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Polaris RZR 570 2017 Service Manual
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Polaris RZR 570 2017 Service Manual

Polaris RZR 570 2017 Service Manual

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2017-2021 RZR 570 / S 570
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a 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 2020 (PN 9850074 R01)
© Copyright 2020 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. 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.

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Summary of Contents for Polaris RZR 570 2017

  • Page 1 Publication Printed October 2020 (PN 9850074 R01) © Copyright 2020 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 The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 4 Initial Release FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
  • Page 5 2017-2021 RZR 570 / S 570 Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING SYSTEM CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION CHAPTER 8 :...
  • Page 7 ................1.34 DECIMAL EQUIVALENTS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 8 = 2021 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN may be found stamped on a portion of the left rear upper frame , above the rear wheel.
  • Page 9 RZR 570 Z21CHA57A2 / K2 2021 9931521 RZR 570 EPS Z21CHE57AK NOTICE Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 10 Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
  • Page 11 CV Boot Clamp Pliers Drive Clutch Holding Drive Clutch Puller Fuel Pressure Gauge Water Pump Drive & (ear) Tool (short) Adapter Rotor Removal Tool 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 12 Engine Stand Adapter Clutch Center Crankshaft Removal / Engine Stand Adapter Water Pump Sleeve (2″) Distance Tool Installation Tool Kit Mechanical / Oil Seal Installation Kit 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Valve Spring Cylinder Leakdown Valve Spring Connector Test Kit Oil Presure gauge Compressor tester Compressor Adapter PV-43568 PW-47053 Fluke Multimeter Bench Mount Engine Stand 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 14 Cylinder Head Bolts - 2016 to Current Step 2: 30 ft-lbs (40 Nm) Step 3: Loosen all fasteners until they are unseated Step 4: 15 ft-lbs (20 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 Oil Filter Adapter Fasteners 20 ft-lbs (28 Nm) Oil Pump Cover Bolts 7 ft-lbs (10 Nm) Oil Pump Sprocket Bolts 9 ft-lbs (12 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 16 Steering Rack Mounting Bolts 16 ft-lbs (22 Nm) Steering Shaft to EPS Unit 16 ft-lbs (22 Nm) Steering Shaft to Steering Rack 36 ft-lb (48 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 Wheel Hub Castle Nuts (Rear) 110 ft-lbs (149 Nm) Steel Rims: 36 ft-lbs (49 Nm) Wheel Lug Nuts Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 18 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.13 © Copyright Polaris Industries Inc.
  • Page 20 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 GENERAL INFORMATION DRIVETRAIN ENGINE Domestic Single Cylinder, Liquid Transmission Type Polaris Automatic PVT with EBS Platform Cooled, 4-Stroke, DOHC Shift Type In Line Shift - P / R / N / L / H Engine Front Gearcase 567cc Polaris Demand Drive...
  • Page 22 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.16 © Copyright Polaris Industries Inc.
  • Page 23 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.17 © Copyright Polaris Industries Inc.
  • Page 24 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.18 © Copyright Polaris Industries Inc.
  • Page 25 GENERAL INFORMATION DRIVETRAIN ENGINE Domestic Single Cylinder, Liquid Transmission Type Polaris Automatic PVT with EBS Platform Cooled, 4-Stroke, DOHC Shift Type In Line Shift - P / R / N / L / H Engine Front Gearcase 567cc Polaris Demand Drive...
  • Page 26 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.20 © Copyright Polaris Industries Inc.
  • Page 27 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.21 © Copyright Polaris Industries Inc.
  • Page 28 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.22 © Copyright Polaris Industries Inc.
  • Page 29 GENERAL INFORMATION DRIVETRAIN ENGINE Domestic Single Cylinder, Liquid Transmission Type Polaris Automatic PVT with EBS Platform Cooled, 4-Stroke, DOHC Shift Type In Line Shift - P / R / N / L / H Engine Front Gearcase 567cc Polaris Demand Drive...
  • Page 30 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.24 © Copyright Polaris Industries Inc.
  • Page 31 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.25 © Copyright Polaris Industries Inc.
  • Page 32 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.26 © Copyright Polaris Industries Inc.
  • Page 33 GENERAL INFORMATION DRIVETRAIN ENGINE Domestic Single Cylinder, Liquid Transmission Type Polaris Automatic PVT with EBS Platform Cooled, 4-Stroke, DOHC Shift Type In Line Shift - P / R / N / L / H Engine Front Gearcase 567cc Polaris Demand Drive...
  • Page 34 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.28 © Copyright Polaris Industries Inc.
  • Page 35 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.29 © Copyright Polaris Industries Inc.
  • Page 36 (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680.4 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.30 © Copyright Polaris Industries Inc.
  • Page 37 GENERAL INFORMATION DRIVETRAIN ENGINE Domestic Single Cylinder, Liquid Transmission Type Polaris Automatic PVT with EBS Platform Cooled, 4-Stroke, DOHC Shift Type In Line Shift - P / R / N / L / H Engine Front Gearcase 567cc Polaris Demand Drive...
  • Page 38 π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.32 © Copyright Polaris Industries Inc.
  • Page 39 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 3–4 7/16–14 2 3/4 7/16–20 25/64 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.33 © Copyright Polaris Industries Inc.
  • Page 40 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 0.5938″ 19/32 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 1.34 © Copyright Polaris Industries Inc.
  • Page 41 BRAKE SYSTEM ..................2.51 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 42 ................2.55 ENGINE / CHASSIS GROUNDS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 43 Inspect, clean, lubricate, adjust and replace parts as cause or see your dealer. necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. BREAK-IN PERIOD The break-in period consists of the first 25 hours of...
  • Page 44 • Ensure rim is not cracked / bent Wheels / Lug Nuts • Verify proper lug nut torque • Inspect cable / line and switch Winch (if equipped) • Ensure operation 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 45 Initial fluid level inspection; add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual...
  • Page 46 Change oil and filter, inspect used oil for contaminants XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual...
  • Page 47 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual...
  • Page 48 Shocks XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 49 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual...
  • Page 50 Change oil and filter, inspect used oil for contaminants XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.10...
  • Page 51 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.11...
  • Page 52 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.12...
  • Page 53 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.13...
  • Page 54 Change oil and filter, inspect used oil for contaminants XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.14...
  • Page 55 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.15...
  • Page 56 Visually inspect shock seals; change oil and seals if leaking Shocks XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.16...
  • Page 57 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.17...
  • Page 58 Change oil and filter, inspect used oil for contaminants XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.18...
  • Page 59 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.19...
  • Page 60 Valve Clearance XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.20...
  • Page 61 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.21...
  • Page 62 Change oil and filter, inspect used oil for contaminants XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.22...
  • Page 63 Inspect / add lubricant if needed XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.23...
  • Page 64 XU - Perform these procedures more often for vehicles subjected to severe use. D - Have an authorized Polaris dealer or qualified person perform these services. When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.
  • Page 65 Check level during pre-ride “MAX and “MIN” lines on the inspection; change fluid every Brake Fluid Polaris DOT 4 Brake Fluid master cylinder reservoir two years * More often under severe use, such as operated in water or under severe loads.
  • Page 66 Gearcase Lubricant at the fill hole threads * More often under severe use, such as operated in water or under severe loads. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.26 © Copyright Polaris Industries Inc.
  • Page 67 Rear A-arm Bushings miles (800 km). Joint Grease washing or submerging the Front Stabilizer Bar Bushings vehicle. Rear Stabilizer Bar Bushings 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.27 © Copyright Polaris Industries Inc.
  • Page 68 U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 16 oz (12) 2870652 Fuel Stabilizer 2872280 2.5 gal (2) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.28 © Copyright Polaris Industries Inc.
  • Page 69 Access Panel Heat Shield If any heat shields are found to be damaged or missing, they must be replaced prior to operation. Exhaust Heat Shield Inspection 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.29 © Copyright Polaris Industries Inc.
  • Page 70 2. Place the transmission in PARK (P). 3. If needed, start the engine and allow it to idle for three minutes until warm. Stop the engine. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.30 © Copyright Polaris Industries Inc.
  • Page 71 16. Verify the transmission is still positioned in PARK (P). 17. Start the engine and let it idle for two minutes. 18. Stop the engine and inspect for leaks. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.31 © Copyright Polaris Industries Inc.
  • Page 72 Refer to Chapter 3 “Engine Assembly and Installation” for 5. Discard Isolators mounting fastener torque values. NOTICE Isolators must be replaced after each use. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.32 © Copyright Polaris Industries Inc.
  • Page 73 17. Reinstall the cargo box access panel and seats (see thickness (feeler) gauge. Record the measurement if Chapter 10) . clearance is out of specification. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.33 © Copyright Polaris Industries Inc.
  • Page 74 5. Reinstall the arrestor and torque the screw to specification. Spark Arrestor Fastener 8 ft-lbs (11 Nm) Head Pipe Fasteners 18 ft-lb (25 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.34 © Copyright Polaris Industries Inc.
  • Page 75 Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Extended Life Coolant is already premixed and ready to use. Do not dilute with water. COOLING SYSTEM EXPLODED VIEW 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.35...
  • Page 76 MAINTENANCE COOLANT LEVEL INSPECTION 8. Fill recovery bottle to MAX level with Polaris 50/50 The pressure cap and recovery bottle are located Extended Life Anti Freeze/Coolant as required for under the front hood of the vehicle. The coolant level freeze protection in your area.
  • Page 77 2. Check tightness of all hose clamps. recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.37 © Copyright Polaris Industries Inc.
  • Page 78 MAINTENANCE 10. Refer to Chapter 3 for the “Cooling System Bleeding Procedure”. Polaris Premium Antifreeze 2880514 - Quart 2880513 - Gallon 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.38 © Copyright Polaris Industries Inc.
  • Page 79 Ensure lines are not kinked or pinched. 2. Be sure fuel line is routed and retained properly. NOTICE Make sure line is not kinked or pinched. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.39 © Copyright Polaris Industries Inc.
  • Page 80 The air box is located underneath the cargo box access panel. 1. Thoroughly clean the air box area to remove dirt and debris. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.40 © Copyright Polaris Industries Inc.
  • Page 81 5. Clean the air box and air box cover thoroughly. 6. Place the filter into the air box with the air filter pleats facing UP. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.41 © Copyright Polaris Industries Inc.
  • Page 82 MEASUREMENT Tire Lug Service Limit: Replace if 1/8″ (3 mm) or less. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.42 © Copyright Polaris Industries Inc.
  • Page 83 Check to see the boot clamps are properly positioned. Refer to Drive Shaft CV Joint / Boot Replacement for drive shaft boot replacement. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.43 © Copyright Polaris Industries Inc.
  • Page 84 3. If lubricant level is not even with the bottom threads, 12. Check for leaks. Dispose of used lubricant properly. add the recommended lubricant as needed. Do not overfill. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.44 © Copyright Polaris Industries Inc.
  • Page 85 5. Remove the fill plug 6. Place a drain pan under the front gearcase drain plug. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.45 © Copyright Polaris Industries Inc.
  • Page 86 11. Reinstall fill plug with a new O-ring and torque to specification. TORQUE Fill / Drain Plug: 10 ft-lbs (14 Nm) 12. Check for leaks. Dispose of used fluid properly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.46 © Copyright Polaris Industries Inc.
  • Page 87 Whenever steering components are replaced, check front end alignment. Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. • If abnormal movement is detected, inspect the hub and Use only genuine Polaris replacement parts.
  • Page 88 To adjust toe alignment: • Hold tie rod end to keep it from rotating. • Loosen jam nuts at both end of the tie rod. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.48 © Copyright Polaris Industries Inc.
  • Page 89 • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.49 © Copyright Polaris Industries Inc.
  • Page 90 Shock Spanner Wrench 2871095 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.50 © Copyright Polaris Industries Inc.
  • Page 91 Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.51 © Copyright Polaris Industries Inc.
  • Page 92 After 8 full clicks of lever travel, the vehicle should not roll while parked. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.52 © Copyright Polaris Industries Inc.
  • Page 93 MAINTENANCE 10. If additional adjustment is needed, the cable can be adjust on the parking brake handle side jam nut 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.53 © Copyright Polaris Industries Inc.
  • Page 94 BATTERY MAINTENANCE NOTICE Keep battery terminals and connections free of Battery charge can be maintained by using a Polaris corrosion. If cleaning is necessary, remove the corrosion battery tender charger or by charging once a month to with a stiff wire brush. Wash with a solution of one make up for normal self-discharge.
  • Page 95 11. Install spark plug wire into spark plug / engine. 12. Reinstall cargo box access panel. 13. Reinstall the (-) negative battery cable and driver’s seat. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.55 © Copyright Polaris Industries Inc.
  • Page 96 MAINTENANCE NOTES 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 2.56 © Copyright Polaris Industries Inc.
  • Page 97 ENGINE ASSEMBLY - BOTTOM END ..............3.77 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 98 ..................3.84 COOLING SYSTEM 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 99 2017 Oil Gallery Plug: Oil Capacity: 2 Quarts (1.9 L) 12 ft-lbs (16 Nm) Oil Filter Wrench: PU-50105 or 2.5″ (64 mm) Oil Type: Polaris PS-4 Synthetic Engine Oil Oil Pressure: TORQUE (using Polaris PS-4 at operating temperature) 2018 Oil Gallery Plug:...
  • Page 100 ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 101 Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 102 See Service Procedure Listed Crankshaft Runout Limit (PTO and MAG) In This Chapter 1.1798” - 1.1802" (29.969 - Bearing Journal O.D. (Standard) Balance Shaft 29.979 mm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 103 ENGINE / COOLING SYSTEM ENGINE ASSEMBLY VIEWS COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 104 Step 7: Additional 180° Torque the Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) 7 ft-lbs (10 Nm) M6 Bolts: 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 105 Stator Cover Bolts Water Cover Bolts bolt threads) CAM CARRIER VALVE COVER 7 ft-lbs (10 Nm) 7 ft-lbs (10 Nm) Camshaft Carrier Bolts Valve Cover Bolts 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 106 ENGINE / COOLING SYSTEM CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.10 © Copyright Polaris Industries Inc.
  • Page 107 ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.11 © Copyright Polaris Industries Inc.
  • Page 108 Applicable only to 2017 Models and prior: Apply a drop of Loctite 641 (Yellow) to the crankshaft taper before assembly. Loctite 603 (Green) can be used if 641 is not available. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.12 © Copyright Polaris Industries Inc.
  • Page 109 ENGINE / COOLING SYSTEM CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.13 © Copyright Polaris Industries Inc.
  • Page 110 ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.14 © Copyright Polaris Industries Inc.
  • Page 111 ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.15 © Copyright Polaris Industries Inc.
  • Page 112 Intake Baffle Box PVT Intake Pre-Filter Cargo Box Intake Duct Clamp Clamps 18 in-lb (2 Nm) Air Box Intake Duct Clamp 36 in-lb (4 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.16 © Copyright Polaris Industries Inc.
  • Page 113 Heat Shield Screw Exhaust Gasket Exhaust Hanger Isolator Bolt Exhaust Spring Silencer Spark Arrestor Exhaust Gasket Silencer Fastener Headpipe 8 ft-lbs (11 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.17 © Copyright Polaris Industries Inc.
  • Page 114 3.18). 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. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.18...
  • Page 115 Use of a high-pressure washer is not recommended. 7. Remove the hose and completely drain the engine. Radiator Removal 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.19 © Copyright Polaris Industries Inc.
  • Page 116 TORQUE Thermostat Cover Bolts: 7 ft-lbs (10 Nm) 9. Be sure to properly fill and bleed cooling system as outlined in this chapter. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.20 © Copyright Polaris Industries Inc.
  • Page 117 12. Inspect the water pump cover and impeller for 8. Raise and safely support the vehicle. Remove the damage. Replace as necessary. right-hand rear wheel. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 118 CAUTION Be sure engine coolant does not contaminate the engine oil during stator cover service. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 119 Be sure bearing is fully seated in cover or severe engine damage may result. 24. Clean and de-grease the water pump drive shaft 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.23 © Copyright Polaris Industries Inc.
  • Page 120 (J) until it is fully seated in the cover. 31. Install a new stator cover gasket onto the engine. 27. Lubricate the new water pump oil seal with clean engine oil. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 121 PA-49317 to the water cover bolt holes to aid in stator cover installation. Stator Cover and Water Pump Cover: 9 ft-lb (12 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 122 50. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 51. Check for leaks. 40. Install a new water pump cover gasket. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 123 10. Allow engine and cooling system to completely cool down (see CAUTION). 2. Remove the hood. 11. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator 3. Remove the recovery bottle cap and fill the bottle filler neck.
  • Page 124 1. If vehicle was recently operated, allow it to cool down before attempting to perform any work. 2. Thoroughly clean the engine and chassis. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.28 © Copyright Polaris Industries Inc.
  • Page 125 8. Elevate the rear of the vehicle off the ground using a suitable lift and remove the left rear wheel. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.29 © Copyright Polaris Industries Inc.
  • Page 126 Make note of line routing for installation. 17. Disconnect the ignition coil harness connector and remove the spark plug wire from the engine. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.30 © Copyright Polaris Industries Inc.
  • Page 127 (I) and ECT (J) harness connector. 28. Use an overhead or portable engine hoist and suitable engine straps to secure the engine in its current position. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.31 © Copyright Polaris Industries Inc.
  • Page 128 (B) and instal the eight bolts and washers (C). Do not tighten fasteners at this time. Engine Stand Adapter PU-50824 NOTICE DO NOT torque fasteners at this time. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.32 © Copyright Polaris Industries Inc.
  • Page 129 ACE 570 2015-16 RGR ETX 2013–19 RZR 570 2014–19 RANGER 500/570 2015-19 RANGER 570 Full-Size 2014-19 RANGER 900/1000 2015-19 RZR 900 2016-19 RZR 1000 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.33 © Copyright Polaris Industries Inc.
  • Page 130 Front Engine Mount Fasteners: duct, intake boot and air box. 40 ft-lbs (54 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 131 29. Install the rear bumper and cargo box assembly as outlined in the body chapter. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.35 © Copyright Polaris Industries Inc.
  • Page 132 / coolant. 32. If the engine oil was completely drained, add approximately 2 quarts (1.9 L) of Polaris PS-4 Synthetic Engine Oil into the crankcase. 33. Install a new oil filter. Lubricate the seal with engine oil prior to installation (see Chapter 2 –...
  • Page 133 Oil Type Polaris PS-4 Synthetic Engine Oil Oil Pressure Minimum Specification (using Polaris PS-4 Plus at operating temperature) 10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.37...
  • Page 134 . Stuff spark plug hole with a shop towel to prevent anything from falling into the combustion chamber (if further engine disassembly is required). 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.38 © Copyright Polaris Industries Inc.
  • Page 135 TORQUE Camshaft Sprocket Bolt: 14 ft-lbs (19 Nm) Replace camshaft sprocket bolt if loosened or removed. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.39 © Copyright Polaris Industries Inc.
  • Page 136 Removal of the decompression mechanism is not necessary unless replacement is required. 1. Thoroughly clean and inspect the decompression mechanism located on the exhaust camshaft. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.40 © Copyright Polaris Industries Inc.
  • Page 137 4. Tap cylinder head lightly with a soft faced hammer until loose. Tap only in reinforced areas or on thick parts of the cylinder head casting. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.41 © Copyright Polaris Industries Inc.
  • Page 138 7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.42 © Copyright Polaris Industries Inc.
  • Page 139 0.2165" - 0.2171" (5.500 - 5.515 mm) 8. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.43 © Copyright Polaris Industries Inc.
  • Page 140 The valve may overheat and warp, resulting in burnt valves. NOTICE Polaris Premium Carbon Clean can be used to help remove carbon deposits. Do not use a metal scraper, a coarse wire brush or abrasive cleaners to clean the cylinder head. Damage may result.
  • Page 141 • 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. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.45 © Copyright Polaris Industries Inc.
  • Page 142 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.46 © Copyright Polaris Industries Inc.
  • Page 143 4. Repeat steps for the second ring. 5. Remove oil control ring top rail first, then remove the bottom rail. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.47 © Copyright Polaris Industries Inc.
  • Page 144 Std.: 0.8665 - 0.8670″ (22.010 - 22.023 mm) Piston Pin Bore: Std.: 0.8662 - 0.8665″ (22.004 - 22.010 mm) Service Limit: 0.8651″ (21.975 mm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.48 © Copyright Polaris Industries Inc.
  • Page 145 Always leave .002 - .003" (.05 - .07 mm) for finish bore sizing with a fine stone. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.49 © Copyright Polaris Industries Inc.
  • Page 146 3. Lubricate all camshaft lobes and bearing journal Using a common spring loaded finger type glaze surfaces with Polaris PS-4 engine oil prior to breaker for honing is never advised. Polaris installation.
  • Page 147 “E” marks aligned with gasket surface. 7. Carefully install the camshaft carrier onto the camshafts. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.51 © Copyright Polaris Industries Inc.
  • Page 148 18. Check the valve lash after tensioner installation and two engine revolutions. NOTICE Verify the valve lash after rotating the engine. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.52 © Copyright Polaris Industries Inc.
  • Page 149 1/4” drive socket extension through flywheel is aligned with the CPS mounting hole. the crankcase and into the crankshaft locating hole 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.53 © Copyright Polaris Industries Inc.
  • Page 150 5. Install the three valve cover shoulder bolts new isolators Around each T40 fastener. 6. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.54 © Copyright Polaris Industries Inc.
  • Page 151 Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.55 © Copyright Polaris Industries Inc.
  • Page 152 2. Install a new base gasket. NOTICE Base gasket and surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.56 © Copyright Polaris Industries Inc.
  • Page 153 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.57 © Copyright Polaris Industries Inc.
  • Page 154 11. Repeat this procedure for remaining valves. 12. Exercise each valve through its travel to ensure the valve keepers are seated correctly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.58 © Copyright Polaris Industries Inc.
  • Page 155 4. Carefully set the cylinder head in place on alignment pins. NOTICE Install NEW cylinder head bolts. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.59 © Copyright Polaris Industries Inc.
  • Page 156 Do not touch sealing surfaces of the new head gasket. Torque The Outer M6 Head Bolts 89 ± 9 in-lbs (10 ± 1 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.60 © Copyright Polaris Industries Inc.
  • Page 157 7. Torque the camshaft carrier bolts in sequence to specification. 3. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. TORQUE Camshaft Carrier Bolts: 7 ft-lbs (10 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.61...
  • Page 158 20. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.62 © Copyright Polaris Industries Inc.
  • Page 159 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 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.63 © Copyright Polaris Industries Inc.
  • Page 160 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 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.64 © Copyright Polaris Industries Inc.
  • Page 161 2. Place flywheel on work bench. Grasp gear and rotate clockwise. It should turn smoothly without binding. 3. Rotate gear counterclockwise. The gear should immediately lock in position and not slip. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.65 © Copyright Polaris Industries Inc.
  • Page 162 If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.66 © Copyright Polaris Industries Inc.
  • Page 163 4. Remove the two bolts that secure the stator wire routing bracket to the stator cover. 5. Remove the stator from the stator cover. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.67 © Copyright Polaris Industries Inc.
  • Page 164 ENGINE / COOLING SYSTEM OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.68 © Copyright Polaris Industries Inc.
  • Page 165 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.69 © Copyright Polaris Industries Inc.
  • Page 166 Oil Pressure the pump cover mating surfaces. Minimum Specification 2. Align the gerotor according to the orientation dots. (using Polaris PS-4 at operating temperature) 10 PSI @ 1200 RPM (Minimum) 3. Place the drive pin through the oil pump drive 40 PSI @ 7000 RPM (Minimum) shaft.
  • Page 167 (28Nm) apply loctite 272) that secure oil filter Never strike the engine mounts with a hammer. adapter to the crankcase. Discard O-rings and through clean the adaptor for reassembly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.71 © Copyright Polaris Industries Inc.
  • Page 168 2. Pull upward on the balance shaft and remove it from the crankcase. 3. Inspect drive gear for broken or damaged teeth. 4. Inspect bearing surfaces for scoring or signs of wear. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.72 © Copyright Polaris Industries Inc.
  • Page 169 0.8665 - 0.8670″ (22.010 - 22.023 mm) 4. Remove all special tools from the crankcase. Service Limit: 0.08682″ (22.053 mm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.73 © Copyright Polaris Industries Inc.
  • Page 170 2. If not already performed, remove the screws that secure the bearing retainer to the case. Retaining Ring 3. Remove the retaining ring. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.74 © Copyright Polaris Industries Inc.
  • Page 171 3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.75 © Copyright Polaris Industries Inc.
  • Page 172 2. Be sure alignment pins are in place where used. 3. Be sure oil passages are clean and free of any cleaning solvent. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.76 © Copyright Polaris Industries Inc.
  • Page 173 6. With the help of an assistant, slowly tighten the nut until the crankshaft is completely seated into the crankcase bearings. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 174 Be sure seal lip does not fold back when moving over the crankshaft flange. 11. Drive seal until flush with seal bore. 12. Turn PTO crankcase over and support with crankshaft upright. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.78 © Copyright Polaris Industries Inc.
  • Page 175 . Be sure alignment pins are in place. Crankcase Sealant: PN 2871557 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.79 © Copyright Polaris Industries Inc.
  • Page 176 Loctite® 272™ PW-47054 10. Place engine onto the engine stand for top end engine assembly as outlined in this chapter. Engine Stand: PU-50624-A 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.80 © Copyright Polaris Industries Inc.
  • Page 177 9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 4. Rotate crankshaft so the flywheel key is facing upward. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.81 © Copyright Polaris Industries Inc.
  • Page 178 4. Set the stator in housing and press wire grommet Stator Mounting Bolts: into slot on housing. 9 ft-lbs (12 Nm) Apply Loctite® 242™ 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.82 © Copyright Polaris Industries Inc.
  • Page 179 • Low compression Slow Engine Cranking • Crankcase breather restricted • Weak battery • Loose Electrical connections • Decompression Mechanism not functioning properly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.83 © Copyright Polaris Industries Inc.
  • Page 180 • Faulty water pump mechanical seal (coolant leak) • Ignition timing incorrect • Faulty pump shaft oil seal (oil leak) • Sheared flywheel key 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 3.84 © Copyright Polaris Industries Inc.
  • Page 181 ................4.25 ECU REPLACEMENT 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 182 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........
  • Page 183 ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 184 • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 185 Temperature / Manifold Absolute Pressure (TMAP) Sensor Fuel Injector Crankshaft Position Sensor (CPS) Fuel Rail Fuel Pump /Sender (in-tank) Electronic Throttle Control (ETC) Engine Coolant Temperature (ECT) Sensor 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 186 During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 187 This process repeats it self in rapid succession, limiting operation to the preset maximum. RZR 570 EFI RPM Limit: Max RPM Limit - Injector and ignition suppression. • 7750 RPM (All Gears) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 188 TPS to the throttle body is altered, the TPS must be adjusted. For the purpose of troubleshooting, a known-good ECU from another Polaris RZR 570 of the same model may be used without system or engine component damage. NOTICE...
  • Page 189 2. Remove the cargo box access panel. 3. Disconnect vehicle harness from T-MAP sensor. 4. Remove the retaining bolt and remove the sensor from the intake boot. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 190 Check both wires in this matter. engine will stop running. They should both read OL, indicating no shorts to ground. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.10 © Copyright Polaris Industries Inc.
  • Page 191 6. Subtract the sensor length from the sensor mounting point to encoder flywheel measurement. Verify that the calculated air gap is within specification. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.11 © Copyright Polaris Industries Inc.
  • Page 192 6. Reconnect CPS harness connector. CPS REPLACEMENT 1. Access the CPS harness from the right rear side of the vehicle. 2. Disconnect the CPS harness connector. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.12 © Copyright Polaris Industries Inc.
  • Page 193 If a problem is encountered, and you 5. Remove the ETC housing from vehicle. determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do 6. Reverse these steps for installation. Torque the ETC not replace the ETC without factory authorization.
  • Page 194 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. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 195 5. Place the throttle pedal assembly on the mounting pedal. If the PPS is faulty, the throttle pedal assembly studs and loosely install the three fasteners. must be replaced. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.15 © Copyright Polaris Industries Inc.
  • Page 196 7. Manually cycle the throttle pedal to verify the throttle pedal moves freely. 8. Connect the negative (-) battery cable and install the seat. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.16 © Copyright Polaris Industries Inc.
  • Page 197 MODE button or turn the ignition key OFF once the 2. Press and hold the MODE button to enter the codes are recorded. diagnostics code menu. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.17 © Copyright Polaris Industries Inc.
  • Page 198 P1692 (INTL) Driver Circuit Grounded P1693 Driver Circuit Open / Grounded P1481 Fan Relay Driver Circuit 1071 Driver Circuit Short to B+ P1482 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.18 © Copyright Polaris Industries Inc.
  • Page 199 Driver Circuit Open / Grounded P1535 Idle Air Control Valve (IAC) 520270 Driver Circuit Short to B+ P1539 M17; IAC Stepper Pin 6 Driver Circuit Grounded P1538 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.19 © Copyright Polaris Industries Inc.
  • Page 200 • Plugged air filter • Leaking injector (rich condition) • Belt dragging • Throttle stop screw tampering Symptom: Erratic Idle. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.20 © Copyright Polaris Industries Inc.
  • Page 201 • Perform guided diagnostic procedures provided in the Digital Wrench® Diagnostic Kit to install • Create customer service account records the Polaris Digital Wrench® diagnostic software on your computer. • Perform output state control tests (some models) The Digital Wrench® diagnostic software allows the...
  • Page 202 ENGINE ELECTRICAL 2. Proceed to http://polaris.diagsys.com to see if a 5. Click on “Digital Wrench Version Updates”. newer update is available. NOTICE 3. If a newer update is available, it should be You must already have the current version installed downloaded before using Digital Wrench®...
  • Page 203 ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.23 © Copyright Polaris Industries Inc.
  • Page 204 Perform specialized testing Run the Help System. and adjustment functions service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.24 © Copyright Polaris Industries Inc.
  • Page 205 To successfully reprogram the ECU, an Authorization Key must be obtained by entering • Proceed to http://polaris.diagsys.com for specific a Request Code in the box provided on the Reflash information and FAQs on how to troubleshoot Authorization site.
  • Page 206 10. Enter or paste the Request Code into the box. click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.26 © Copyright Polaris Industries Inc.
  • Page 207 13. Enter or paste the Authorization Key in the box located on the Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 4.27 © Copyright Polaris Industries Inc.
  • Page 208 PMDW app and the WVL. See the user’s guide for a complete list of compatible vehicles. You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download.
  • Page 209 ................5.20 FUEL TANK INSTALLATION 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 210 PU-47469 and PC Interface Cable PU-47470. This website: www.polaris.diagsys.com module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier SPX at (1-800-328-6657) or http://polaris.spx.com...
  • Page 211 • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 212 IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 213 Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 214 9. Gently pull and twist to free the injector from the fuel rail. 10. Upon installation of the new fuel injector, lightly lubri- cate the injector O-rings to aid installation. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 215 , breather hoses and through the front Panduit strap 3. Route the supply line under the PVT outlet hose and attach to the fuel rail 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 216 Collapsing fuel tank Engine miss or hesitation Symptoms of a restricted fuel tank vent include the following: Loss of engine performance High exhaust temperatures 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 217 Squeeze the connector tabs together and push the locking up. 3. Attach the vent line to the fitting in the frame 2. Pull on the fuel line for removal. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 218 5. Snap the fuel line back over the nipple and slide the locking mechanism back into place. Verify the connector tabs snap back into place. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.10 © Copyright Polaris Industries Inc.
  • Page 219 DESCRIPTION PFA Nut 70 ft-lbs (95 Nm) Fuel Pump Preliminary Fuel Filter Fuel Sender Float Arm Gasket (replace if removed) Fuel Tank Assembly 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.11 © Copyright Polaris Industries Inc.
  • Page 220 7.0 volts is being supplied. If during starting the battery voltage drops below 7.0 volts, the ECU will fail to operate the system. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.12 © Copyright Polaris Industries Inc.
  • Page 221 ECU operation by plugging in a known-good ECU of the same model. NOTICE If the pump still does not operate, replace the fuel pump assembly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.13 © Copyright Polaris Industries Inc.
  • Page 222 6. Ensure that static has been discharged by touching a ground source such as the engine or frame. 4. Remove the PFA cover. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.14 © Copyright Polaris Industries Inc.
  • Page 223 NOTICE Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 8. Disconnect the fuel pump electrical harness 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.15 © Copyright Polaris Industries Inc.
  • Page 224 It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel. Do not use water or any other chemicals to remove debris. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.16 © Copyright Polaris Industries Inc.
  • Page 225 24. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.17 © Copyright Polaris Industries Inc.
  • Page 226 9. Disconnect the driver’s seat belt switch harness. 10. Remove the rear seat base assembly from the vehicle by removing the two fasteners retaining the rear seat base. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.18 © Copyright Polaris Industries Inc.
  • Page 227 16. Remove the two tank bracket fasteners that retain the fuel tank in the chassis. Swing the tank brackets clear of the fuel tank for removal. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.19 © Copyright Polaris Industries Inc.
  • Page 228 Shift Lever Bracket Fasteners: 17 ft-lbs (23 Nm) 4. Reinstall the rear RH fender well and secure with 10. Reconnect the fuel pump electrical harness. fasteners. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.20 © Copyright Polaris Industries Inc.
  • Page 229 Check for leaks. 14. Finally, install the rear service panel along with the seats. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.21 © Copyright Polaris Industries Inc.
  • Page 230 FUEL SYSTEM NOTES 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 5.22 © Copyright Polaris Industries Inc.
  • Page 231 ................6.35 TROUBLESHOOTING 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 232 CLUTCH SETTINGS Shift Drive Driven Altitude Weight Spring Spring 0-1500 25-52G (0-5000) (5632409) Meters Black Red/Wt (Feet) (7043594) (7044505) 1500-3700 25-48 (5000 - 12000) (5633217) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 233 During the development of optimum engine RPM. At full throttle a perfectly matched the Polaris vehicle, the PVT system is matched first to the PVT system should hold engine RPM at the peak of the engine power curve; then to average riding conditions power curve.
  • Page 234 PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 235 PVT system. 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD Clutch malfunction. certified technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or Poor engine performance.
  • Page 236 Drive Clutch Mounting Bolt Driven Clutch 47 ft-lbs (64 Nm) Inner PVT Cover Fasteners PVT Cover Seal 12 ft-lbs (16 Nm) Outer PVT Cover Inner PVT Cover 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 237 PVT inlet duct to the outer clutch cover from the vehicle. the inner clutch cover. Disengage hose from the inner clutch cover. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 238 TORQUE Wheel Nuts: Steel Rims: 36 ft-lbs (49 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 239 PVT SYSTEM 16. Reconnect the battery cable. 17. Install engine service panel and both seats. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 240 3. If reusing the drive belt, mark the belt direction of rotation so that it can be installed in the same direction. Remove the belt from the drive and driven clutches. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.10 © Copyright Polaris Industries Inc.
  • Page 241 5-7 times to properly seat the belt in the driven clutch. 5. Non-EBS Models ONLY: Torque driven clutch retaining bolt to specification. TORQUE Driven Clutch Retaining Bolt: 43 lb-ft (58 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.11 © Copyright Polaris Industries Inc.
  • Page 242 1. Remove the Clutch Center Distance tool from the engine and transmission. Clutch Center Distance Tool: 2. Remove the inner PVT Cover. PU-50658-A 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.12 © Copyright Polaris Industries Inc.
  • Page 243 Rear Trans. Isolator Bolts: 40 ft-lbs (54 Nm) 8. Remove the Clutch Center Distance tool and reassemble the PVT system as outlined in this chapter. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.13 © Copyright Polaris Industries Inc.
  • Page 244 (Apply 0.4 mL Loctite® 7088 Primer and 0.4 mL Loctite® 620™) Cover Bolt Shift Weight 100 in-lb (12 Nm) Shift Weight Bolt 20 in-lb (2 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.14 © Copyright Polaris Industries Inc.
  • Page 245 3. Remove the six cover bolts evenly in a cross pattern 7. Remove the limiter spacer and inspect for wear. and remove cover plate. Replace if excessive wear is evident. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.15 © Copyright Polaris Industries Inc.
  • Page 246 Distortion of the spring indicates stress fatigue, requiring IMPORTANT replacement. The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 247 It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 248 Take care not to damage roller bushing or bearing surface of the new pin during installation. Button to Tower Clearance: .000-.012” 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.18 © Copyright Polaris Industries Inc.
  • Page 249 2. Remove the moveable clutch sheave . Inspect for bearing with the bearing end facing up, and the damage and wear. bushing end facing down, as shown. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 250 Tool Drive Clutch Cover Bushing Removal/ 5020629 Installation Tool (all clutches) P-90 Driven Clutch Cover Bushing 5020631 Removal Tool Main Puller Adapter 5020632 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.20 © Copyright Polaris Industries Inc.
  • Page 251 Turn puller barrel to increase tension on sheave if needed. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.21 © Copyright Polaris Industries Inc.
  • Page 252 Torque nuts to specification. into cover bushing. TORQUE 24. With inside of cover toward vise, slide cover onto Shift Weight Nuts puller. 20 in-lbs (2 N·m) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.22 © Copyright Polaris Industries Inc.
  • Page 253 IMPORTANT If the aligning marks are not in alignment, the clutch will not be in balance. The drive clutch assembly must be replaced. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.23 © Copyright Polaris Industries Inc.
  • Page 254 PVT SYSTEM 10. Torque cover bolts evenly to specification. TORQUE Drive Clutch Cover Bolts 8 ft-lbs (11 N·m) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.24 © Copyright Polaris Industries Inc.
  • Page 255 Driven Clutch Spring Fixed Sheave Thrust Washer Spring Cup 1.189 x 0.838 x 0.12 Rollers Plate Screws Washers 12 ft-lbs (16 Nm) E-Clips 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.25 © Copyright Polaris Industries Inc.
  • Page 256 2. Remove the driven clutch from the vehicle. (See PVT Disassembly page 8. Separate the stationary and the moveable sheaves. Keep track of the number of thrust washers between the sheaves. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.26 © Copyright Polaris Industries Inc.
  • Page 257 13. Lube splines with a light film of grease. Do not lubricate the bearings! CLUTCH ASSEMBLY 1. Install the rollers, washers and E-clips. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.27 © Copyright Polaris Industries Inc.
  • Page 258 Torque the retaining ring screws specification. TORQUE Clutch Spring Retaining Ring Bolts: 11 ft-lbs (15 Nm) 7. Install driven clutch assembly and drive belt. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 259 PVT SYSTEM DRIVEN CLUTCH SERVICE (EBS) DRIVEN CLUTCH EXPLODED VIEW (EBS) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.29 © Copyright Polaris Industries Inc.
  • Page 260 Remove the spider assembly and spring. Universal Clutch Compressor: PU-50518-A NOTICE Spring is compression only and has no torsional wind. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.30 © Copyright Polaris Industries Inc.
  • Page 261 9. Pull out the clutch slider pins and sliders 2. Inspect the compression spring for cracks or other damage. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.31 © Copyright Polaris Industries Inc.
  • Page 262 The flanged bearings are not serviceable. If either clutch sheave bearing requires replacement, the entire driven clutch assembly must be replaced. Refer to the Polaris Electronic Parts catalog for specific parts availability. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.32...
  • Page 263 6. Align the X’s on the spider and moveable sheave. 3. Install the spring pins to retain the slider pins. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.33 © Copyright Polaris Industries Inc.
  • Page 264 9. Once back together, verify the grease / tape marks made during disassembly are properly aligned. 10. Install the drive clutch on the vehicle. See PVT Assembly page 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.34 © Copyright Polaris Industries Inc.
  • Page 265 PVT cover overheating Belt slippage due to water, oil, grease, etc., Inspect system. Clean , repair or replace as (melting) rubbing on cover. necessary. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.35 © Copyright Polaris Industries Inc.
  • Page 266 Thin spots on belt, worn belt . Replace belt. Refer to belt burnt troubleshooting Engagement and instruct operator. erratic or stabby Drive clutch bushings stick. Inspect and repair clutches. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 6.36 © Copyright Polaris Industries Inc.
  • Page 267 ..............7.34 TROUBLESHOOTING CHECKLIST 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 268 LUBRICATION FLUID CAPACITY Recommended Transmission Lubricant: AGL (PN 2878068) (Quart) Capacity (Standard): 44 oz. (1300 ml) Capacity LE / INTL: 41 oz. (1200 ml) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 269 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 270 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 271 10. Pull sharply forward to remove the prop shaft from transmission shaft. 11. Remove the rear bumper and cargo box as an assembly (see Chapter 10 – ). 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 272 Maneuver the brace Remove the air box assembly. forward for transmission removal clearance. Note the routing of the transmission breather hose and wire harness. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 273 29. Place a support in-between the main frame and the engine crankcase to support the engine in its current position. Do not pinch brake line. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 274 33. Rotate the top of the transmission to the left side of the vehicle. With the help of an assistant, lift the assembly out of the vehicle frame. Clutch Center Distance Tool: PU-50658-A 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 275 Torque new fasteners to specification. TORQUE Control Arm Fasteners: 40 ft-lb (54 Nm) 14. INTL - Install the parking break cable and assembly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 276 Cargo Box Bracket Fasteners: 44 ft-lbs (60 Nm) 17 ft-lbs (23 Nm) CAUTION 21. Lubricate the transmission splines with Polaris All Purpose Grease. Install the prop shaft onto the New bolts have a pre-applied locking agent which is transmission splines.
  • Page 277 32. Verify all wire and hose routing are correct. Connect the (-) negative battery cable. 33. Install the engine service panel and seats. 34. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris AGL (see Chapter 2 – Transmission Lubrication page 2.44). FLUID CAPACITY...
  • Page 278 16. Place the gear cluster assembly on a clean surface for inspection. If disassembly is required, refer to “Gear Cluster Disassembly”. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.12 © Copyright Polaris Industries Inc.
  • Page 279 22. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.13 © Copyright Polaris Industries Inc.
  • Page 280 CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 281 31. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.15 © Copyright Polaris Industries Inc.
  • Page 282 IMPORTANT TURF mode is only available in drive gears and when the parking brake is released (INTL models). 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.16 © Copyright Polaris Industries Inc.
  • Page 283 Female Gear Assembly Differential Cover Assembly Planetary Differential Assembly Fasteners Engagement Dog Bearing Shift Fork Retainer Fastener Torsion Spring Retainer Shift Fork Solenoid Spring Solenoid 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 284 Planetary Differential Bushing Replacement (Turf Mode Models Only) page 7.19. 2. Remove the six screws retaining the differential cover and remove the cover. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 285 5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.19 © Copyright Polaris Industries Inc.
  • Page 286 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 287 Differential Cover Screws (8.8 Fastener): 4. Apply Loctite® 2760™ to cover screws. 22 ft-lbs (30 N·m) TORQUE Differential Cover Screws (10.9 Fastener):28 ft-lbs (38 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.21 © Copyright Polaris Industries Inc.
  • Page 288 TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 289 Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.23 © Copyright Polaris Industries Inc.
  • Page 290 8. Apply Loctite ® ™ to the threads of the bearing and may have some tight spots. cover retaining screws. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.24 © Copyright Polaris Industries Inc.
  • Page 291 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.25 © Copyright Polaris Industries Inc.
  • Page 292 Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.26 © Copyright Polaris Industries Inc.
  • Page 293 20 ft-lbs (27 N·m) shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.27 © Copyright Polaris Industries Inc.
  • Page 294 Install and torque the bolts to specification. TORQUE Transmission Gear Sector Cover Bolts: 12 ft-lbs (16 N·m) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.28 © Copyright Polaris Industries Inc.
  • Page 295 TRANSMISSION TRANSMISSION ASSEMBLY VIEW 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.29 © Copyright Polaris Industries Inc.
  • Page 296 Shaft, Front Output Seal, Dual Lip Shaft, Input, Helical Seal, Triple Lip Shim Shaft, Reverse, 27T Sensor, Speed Shim Bearing, Needle Cage Bellcrank 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.30 © Copyright Polaris Industries Inc.
  • Page 297 TRANSMISSION TRANSMISSION ASSEMBLY VIEW (INT’L) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 298 105. Screw, M8 x 1.25 x 25 34. Bearing, Ball 68. Shift Dog, Park 106. Ring Gear, 53T 35. Bearing, Ball 108. Bearing, Plain 69. Gear, 44T 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.32 © Copyright Polaris Industries Inc.
  • Page 299 TRANSMISSION TRANSMISSION / REAR GEARCASE VENT LINE Description Hose Clamp Retention Point Vent Line Termination Fitting 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 300 If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 301 ............... .8.33 REAR HUB EXPLODED VIEW 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 302 Roll Pin Removal Tool CV Boot Clamp Pliers 8700226 (earless type) Axle Boot Clamp Tool PU-48951 Bosch Automotive Service Solutions – 1-800-328-6657 or http://polaris.service-solutions.com/ 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 303 8. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper and lower ball joint ends. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 304 Use care to not allow any of the Loctite ® compound to get in the bearing. 8. Wipe the housing clean of any excess compound and install the snap ring. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 305 9. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TORQUE Front Wheel Hub Castle Nut: 80 ft-lb (108 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 306 6. Remove the nuts, washers and bolts , retaining the rear bearing carrier to the upper and lower A-arms. Discard nuts and replace with new. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 307 Use care to not allow any of the Loctite ® compound to get in the bearing. 8. Wipe the housing clean of any excess compound and install the snap ring. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 308 3. Apply grease to drive shaft axle splines. 4. Install rear wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 309 Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 8. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 310 8. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper and lower ball joint ends. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.10 © Copyright Polaris Industries Inc.
  • Page 311 4. Install the ball joint ends into the front bearing carrier. align cotter pin holes. TORQUE Front Wheel Hub Castle Nut: 80 ft-lb (108 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.11 © Copyright Polaris Industries Inc.
  • Page 312 CAUTION Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.12 © Copyright Polaris Industries Inc.
  • Page 313 8. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.13 © Copyright Polaris Industries Inc.
  • Page 314 9. Install wheel and four wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Nuts: Steel Rims: 36 ft-lbs (49 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.14 © Copyright Polaris Industries Inc.
  • Page 315 OUTER CV JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps IMPORTANT Tap on inner race only! 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.15 © Copyright Polaris Industries Inc.
  • Page 316 14. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.16 © Copyright Polaris Industries Inc.
  • Page 317 Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.17 © Copyright Polaris Industries Inc.
  • Page 318 NOTICE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.18 © Copyright Polaris Industries Inc.
  • Page 319 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.19 © Copyright Polaris Industries Inc.
  • Page 320 Refer to PVT Disassembly page 6.7. 6. Remove the two screws retaining the brake line junction block and move the junction block towards the outside of the vehicle. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.20 © Copyright Polaris Industries Inc.
  • Page 321 Drive Clutch Retaining Bolt: 47 ft-lbs (64 Nm) Outer Clutch Cover Screws: 100 in-lbs (12 Nm) Brake Line Junction Block Mounting Screws: 36 in-lbs (4 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.21 © Copyright Polaris Industries Inc.
  • Page 322 If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.22 © Copyright Polaris Industries Inc.
  • Page 323 10 ft-lbs (14 N·m) Fill / Check Plug Roller Cage 10 ft-lbs (14 N·m) Roller Pinion Gear Spring Retainer Snap Ring O-ring Cover Plate Screws 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.23 © Copyright Polaris Industries Inc.
  • Page 324 FINAL DRIVE FRONT GEARCASE VENT LINE ROUTING The front gearcase vent line routs vertical and loops through a section of the frame. Hose Clamp 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.24 © Copyright Polaris Industries Inc.
  • Page 325 Should have a minimum of 11 Vdc. 3. If electrical tests are within specification, remove gearcase (see Chapter 7 – Front Gearcase Removal page ) and inspect components. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.25 © Copyright Polaris Industries Inc.
  • Page 326 5. Remove the vent line from the front gearcase. 6. Remove the four bolts retaining the front gearcase to frame. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 327 Remove any metal particles from the drain plug AWD Diagnosis page 8.25 for detailed inspection magnet. process. 2. Remove the seven cover screws and remove the cover plate assembly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.27 © Copyright Polaris Industries Inc.
  • Page 328 9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 329 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.29 © Copyright Polaris Industries Inc.
  • Page 330 4. Install the RH output hub into the gearcase housing. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.30 © Copyright Polaris Industries Inc.
  • Page 331 11. Install a new O-ring on the cover plate assembly. NOTICE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.31 © Copyright Polaris Industries Inc.
  • Page 332 6. Add the proper lubricant to the front gearcase. Polaris Demand Drive Fluid: 2877922 TORQUE Front Gearcase Capacity: Cover Plate Screws: 6.75 fl. oz. (200 ml) 9 ft-lbs (12 N·m) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.32 © Copyright Polaris Industries Inc.
  • Page 333 FINAL DRIVE WHEEL HUBS FRONT HUB EXPLODED VIEW REAR HUB EXPLODED VIEW 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.33 © Copyright Polaris Industries Inc.
  • Page 334 FINAL DRIVE NOTES 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 8.34 © Copyright Polaris Industries Inc.
  • Page 335 ................9.22 SHOCK ASSEMBLY VIEWS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 336 Bosch Automotive Service Solutions – 1-800-328-6657 or http://polaris.service-solutions.com/ TOOL DESCRIPTION PART NUMBER Shock Spanner Wrench 2871095 Shock Spring Compressor Tool 2870623 Multi-Function Pliers 2876389 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 337 Steering Wheel Tie Rod End 23 ft-lb (31 Nm) 13 ft-lbs (18 Nm) Steering Rack Fasteners Bushing Steering Rack Tilt Shock 16 ft-lbs (22 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 338 5. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 339 9. Refer to steps 11-13 of Steering Shaft Bearing Be sure the lower washers and spacers are still on the Replacement for steering shaft installation. steering shaft. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 340 36 ft-lb (48 Nm) operation. 11. Install the two fasteners that retain the pivot tube. Torque fasteners to specification. TORQUE Pivot Tube Fasteners: 23 ft-lb (31 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 341 16 ft-lbs (22 Nm) Shaft to EPS Fastener Tie Rod Jam Nut Bearing Upper Steering Shaft 16 ft-lbs (22 Nm) 13 ft-lbs (18 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 342 4. Place the assembly in a vise. 4. Lift the steering wheel up and remove the two fasteners that retain the pivot tube. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 343 4. While supporting the power steering unit, remove the four nuts from the mount bracket. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 344 3. Place power steering mount bracket over the brake pedal mount studs and finger tighten the four nuts. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.10 © Copyright Polaris Industries Inc.
  • Page 345 Torque the nut to specification and reinstall the plastic wheel cover. TORQUE Steering Wheel Nut: 65 ft-lbs (88 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.11 © Copyright Polaris Industries Inc.
  • Page 346 Ball Joint Fasteners 23 ft-lb (31 Nm) Shock Fasteners 37 ft-lb (50 Nm) CV Guard Fasteners 36 in-lb (4 Nm) Grease Fittings 36 in-lb (4 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.12 © Copyright Polaris Industries Inc.
  • Page 347 11. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 12. Insert new A-arm bushings and pivot tube into new A-arm. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.13 © Copyright Polaris Industries Inc.
  • Page 348 Install lower ball joint pinch bolt (E) into the bearing carrier and torque bolt to specification. WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.14 © Copyright Polaris Industries Inc.
  • Page 349 A-arm to engage the Installation Adapter and Spacer. 5. Tighten the Press Asm. screw and fully install the ball joint into the arm. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.15 © Copyright Polaris Industries Inc.
  • Page 350 Properly support the bumper support and wires that are 7. Remove the four bolts retaining the upper radiator attached. mount bracket and remove the bracket from the frame. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.16 © Copyright Polaris Industries Inc.
  • Page 351 Lower Radiator Bracket Mounting Bolts: 8 ft-lbs (11 Nm) Front Bumper Support Bracket: 8 ft-lbs (11 Nm) Stabilizer Bar Linkage Fasteners: 37 ft-lb (50 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.17 © Copyright Polaris Industries Inc.
  • Page 352 Stabilizer Bar Mounting Fasteners Stabilizer Bar Linkage Fasteners A-Arm Mounting Fasteners 18 ft-lb (24 Nm) 40 ft-lbs (55 Nm) 40 ft-lb (54 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.18 © Copyright Polaris Industries Inc.
  • Page 353 40 ft-lb (54 Nm) Upper A-arm Fasteners: 18. Attach lower A-arm to bearing carrier. Torque new 40 ft-lb (54 Nm) fastener to specification. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.19 © Copyright Polaris Industries Inc.
  • Page 354 Remove the bushing and TORQUE bushing brackets from the vehicle. Stabilizer Mounting Bolt: 18 ft-lb (24 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.20 © Copyright Polaris Industries Inc.
  • Page 355 9. Torque the bushing retaining nut on the upper/lower stabilizer bar linkage to specification. TORQUE Stabilizer Bushing Retaining Nut: 40 ft-lbs (55 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.21 © Copyright Polaris Industries Inc.
  • Page 356 37 ft-lb (50 Nm) Primary Spring Fasteners 37 ft-lb (50 Nm) Primary Spring Rear Shock Spring Spacer Front Shock Rear Shock Secondary Spring Rear Shock Spacer 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.22 © Copyright Polaris Industries Inc.
  • Page 357 3. Reverse the procedure to reinstall the shock. Torque new fasteners to specification. TORQUE Shock Mounting Fasteners: 37 ft-lb (50 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.23 © Copyright Polaris Industries Inc.
  • Page 358 STEERING / SUSPENSION NOTES 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 9.24 © Copyright Polaris Industries Inc.
  • Page 359 ............10.28 CALIPER OVERHEATS (BRAKES DRAG) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.1 © Copyright Polaris Industries Inc.
  • Page 360 ..................10.28 BRAKES LOCK 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.2 © Copyright Polaris Industries Inc.
  • Page 361 .010" (.254 mm) SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION Mity Vac™ Pressure Test Tool 2870975 Bosch Automotive Service Solutions – 1-800-328-6657 or http://polaris.service-solutions.com/ 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.3 © Copyright Polaris Industries Inc.
  • Page 362 MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.
  • Page 363 3. Add brake fluid to the indicated MAX level of should be no less than 1/2"(1.3 cm). reservoir. 13. Check brake system for fluid leaks. Polaris DOT 4 Brake Fluid: 2872189 4. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw.
  • Page 364 17 ft-lbs (23 Nm) 36 in-lbs (4 Nm) Rear Caliper Fasteners Brake Switch Brake Line Clamps 44 ft-lbs (60 Nm) 15 ft-lbs (20 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.6 © Copyright Polaris Industries Inc.
  • Page 365 BRAKE SYSTEM BRAKE LINE ROUTING FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.7 © Copyright Polaris Industries Inc.
  • Page 366 BRAKE SYSTEM REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.8 © Copyright Polaris Industries Inc.
  • Page 367 Make note of front and rear brake line locations to master cylinder. Brake Pedal Free-play: .090″ (2.28 mm) 6. Bleed brake system. Refer BRAKE BLEEDING / FLUID CHANGE page 10.5. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.9 © Copyright Polaris Industries Inc.
  • Page 368 Brake Pedal Free-play: .090-.375″ (2.28-9.53 mm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.10 © Copyright Polaris Industries Inc.
  • Page 369 Clevis Pin Parking Brake Lever Fasteners Parking Brake Caliper/Pad Assembly 30 ft-lbs (42 Nm) Clip Parking Brake Switch Cable Adjuster Parking Brake Lever Assembly 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.11 © Copyright Polaris Industries Inc.
  • Page 370 After 8 full clicks of lever travel, the vehicle should not roll while parked. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.12 © Copyright Polaris Industries Inc.
  • Page 371 / shift cable bracket. 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.13 © Copyright Polaris Industries Inc.
  • Page 372 4. Install the new brake disc. Install the flat washer and mounting bolt . Torque the mounting bolt to specification. TORQUE Parking Brake Disc Mounting Bolt: 26 lb-ft (35 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.14 © Copyright Polaris Industries Inc.
  • Page 373 Banjo Bolt Sealing Washer Piston Square O-ring (thin) Caliper Piston Brake Line Brake Bleeder Brake Pad Mount 47 in-lbs (5 Nm) Brake Caliper Brake Pads Boot 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.15 © Copyright Polaris Industries Inc.
  • Page 374 When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 7. Remove the inner pad from the bracket and caliper. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.16 © Copyright Polaris Industries Inc.
  • Page 375 Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.17 © Copyright Polaris Industries Inc.
  • Page 376 Replace if damaged or worn beyond may drag upon assembly. service limit. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. MEASUREMENT Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore Front Caliper Piston Bore I.D.:...
  • Page 377 Brake Disc Thickness New: .0188″ (4.78 mm) Service Limit: 0.170″ (4.32 mm) Brake Disc Thickness Variance Service Limit: 0.002″ (.051 mm) difference between measurements 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.19 © Copyright Polaris Industries Inc.
  • Page 378 18 ft-lb (24 Nm) pads. CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.20 © Copyright Polaris Industries Inc.
  • Page 379 Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.21 © Copyright Polaris Industries Inc.
  • Page 380 REAR CALIPER ASSEMBLY VIEW Socket Set Screw Pistons Bleeder Screw 48 in-lb (5 Nm) Boots Caliper Assembly Caliper Mount Square O-Rings Brake Pad 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.22 © Copyright Polaris Industries Inc.
  • Page 381 When removing caliper, be careful not to damage brake line. Support caliper to avoid kinking or bending brake line. 7. Remove the inner brake pad. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.23 © Copyright Polaris Industries Inc.
  • Page 382 Rear Caliper Piston O.D.: Standard: 1.1875″ (30.16 mm) Service Limit: 1.186″ (30.12 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.24 © Copyright Polaris Industries Inc.
  • Page 383 Install the smaller o-ring in the top groove. MEASUREMENT 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN Rear Brake Pad Thickness: 2872189). Install piston with a twisting motion while pushing inward. Piston should slide in and out 0.298 ±...
  • Page 384 Torque castle nut to specification and install a new 2. Remove wheel hub cotter pin , castle nut cotter pin. washers TORQUE Rear Wheel Hub Castle Nut: 180 ft-lbs (244 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.26 © Copyright Polaris Industries Inc.
  • Page 385 5. Turn the adjustment set screw clockwise until the stationary pad contacts the disc, then back off 1/2 turn. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.27 © Copyright Polaris Industries Inc.
  • Page 386 • Brake pads dragging • Brake caliper dragging PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds serv- ice limit) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 10.28 © Copyright Polaris Industries Inc.
  • Page 387 BODY COMPONENT REMOVAL ..............11.13 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.1 © Copyright Polaris Industries Inc.
  • Page 388 Be sure the area to be flame treated is clean and free of gasoline or flammable residue. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.2 © Copyright Polaris Industries Inc.
  • Page 389 Attach side bars to cab frame using M8 screws and nuts top and bottom. Tighten to specification. M8 Fasteners (Hip Bolster): 8 ft-lb (11 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.3 © Copyright Polaris Industries Inc.
  • Page 390 BODY / FRAME SIDE SAFETY NETS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.4 © Copyright Polaris Industries Inc.
  • Page 391 BODY / FRAME DASH INSTRUMENTS / GLOVEBOX Torx Fasteners 8 ft-lb (11 Nm) Plastic Rivets 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.5 © Copyright Polaris Industries Inc.
  • Page 392 8 ft-lb (11 Nm) Hood Push Rivets Storage Case (LE models) Winch Pocket Cover Cover Screws Storage Case Bracket (LE models) 36 in-lbs (4 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.6 © Copyright Polaris Industries Inc.
  • Page 393 Rear Bumper Fasteners Torque until Fully Seated 8 ft-lb (11 Nm) Rear Bumper Bracket Fasteners Rear Bumper 8 ft-lb (11 Nm) Rear Bumper Bracket 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.7 © Copyright Polaris Industries Inc.
  • Page 394 48 in-lbs (5 Nm) Seat Bottom Screws Seat Base Assembly 48 in-lbs (5 Nm) Seat Base Fasteners Seat Latch 48 in-lbs (5 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.8 © Copyright Polaris Industries Inc.
  • Page 395 BODY / FRAME SEAT BELTS / MOUNTING 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.9 © Copyright Polaris Industries Inc.
  • Page 396 BODY / FRAME FLOOR / ROCKER PANELS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.10 © Copyright Polaris Industries Inc.
  • Page 397 BODY / FRAME REAR CARGO BOX / FENDERS 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.11 © Copyright Polaris Industries Inc.
  • Page 398 BODY / FRAME CHASSIS / MAIN FRAME 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.12 © Copyright Polaris Industries Inc.
  • Page 399 3. Lift the panel upward and towards the front of the vehicle while guiding the seat belt latches through the grommet to remove the panel. 3. Remove the rear bumper from the vehicle. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.13 © Copyright Polaris Industries Inc.
  • Page 400 10. If dash is installed, remove the two push rivets that attach the lower portion of the fender flair to the rocker panels. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.14 © Copyright Polaris Industries Inc.
  • Page 401 2. Remove the five push rivets that secure the rear fender flair and remove the fender flair from the vehicle. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.15 © Copyright Polaris Industries Inc.
  • Page 402 9. Remove the two push pins (D) from both sides of the cargo box / rocker panels. 10. Remove intake grill and foam filters from the LH side of the rear storage box. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.16 © Copyright Polaris Industries Inc.
  • Page 403 6. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.17 © Copyright Polaris Industries Inc.
  • Page 404 BODY / FRAME NOTES 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 11.18 © Copyright Polaris Industries Inc.
  • Page 405 ............. . . 12.32 STARTER SOLENOID BENCH TEST 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.1 © Copyright Polaris Industries Inc.
  • Page 406 ................. 12.45 CAN SYSTEM TESTING 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.2 © Copyright Polaris Industries Inc.
  • Page 407 (K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.3 © Copyright Polaris Industries Inc.
  • Page 408 2. If the wiring diagram does not open the Adobe navigation bars, click on the Adobe Icon. 3. Click on the Layers Icon. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.4 © Copyright Polaris Industries Inc.
  • Page 409 If there is a diagnostic problem with the power steering system, the power steering MIL will illuminate and blink in place of the check engine MIL. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.5 © Copyright Polaris Industries Inc.
  • Page 410 Apply pressure on the bezel while pressing down on the instrument cluster. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.6 © Copyright Polaris Industries Inc.
  • Page 411 • Turn the ignition key to START. There should be con- tinuity between switch pins A and B; C and D; E and F. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.7 © Copyright Polaris Industries Inc.
  • Page 412 • Move the switch to 2WD. There should be no continuity between any pins. • Move the switch to TURF. There should be continuity between switch pins 1 and 2; 4 and 5. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.8 © Copyright Polaris Industries Inc.
  • Page 413 RESISTANCE VALUE GEAR WHEN MEASURED AT SWITCH POSITION TERMINALS A AND B HIGH 620 Ω 300 Ω 160 Ω 75 Ω PARK 24 Ω 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.9 © Copyright Polaris Industries Inc.
  • Page 414 TORQUE Brake Switch: 15 ft-lb (20 Nm) 4. Bleed the brake system. See Chapter 9 – BRAKE BLEEDING / FLUID CHANGE page 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.10 © Copyright Polaris Industries Inc.
  • Page 415 Testing The Parking Brake Switch 1. Disconnect the harness connector at the parking brake switch (Orange/Red and Red/Blue wires). 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.11 © Copyright Polaris Industries Inc.
  • Page 416 4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.12 © Copyright Polaris Industries Inc.
  • Page 417 CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.13 © Copyright Polaris Industries Inc.
  • Page 418 AWD Switch Transmission Switch Fuel Injector 12V Receptacle Speed Sensor Instrument Cluster Diagnostic Plug AWD Coil Fuse Box Ignition Coil Voltage Regulator EPS Power 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.14 © Copyright Polaris Industries Inc.
  • Page 419 CHASSIS ELECTRICAL MAIN HARNESS ROUTING NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.15 © Copyright Polaris Industries Inc.
  • Page 420 CHASSIS ELECTRICAL MAIN HARNESS RETENTION LOCATIONS Front The white tape on the harness signifies a retention point. Zip Tie Retention Locations Rear 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.16 © Copyright Polaris Industries Inc.
  • Page 421 80% of all electrical issues are caused by bad/failed connections and grounds. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.17 © Copyright Polaris Industries Inc.
  • Page 422 Maximum of .01 DCA (10 mA) Charging system damage will occur if incompatible components are installed. Always reference the Polaris 9. If over 10 milliamps, go to the fuse block and start Electronic Parts Catalog for the proper part numbers.
  • Page 423 TEST 2: Resistance Value of Each Stator Leg to Ground 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.19 © Copyright Polaris Industries Inc.
  • Page 424 If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. TORQUE Regulator Mounting Fasteners: 75 in-lb (6 Nm) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.20 © Copyright Polaris Industries Inc.
  • Page 425 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. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.21 © Copyright Polaris Industries Inc.
  • Page 426 5. Add electrolyte to bring the level back to the upper level mark on the battery case. 6. Charge battery for 10 - 17 hours at 1 to 1.5 AMPS. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.22 © Copyright Polaris Industries Inc.
  • Page 427 (negative) cable first. When reinstalling the battery, install the black (negative) 6. Verify that cables are properly routed and reinstall cable last. the driver’s seat. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.23 © Copyright Polaris Industries Inc.
  • Page 428 OPEN CIRCUIT VOLTAGE load testing. STATE OF CHARGE MAINTENANCE FREE Authorized Polaris dealers/distributors are required to 12.7 V and up 100% use the conductance analyzer when testing 12V Polaris batteries. 75% Charged 12.5 V 50% Charged 12.2 V 25% Charged 12.0 V...
  • Page 429 Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.25 © Copyright Polaris Industries Inc.
  • Page 430 If electrolyte contacts the vehicle frame, corrosion will occur. 7. Route cables so they are tucked away in front and behind battery. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.26 © Copyright Polaris Industries Inc.
  • Page 431 Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.27 © Copyright Polaris Industries Inc.
  • Page 432 5. Install the front bumper as shown in Chapter 5 if previously removed. 6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlamp Adjustment” procedure as shown in this chapter. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.28 © Copyright Polaris Industries Inc.
  • Page 433 Apply Dielectric Grease (PN 2871329). 3. Test the tail light, brake light and turn signal (INTL Only) to verify it is working properly. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.29 © Copyright Polaris Industries Inc.
  • Page 434 (68°F = 20°C), disconnect the harness. 2. With the meter in the ohms mode, place the meter leads onto the sensor contacts. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.30 © Copyright Polaris Industries Inc.
  • Page 435 Refer to the voltage drop tests on the starter system in this chapter. Voltage should not exceed .1 DC volts per connection 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.31 © Copyright Polaris Industries Inc.
  • Page 436 Steel Rims: 36 ft-lbs (49 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° ELECTRICAL TESTING Condition: Starter fails to turn over the engine. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.32 © Copyright Polaris Industries Inc.
  • Page 437 CHASSIS ELECTRICAL 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.33 © Copyright Polaris Industries Inc.
  • Page 438 The PROPER EPS SYSTEM DIAGNOSING system is Polaris Digital Wrench compatible for simplified READ BEFORE YOU REPLACE THE EPS UNIT! diagnostics and system troubleshooting through the vehicle’s diagnostic port.
  • Page 439 CHASSIS ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.35 © Copyright Polaris Industries Inc.
  • Page 440 CHASSIS ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.36 © Copyright Polaris Industries Inc.
  • Page 441 CHASSIS ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.37 © Copyright Polaris Industries Inc.
  • Page 442 Power In Lights 15A Fuse Power Out Coil High Power In Fuel Pump Relay Power Out Coil Low Fuel Pump 10A Fuse Power In 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.38 © Copyright Polaris Industries Inc.
  • Page 443 Power In Accessory 15A Fuse Power Out Coil High Power In Brake Relay Power Out Coil Low Spare 20A Fuse Spare 10A Fuse 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.39 © Copyright Polaris Industries Inc.
  • Page 444 Power In Fuel Pump Relay Power Out Coil Low Power In Key 10A Fuse Power Out Power In Drive 10A Fuse Power Out 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.40 © Copyright Polaris Industries Inc.
  • Page 445 Term 10A Fuse Power Out Power In Accessory 15A Fuse Power Out Spare 10A Fuse Spare 15A Fuse Spare 20A Fuse (NOT USED) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.41 © Copyright Polaris Industries Inc.
  • Page 446 Fuel Pump Relay Power Out Coil Low Power In Unsw 10A Fuse Power Out Power In Drive 10A Fuse Power Out Chassis Relay Coil High 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.42 © Copyright Polaris Industries Inc.
  • Page 447 Coil High Power In Headlight Relay Power Out Coil Low Power In HDLT 20A Fuse Power Out Power In Key 10A Fuse Power Out 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.43 © Copyright Polaris Industries Inc.
  • Page 448 EPS Relay (if EPS Unit (power plug) applicable) Fan Circuit Fan Relay - Power In Breaker EPS Fuse (if EPS Relay - Power In applicable) 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.44 © Copyright Polaris Industries Inc.
  • Page 449 120 Ω. Anything other than 120 Ω is bad. • A RZR not equipped with a PIDD should see a reading of 60 Ω. A reading of 120 Ω is bad. 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.45 © Copyright Polaris Industries Inc.
  • Page 450 CHASSIS ELECTRICAL NOTES 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual 12.46 © Copyright Polaris Industries Inc.
  • Page 451 Disc Replacement (Rear) ........10.26 Coolant Drain ............3.19 Disc Runout (Front) ..........10.19 Coolant Drain / Fill .............2.37 General Specifications ..........10.3 Coolant Level Inspection..........2.36 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 452 Camshaft Sprocket Inspection........3.39 Updates ...............4.22 Camshaft Timing - Quick Reference ......3.53 Digital Wrench® Combustion Chamber Cleaning.........3.44 Polaris Mobile Digital Wrench® (PMDW) .....4.28 Cooling System............3.18 Disassembly, Engine Lower End........3.65 Cylinder Head Inspection .........3.42 Disc Cylinder Head Installation - Black Bolts .......3.59 Inspection (front) ..........
  • Page 453 Pinouts ..............12.6 Installation ............8.11 Front Gearcase............8.24 Removal...............12.6 Intake System Assembly .............8.30 Assembly View ............3.16 Assembly View ............8.23 Disassembly / Inspection .........8.27 Installation ............8.32 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 454 RZR 570........1.16-1.17, 1.20-1.21, 1.25 Inspection (front) ..........10.19 RZR 570 EPS........1.18-1.19, 1.22-1.23 Inspection (rear)........... 10.25 Parking Brake Assembly View (INT’L) .......... 10.11 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 455 Disassembly ............7.11 Starter Motor, Removal..........12.31 Gear / Shaft / Bearing Inspection .......7.22 Starter Solenoid Installation ............. 7.8 Operation ............12.32 Lubrication............2.44 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual IX.5 © Copyright Polaris Industries Inc.
  • Page 456 Wheel Alignment ............2.47 Wheel Bearing Inspection.............2.47 Wiring Diagrams ............47 Wiring Harness Component Locations ........... 12.14 Retention Locations ..........12.16 Routing .............. 12.15 9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 457 HARNESS -CHASSIS RZR 570 NON-EPS HARNESS -CHASSIS RZR 570 NON-EPS 13 17 21 25 29 33 37 41 45 8 12 16 20 24 28 32 36 40 44 48...
  • Page 458 HARNESS - CHASSIS RZR 570 EPS HARNESS - CHASSIS RZR 570 EPS...
  • Page 459 HARNESS - CHASSIS RZR S 570 HARNESS - CHASSIS RZR S 570...
  • Page 460 HARNESS - CHASSIS RZR 570 INTL HARNESS - CHASSIS RZR 570 INTL...

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