 12. Remove driveshaft from both sides (see Chapter 7). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.10 © Copyright Polaris Industries Inc.
Page 367 16. Remove the wire ties retaining the main harness harness to transmission and mounts. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.11 © Copyright Polaris Industries Inc.
Page 368: Transmission Installation
6. Torque the upper, then lower engine to transmission adapter take up nuts (4) counterclockwise to specification. Repeat the Step 7 process. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.12 © Copyright Polaris Industries Inc.
Page 369 12. Install and properly route the vent hose. TORQUE 13. Lubricate the transmission splines and mid prop shaft joint splines with Polaris All Purpose Grease. Install Engine to Transmission Coupler Nuts: the prop shaft onto the transmission output shaft (see 88 ft-lbs (119 Nm) Chapter 7).
Page 370 23. Connect the (-) negative battery cable and reinstall the seat base. 24. Reinstall the cargo box. 25. 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.
Page 371 3. By hand, install the coupler brackets and the eight engine to transmission coupler bolts. Do not torque fasteners at this time. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.15 © Copyright Polaris Industries Inc.
Page 372 11. Install and properly route the vent hose. 12. Lubricate the transmission splines and mid prop shaft joint splines with Polaris All Purpose Grease. Install the prop shaft onto the transmission output shaft (see Chapter 7). 13. Install inner clutch cover, outlet duct, drive clutch, driven clutch, belt and outer clutch cover (see Chapter 6).
Page 373 22. Connect the (-) negative battery cable and reinstall the seat base. 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.
Page 375: Transmission Disassembly
Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.19 © Copyright Polaris Industries Inc.
Page 376 (R). Remove the shift drum (R) from the transmission housing. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.20 © Copyright Polaris Industries Inc.
Page 377 22. Remove the retaining ring and engagement dog from the reverse shaft (see Figure 8-1). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.21 © Copyright Polaris Industries Inc.
Page 378 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.22 © Copyright Polaris Industries Inc.
Page 379 32. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.23 © Copyright Polaris Industries Inc.
Page 380: Planetary Differential Disassembly
2. Thoroughly clean the bore of the ring gear and check for any unwanted burs. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.24 © Copyright Polaris Industries Inc.
Page 381 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.25 © Copyright Polaris Industries Inc.
Page 382: Planetary Differential Assembly
13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.26 © Copyright Polaris Industries Inc.
Page 383: Gear / Shaft / Bearing Inspection
Differential Cover Screws: 22 ft-lbs (30 Nm) GEAR / SHAFT / BEARING INSPECTION 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.27 © Copyright Polaris Industries Inc.
Page 384: Snorkel Gear Backlash Procedure
8. Apply Loctite® 242™ to the threads of the bearing cover retaining screws. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.28 © Copyright Polaris Industries Inc.
Page 385 Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.29 © Copyright Polaris Industries Inc.
Page 386 18. Install shift fork (S) and torsion spring into transmission housing as an assembly. Load spring as shown in image below 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.30 © Copyright Polaris Industries Inc.
Page 388 NOTE Shift fork pins should be offset towards the input shaft as shown above. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.32 © Copyright Polaris Industries Inc.
Page 389 (.070" or 1.8 mm from outer face of bore). 33. Install the spacer onto the shift drum shaft. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.33 © Copyright Polaris Industries Inc.
Page 390 Install and torque the bolts to specification. TORQUE Sector Cover Bolts: 11 ft-lbs (15 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.34 © Copyright Polaris Industries Inc.
Page 391: Troubleshooting
(rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.35 © Copyright Polaris Industries Inc.
Page 392: Transmission
TRANSMISSION TRANSMISSION TRANSMISSION ASSEMBLY VIEW 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.36 © Copyright Polaris Industries Inc.
Page 393 Screw, Cap M8 - 1.25 x 25 104. Bearing, Ball Sprocket, 48T Bracket, Wire Harness 105. Bearing, Ball 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 6.37 © Copyright Polaris Industries Inc.
Page 397: General Information
36 ft-lbs (49 Nm) Wheels) Wheel Lug Nuts 30 ft-lbs + 90º (41 Nm + (Aluminum Wheels) 90º) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 398: Front Hub / Bearing
Step 3. 5. Remove hub cap, cotter pin , front spindle nut and washer. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 399: Hub Installation
8. Install hub cap. Use care to not allow any of the Loctite compound to get in the bearing. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 400 11. Install wheel, washers, wheel nuts, and tighten evenly in a cross pattern to specified torque. Refer to “Torque Specifications”. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 401: Front Hub/Wheel Exploded View
30 ft-lbs + 90º (41 Nm + 90º) Washer Tire Front Hub Stud Brake Disc Bolt 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 402: Front Drive Shaft
5. Remove and discard the cotter pin, then remove the front hub castle nut. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 403: Front Drive Shaft Installation
2. Install drive shaft into strut housing. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 404: Front Gearcase Removal And Installation
(Item 2) to the retaining dart. 6.7–7.6 fl. oz. (200–225 ml) TORQUE Front Gearcase Mounting Bolts: 33 ft-lbs (56 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.10 © Copyright Polaris Industries Inc.
Page 405: Gearcase Removal
5. Remove the vent line (Item 4) from the front gearcase. 6. Remove the (4) bolts (Item 2) securing the front gearcase to frame. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.11 © Copyright Polaris Industries Inc.
Page 406 Clutch Housing (Ring Gear) Drain Plug, Magnetic Roll Cage Retaining Ring, External Hub / Race Assembly 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.12 © Copyright Polaris Industries Inc.
Page 407: All Wheel Drive Operation
The front drive will remain engaged until the torque requirement goes away (i. e. rear wheels regain traction). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.13 © Copyright Polaris Industries Inc.
Page 409: Gearcase Disassembly / Inspection
2. Remove the (7) cover screws and remove the cover plate assembly. NOTE Nylon spacer is non-serviceable and should not be removed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.15 © Copyright Polaris Industries Inc.
Page 410 7. Remove the RH output hub assembly from the spring from the top of the ring gear. gearcase housing. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.16 © Copyright Polaris Industries Inc.
Page 411 Most parts are to be replaced as an assembly or as a complete kit. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.17 © Copyright Polaris Industries Inc.
Page 412: Gearcase Assembly
16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.18 © Copyright Polaris Industries Inc.
Page 413 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.19 © Copyright Polaris Industries Inc.
Page 414 Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.20 © Copyright Polaris Industries Inc.
Page 415: Front Gearcase (Adc)
FINAL DRIVE FRONT GEARCASE (ADC) EXPLODED VIEW, FRONT GEARCASE (4WDC) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.21 © Copyright Polaris Industries Inc.
Page 416 Torque: 8-10 ft-lbs (11-14 Nm) RING, RETAINING, INTERNAL KIT, SPRING RING, RETAINING, EXTERNAL ASM., GEAR HOUSING AND PINION GEAR 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.22 © Copyright Polaris Industries Inc.
Page 418: Disassembly / Inspection, Front Gearcase (Adc)
6. Remove and inspect the armature plates . Refer to “AWD Diagnosis” for detailed inspection process. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.24 © Copyright Polaris Industries Inc.
Page 419 The rollers must slide up and down freely within the roller cage surfaces. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.25 © Copyright Polaris Industries Inc.
Page 421: Reassembly, Front Gearcase (Adc)
6. Install the LH output hub into the gearcase housing. The output hub should spin freely. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.27 © Copyright Polaris Industries Inc.
Page 422 10. Align the spring retainer dowel pin with the ring gear dowel pin and install the retainer on top of the torsion spring. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.28 © Copyright Polaris Industries Inc.
Page 423 Demand Drive Hub Fluid 8.97 oz. (265 ml) 17. Install the drain plug. Torque to specification. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.29 © Copyright Polaris Industries Inc.
Page 424: Troubleshooting, Front Gearcase (Adc)
ADC is not indexing cage in both directions 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.30 © Copyright Polaris Industries Inc.
Page 425 If worn and damaged, not, continue onto replace output cover. additional problems listed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.31 © Copyright Polaris Industries Inc.
Page 427: Rear Bearing Carrier
7. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.33 © Copyright Polaris Industries Inc.
Page 428: Disassembly
Replace housing if damaged. 5. Replace the bearing carrier bushings if worn or damaged. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.34 © Copyright Polaris Industries Inc.
Page 429: 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.35 © Copyright Polaris Industries Inc.
Page 430 Install a new cotter pin TORQUE Rear Hub Castle Nut: 110 ft-lbs (150 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.36 © Copyright Polaris Industries Inc.
Page 431: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.37 © Copyright Polaris Industries Inc.
Page 432: Drive Shaft Service
1. Using side cutters, cut away and discard the boot clamps. NOTE Tap on inner race only! 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.38 © Copyright Polaris Industries Inc.
Page 434 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.40 © Copyright Polaris Industries Inc.
Page 435: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.41 © Copyright Polaris Industries Inc.
Page 437: Drive Shaft Assembly View
Axle Boot Clamp Tool. Axle Boot Clamp Tool PU-48951 or 8700226 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.43 © Copyright Polaris Industries Inc.
Page 438 8. Use a NEW roll pin upon installation. FRONT PROP SHAFT COMPONENTS DESCRIPTION Grease Zerk Rear Yoke U-Joint Front Yoke 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.44 © Copyright Polaris Industries Inc.
Page 439 36 ft-lbs (49 Nm) 12. If front prop shaft was removed, use a NEW roll pin upon installation. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.45 © Copyright Polaris Industries Inc.
Page 440 9. Grease the prop shaft yoke(s). 10. Reinstall the large storage container and front seat base. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 7.46 © Copyright Polaris Industries Inc.
Page 444: Torque Specifications
Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 445: Special Tools
Included in this machine’s tool kit, the multi-function pliers is designed to remove the plastic push rivets used to fasten body components. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 446: Steering Assembly
STEERING / SUSPENSION STEERING ASSEMBLY STEERING ASSEMBLY VIEW (NON-EPS) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 447 40 ft-lbs (54 Nm) 36 ft-lbs (49 Nm) 65 ft-lbs (88 Nm) BUSHING, STEERING PIN, COTTER LOCTITE® 271 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 448: Steering Assembly View (Eps)
STEERING / SUSPENSION STEERING ASSEMBLY VIEW (EPS) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 449 40 ft-lbs (54 Nm) 49 ft-lbs (66 Nm) 65 ft-lbs (88 Nm) BUSHING, STEERING PIN, COTTER LOCTITE 271 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 450: Steering Wheel Removal (Non-Eps Models)
4. Note the order and location of the spacers between the pivot tube and steering shaft. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 451: Steering Shaft / Steering Rack Removal (Non-Eps Models)
2. Remove upper and lower dash panels. 3. Remove the steering wheel tilt assembly fasteners. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 452: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.10 © Copyright Polaris Industries Inc.
Page 453: Power Steering Unit Removal
WARNING Electronic Power Steering (EPS) units are not interchangeable between ATV and RANGER product lines. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.11 © Copyright Polaris Industries Inc.
Page 455: Front Strut
1. Hold strut rod and remove top nut. Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.13 © Copyright Polaris Industries Inc.
Page 456: Ball Joint Replacement
A-arm from ball joint stud 6. Remove screws and ball joint retaining plate 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.14 © Copyright Polaris Industries Inc.
Page 457 30 ft-lbs (41 Nm) 11. Install new cotter pin with open ends toward rear of machine. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.15 © Copyright Polaris Industries Inc.
Page 458: Rear A-Arms
Lower A-arm Removal 8. Remove the fastener attaching the lower A-arm to the bearing carrier. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.16 © Copyright Polaris Industries Inc.
Page 459: Installation
40 ft-lbs (54 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.17 © Copyright Polaris Industries Inc.
Page 460: Assembly View
Upper A-Arm Bearing Carrier Grease Zerk Nuts Wheel Bearing 40 ft-lbs (54 Nm) Snap Ring 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.18 © Copyright Polaris Industries Inc.
Page 461: Rear Stabilizer Bar / Linkage
9. If the stabilizer linkage was removed, torque the lower shock retaining bolt to specification. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.19 © Copyright Polaris Industries Inc.
Page 462: Assembly View
3. Reverse the procedure to reinstall the shock. Torque NEW fasteners to specification. TORQUE Shock Fasteners: 40 ft-lbs (54 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 8.20 © Copyright Polaris Industries Inc.
Page 465: General Information
PART NUMBER TOOL DESCRIPTION Mity Vac™ Pressure Test 2870975 Tool Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 466: Brake System Notes
Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 467: 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 468: Brake System Assembly View
Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm) Screw Torque to 12–15 ft-lbs (16–20 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 469: Ranger Crew
Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm) Screw Torque to 12–15 ft-lbs (16–20 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 470: Master Cylinder
Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 471: Foot Brake Pedal
1. Reverse steps for foot brake installation. 2. Tighten pivot bolt sufficiently. Refer to the general torque specifications in Chapter 1. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual © Copyright Polaris Industries Inc.
Page 472: Brake Procedures
Add fluid as necessary to maintain level in reservoir. Master Cylinder Fluid Level Between the MIN and MAX line CAUTION Polaris DOT 4 Brake Fluid Maintain at least 1/2"(1.27 cm) of brake fluid in the (P/N 2872189) reservoir to prevent air from entering the master cylinder.
Page 473: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.11 © Copyright Polaris Industries Inc.
Page 474: Front Brake Pads - Ranger
Remove excess fluid from reservoir as required. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.12 © Copyright Polaris Industries Inc.
Page 475: Pad Assembly / Installation- Ranger
Maintain at least 1/2"(12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.13 © Copyright Polaris Industries Inc.
Page 476: Front Caliper - Ranger
NOTES Finger Tighten Adjuster Screw 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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.14...
Page 477: Front Caliper Removal- Ranger
NOTE Be sure to clean seal grooves in caliper body. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.15 © Copyright Polaris Industries Inc.
Page 478: 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 479: Front Caliper Installation
Steel Wheel Lug Nuts: 36 ft-lbs (49 Nm) 6. Burnish brake pads as outlined in this chapter 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.17 © Copyright Polaris Industries Inc.
Page 480: Front Brake Pads - Crew
When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.18 © Copyright Polaris Industries Inc.
Page 481: Pad Inspection
Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.19 © Copyright Polaris Industries Inc.
Page 482 Up to MAX line inside reservoir 7. Install wheel and torque wheel nuts to specification (see “Chapter 2 - Maintenance”). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.20 © Copyright Polaris Industries Inc.
Page 483: Front Caliper - Crew
NOTES 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 FRONT CALIPER REMOVAL- CREW 2. Remove the four wheel nuts and the front wheel.
Page 485: Front Caliper Inspection - Crew
3. Inspect the brake disc and pads as outlined in this chapter. NOTE Be sure to clean seal grooves in caliper body. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.23 © Copyright Polaris Industries Inc.
Page 486: Front Caliper Assembly - Crew
TORQUE 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing Front Caliper Mount Bolt: inward. Piston should slide in and out of bore 46 ft-lbs (62 Nm) smoothly, with light resistance.
Page 487 If new brake pads are installed, brake burnishing is required. SeeBrake Burnishing Procedure, page 9.11. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.25 © Copyright Polaris Industries Inc.
Page 488: Front Brake Disc
Service Limit .140”/3.56 mm MEASUREMENT Brake Disc Thickness Variance: Service Limit .002” (.051 mm) difference between measurements 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.26 © Copyright Polaris Industries Inc.
Page 489: Disc Removal / Replacement
4. Apply Loctite® 272 to new bolts, install and tighten to specification. TORQUE Front Brake Disc Mounting Bolts: 18 ft-lbs (25 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.27 © Copyright Polaris Industries Inc.
Page 490: Rear Brake Pad Service
When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.28 © Copyright Polaris Industries Inc.
Page 491: Brake Pad Inspection
5. Fill master cylinder to Max level. 6. Burnish brakes as outlined in this chapter. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.29 © Copyright Polaris Industries Inc.
Page 492: Rear Caliper
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 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.30...
Page 493: Caliper Removal
Be sure to clean seal grooves in caliper body. 4. Clean disc, caliper body, and pistons with brake cleaner or alcohol. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.31 © Copyright Polaris Industries Inc.
Page 494: Rear Caliper Inspection
3. Inspect the brake disc and pads as outlined for brake pad replacement in this chapter. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.32 © Copyright Polaris Industries Inc.
Page 495: Rear Caliper Installation
If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE PADS - Brake Burnishing Procedure”). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.33 © Copyright Polaris Industries Inc.
Page 496: Rear Brake Disc
These types of products are flammable and may also reduce the friction between the brake pad and caliper. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.34 © Copyright Polaris Industries Inc.
Page 497: Disc Removal / Replacement
Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.35 © Copyright Polaris Industries Inc.
Page 498: Parking Brake System
35 in-lb (4 Nm) Bolt - M8 x 1.25 x 20 (QTY.2) 17 ft-lb (23 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.36 © Copyright Polaris Industries Inc.
Page 499 Clevis Pin - 1/4 x 3/4 (QTY.1) — Push Rivet (QTY.4) — Clip, Silencer — 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.37 © Copyright Polaris Industries Inc.
Page 500: Parking Brake Caliper Service
1. Place vehicle on level ground and block the wheels. 2. Release the parking brake. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.38 © Copyright Polaris Industries Inc.
Page 501: Caliper Disassembly / Inspection
5. Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.39 © Copyright Polaris Industries Inc.
Page 502: New Brake Pad Installation
1. Assemble the stationary actuator with bolts upright as shown. Grease the tracks and install three balls. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.40 © Copyright Polaris Industries Inc.
Page 503: Parking Brake Caliper Installation
3. Install the cable to lever arm with pin (pin is installed from front to rear). 4. Install retainer clip in pin. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.41 © Copyright Polaris Industries Inc.
Page 504 BRAKE SYSTEM 5. Test parking brake for proper function and adjust if necessary. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.42 © Copyright Polaris Industries Inc.
Page 505: Parking Brake Disc Service
2. Follow prop shaft removal procedure (See Final Drive Chapter) to remove prop shaft / disc assembly. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.43 © Copyright Polaris Industries Inc.
Page 506: Troubleshooting
• Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 9.44 © Copyright Polaris Industries Inc.
Page 508: Torque Specifications
Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.2 © Copyright Polaris Industries Inc.
Page 509: Chassis / Body
Bumper Screen Screws Torque to 22 ft-lbs (30 Nm) Screws Torque to 8 ft-lbs (11 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.3 © Copyright Polaris Industries Inc.
Page 510: Crew Frame Assembly View
Screws Torque to 22 ft-lbs Screws Torque to 8 ft-lbs Screws Torque to 40 ft-lbs 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.4 © Copyright Polaris Industries Inc.
Page 511 Torque to 36 ft-lbs (49 Nm) Screws Torque to 18 in-lbs (27 Nm) Screw Torque to 8 ft-lbs 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.5 © Copyright Polaris Industries Inc.
Page 512: Crew Cab Frame
Torque to 36 ft-lbs (48 Nm) Screws Torque to 36 ft-lbs (48 Nm) Nets - Door 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.6 © Copyright Polaris Industries Inc.
Page 513: Dash Instruments / Controls
REF. DESCRIPTION NOTES Instrument Cluster Bezel Key Switch 12V Accessory Plug Turf Switch Dash Panel 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.7 © Copyright Polaris Industries Inc.
Page 514: Hood / Dash / Front Fascia
Front Fascia Dash Panel Glove Box Lid Hood Strap Hood Hinge Pins Push Rivet Hood Latch 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.8 © Copyright Polaris Industries Inc.
Page 515: Floor / Rear Fenders
Main Floor Floor Cover Cup Holder Push Rivet Screws Torque to 5 ft-lbs (7 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.9 © Copyright Polaris Industries Inc.
Page 516: Seat Mounting / Seat Belts
RH Seat Belt Assm Seat Base Frame Screw 24 in-lbs (3 Nm) Bolt 40 ft-lbs (54 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.10 © Copyright Polaris Industries Inc.
Page 517: Crew Floor / Rear Fenders
Front Seat Panel Rear Main Floor Storage Box Front Inner Fender Cup Holder Floor Cover Push Rivet 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.11 © Copyright Polaris Industries Inc.
Page 518: Crew Seat Mounting / Seat Belts
Rear Seat Base Frame Seat Base Seat Back Screw 24 in-lbs (3 Nm) Bolt 40 ft-lbs (54 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.12 © Copyright Polaris Industries Inc.
Page 519: Rear Cargo Box
BODY / FRAME REAR CARGO BOX CARGO BOX - TAILGATE / BOX SUPPORT 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.13 © Copyright Polaris Industries Inc.
Page 520 Tailgate Latch Screw Torque to 8 ft-lbs (11 Nm) Screw Torque to 5 ft-lbs (7 Nm) 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.14 © Copyright Polaris Industries Inc.
Page 521: Box Removal
Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.15 © Copyright Polaris Industries Inc.
Page 522: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.16 © Copyright Polaris Industries Inc.
Page 523: Hood / Dash
Unhook all electrical components to allow the panel to be completely removed. 8. Carefully remove the dash assembly from the vehicle. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.17 © Copyright Polaris Industries Inc.
Page 524: Floors
4. Remove the Torx-head screws retaining the front floor cover. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 10.18 © Copyright Polaris Industries Inc.
Page 529: 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 530: Components Under Hood
• Ignition Switch • Instrument Cluster • Cooling Fan • TRS Connector • Brake Switch • Headlights 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.4 © Copyright Polaris Industries Inc.
Page 531: Switches / Controls
• When the switch is in position #3 (TURF), there should and F. be continuity between terminals 1 (White/Green) and 2 (Orange/White). 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.5 © Copyright Polaris Industries Inc.
Page 532: Differential Solenoid
ECU and Rear Differential Solenoid Relay. • Check the switch wires for loose connections. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.6 © Copyright Polaris Industries Inc.
Page 533: All Wheel Drive (Awd) Coil
• Verify continuity of wire connections with a volt/ohm meter. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.7 © Copyright Polaris Industries Inc.
Page 534: Vehicle Speed Sensor
Sensor Probe Harness (PN 2460761). 3. Pass a screwdriver back and forth in front of the sensor tip. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.8 © Copyright Polaris Industries Inc.
Page 535: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.9 © Copyright Polaris Industries Inc.
Page 536: Rider Information Display
12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.10 © Copyright Polaris Industries Inc.
Page 537: Information Display Area
Engine hours are logged anytime the engine is running. Total hours can not be reset. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.11 © Copyright Polaris Industries Inc.
Page 538 8. Press and hold the MODE button until the hour segment flashes. Release the button. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.12 © Copyright Polaris Industries Inc.
Page 539: Diagnostic Mode
5. If more than one code exists, press the MODE button to advance to the next trouble code. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.13 © Copyright Polaris Industries Inc.
Page 540: Instrument Cluster Pinouts
Apply pressure on the bezel while pressing down on the instrument cluster. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.14 © Copyright Polaris Industries Inc.
Page 543: Headlight Bulb Replacement
90° to lock it in place. 4. Close the hood and adjust headlights using the “Headlight Adjustment” procedure. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.17 © Copyright Polaris Industries Inc.
Page 544: Tail Light / Brake Light
5. Test after installation to verify proper function of tail, brake, and turn signal lamps. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.18 © Copyright Polaris Industries Inc.
Page 546: Ignition Coil
0.5 Ω Test Connection Between High Tension Secondary 7.0 k Ω ± 5% Lead Caps Test 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.20 © Copyright Polaris Industries Inc.
Page 547: Ignition Coil And Ht Lead Replacement
6. Connect harness connection to the ignition coil. 7. Reconnect battery cable and install the drivers seat. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.21 © Copyright Polaris Industries Inc.
Page 548: Relays
12v output to EPS unit Solenoid 12v output to Splice, Chassis Brown Chassis ground #2 Gray ECU controlled ground 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.22 © Copyright Polaris Industries Inc.
Page 549 • Rear Differential Solenoid Relay, controlled by the AWD/2WD/TURF switch and ECM, operates the differential solenoid to unlock the rear end. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.23 © Copyright Polaris Industries Inc.
Page 550: Fuses / Circuit Breaker
Drive System, Fuel Pump 20 A EFI, Power Steering (if equipped), Lights, Accessories 20 A Circuit Breaker 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.24 © Copyright Polaris Industries Inc.
Page 551: Charging System
The battery should be fully charged before performing this test. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.25 © Copyright Polaris Industries Inc.
Page 552 TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.26 © Copyright Polaris Industries Inc.
Page 553: 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. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.27 © Copyright Polaris Industries Inc.
Page 554: 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 555: Battery Inspection
5. Check the vent tube. Make sure it’s not kinked, pinched or otherwise obstructed. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.29 © Copyright Polaris Industries Inc.
Page 556: Battery Removal / Installation
12.50 V 50% Charged 12.20 V 25% Charged 12.0 V 0% Charged 11.9 V or less 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.30 © Copyright Polaris Industries Inc.
Page 557: Specific Gravity Test
7. Route cables so they are tucked away in front and behind battery. OFF SEASON STORAGE See Chapter 2 “Maintenance” for battery service procedures. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.31 © Copyright Polaris Industries Inc.
Page 558: Starter System
Polaris Premium Starter Drive Grease PN 2871460 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.32...
Page 559: Starter Solenoid Bench Test
(A) and (B). If there is no continuity or high resistance, replace the starter solenoid. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.33 © Copyright Polaris Industries Inc.
Page 560: Starter Solenoid Operation
12V power to reach the via the Brown / Yellow wire. starter motor. 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.34 © Copyright Polaris Industries Inc.
Page 561: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual 11.35 © Copyright Polaris Industries Inc.
Page 563 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams Click here for Wiring Diagrams See Operation, page 11.24for Fuse Block pin outs.
Page 564 2015 RANGER ETX...
Page 565 2015 RANGER ETX...
Page 566 2015 RANGER 570...
Page 567 2015 RANGER 570...
Page 568 2015 RANGER 570...
Page 569 2015 RANGER 570...
Page 570 2015 RANGER 570 HD...
Page 571 2015 RANGER 570 HD...
Page 572 2015 RANGER 570 CREW...
Page 573 2015 RANGER 570 CREW...
Page 574 2015 RANGER 570 CREW W/EPS...
Page 575 2015 RANGER 570 CREW W/EPS...
Page 576 Assembly View (CREW) ........... 9.7 Pressure Cap Test .........3.27, 3.104 Bleeding...............9.10 Pressure Test ..........3.27, 3.103 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual IX.1 © Copyright Polaris Industries Inc.
Page 577 Button to Tower Clearance ........5.20 Installed Gap Measurement, Piston ....3.57, 3.136 Disassembly ............5.17 Lower End Assembly ........3.80, 3.167 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual IX.2 © Copyright Polaris Industries Inc.
Page 578 General Information ............ 3.6 Ground Test ..............4.18 Engine ..............2.40 ETC Learn Procedure ........4.18, 4.57 Exhaust System 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual IX.3 © Copyright Polaris Industries Inc.
Page 579 Pedal Position Sensor ..........4.19 Suspension............2.44 Test ..............4.19 Transmission........... 2.28, 6.4 Periodic Maintenance Chart.......... 2.7 Periodic Maintenance Chart Key........2.7 Polaris Mobile Digital Wrench (PMDW) ......4.45 Power Steering Unit (EPS) Installation ............8.11 MAG Side Crankcase Bearing Service ......3.165 Removal............... 8.11 Maintenance PPS ...............4.19...
Page 580 Cylinder Head Warp........3.51, 3.130 Tappet Selection Matrix Engine ..............3.91 Exhaust..............3.71 Engine Lubrication......3.7, 3.39, 3.89, 3.120 Intake ..............3.70 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual IX.5 © Copyright Polaris Industries Inc.
Page 581 Engine / Cooling System ..........3.86 Front Gearcase (ADC)..........7.30 Fuel Injector ............4.33 Starter System............. 11.32 Transmission............6.35 Valve Clearance 9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual IX.6 © Copyright Polaris Industries Inc.

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Polaris RANGER ETX 2015 Owner's Manual

Chapter 1 1 General Information

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Polaris RANGER ETX 2015