Polaris 2012 RANGER RZR 570 Vehicle Manuals

Polaris 2012 RANGER RZR 570 Vehicle Manuals

Manuals and User Guides for Polaris 2012 RANGER RZR 570 Vehicle. We have 1 Polaris 2012 RANGER RZR 570 Vehicle manual available for free PDF download: Service Manual

Polaris 2012 RANGER RZR 570 Service Manual

Polaris 2012 RANGER RZR 570 Service Manual (403 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 19.63 MB

Table of Contents

Table of Contents

3
- Chapter 1
  6
- Engine Designation Number
  6
- General Information
  6
- Model Identification
  6
- Model Information
  6
- Vehicle and Engine Serial Number Location
  6
- Vin Identification
  6
- Special Tools
  7
- Vehicle Information
  7
  - Publication Numbers
    7
  - Replacement Keys
    7
- Misc. Specifications and Charts
  12
  - Conversion Table
    12
  - Standard Bolt Torque Specification
    13
  - Metric Bolt Torque Specification
    13
  - Sae Tap / Drill Sizes
    14
  - Metric Tap / Drill Sizes
    14
Maintenance Chapter 2 Maintenance 2

15
- Maintenance
  15
  - Periodic Maintenance Chart
    17
- Break-In Period
  17
- Chapter 2
  17
- Maintenance Chart Key
  17
- Periodic Maintenance Overview
  17
- Pre-Ride - 25 Hour Maintenance Interval
  18
- 50 - 500 Hour Maintenance Interval
  19
- Maintenance Quick Reference
  20
- Grease Lubrication Points
  22
- Lubricants / Service Products
  23
- General Vehicle Inspection and Maintenance
  24
- Fuel System and Air Intake
  25
  - Fuel System
    25
  - Fuel Line
    25
  - Fuel Pump / Fuel Filters
    26
  - Vent Lines
    26
  - Throttle Pedal Inspection
    26
  - Throttle Freeplay Adjustment
    27
  - Engine and Pvt Intake Pre-Filter Service
    27
  - Air Filter Service
    28
- Engine
  30
  - Engine Oil Level
    30
  - Engine Oil and Filter Service
    30
  - Engine Breather Hose Inspection
    32
  - Engine and Transmission Mounts
    32
  - Compression Test Specification
    32
  - Valve Clearance Inspection
    32
  - Exhaust - Spark Arrestor
    34
- Transmission and Front Gearcase
  35
  - Specification Chart
    35
  - Transmission Lubrication
    35
  - Front Gearcase Lubrication
    37
- Cooling System
  39
  - Cooling System Exploded View
    39
  - Cooling System Overview
    40
  - Coolant Level Inspection
    40
  - Cooling System Pressure Test
    40
  - Coolant Strength / Type
    41
  - Cooling System
    41
  - Coolant Drain / Fill
    41
- Final Drive / Wheel and Tire
  42
  - Wheel and Hub Torque Table
    42
  - Wheel Removal
    42
  - Wheel Installation
    43
  - Tire Inspection
    43
  - Tire Pressure
    44
  - Drive Shaft Boot Inspection
    44
- Electrical and Ignition System
  44
  - Battery Maintenance
    44
  - Battery Removal
    45
  - Battery Installation
    45
  - Battery off Season Storage
    45
  - Spark Plug Service
    46
  - Engine to Frame Ground
    47
- Steering
  47
  - Steering Inspection
    47
  - Steering Wheel Freeplay
    48
  - Tie Rod End / Wheel Hub Inspection
    48
  - Wheel Toe Alignment Inspection
    49
  - Wheel Toe Adjustment
    49
- Suspension
  50
  - Spring Preload Adjustment
    50
- Brake System
  51
Chapter 3 Engine / Cooling System

53
- Engine / Cooling System
  53
  - General Information
    55
- Engine Lubrication Specifications
  55
- Special Tools
  55
- Oil Pressure Test
  56
- Engine Oil Flow Chart
  57
- Engine Service Specifications
  58
  - Engine Specifications - 1204286 Rzr570Ho-11
    58
- Engine Detail - Torque Values / Sequences / Assembly Notes
  60
- Engine Cooling System
  65
  - Cooling System Exploded View and Coolant Flow Diagram
    66
  - Engine Cooling System
    66
  - Cooling System Specifications
    67
  - Cooling System Pressure Test
    67
  - Pressure Cap Test
    68
  - Radiator
    68
  - Coolant Drain / Radiator Removal
    69
  - Thermostat Replacement
    70
  - Cooling System Bleeding Procedure
    70
- Water Pump Service
  72
  - Water Pump Cover and Impeller Service
    72
  - Water Pump Mechanical Seal / Oil Seal Replacement
    73
- Engine Service
  78
  - Accessible Engine Components
    78
  - Top-End Service (Engine in Chassis)
    78
  - Engine Removal
    79
  - Engine Installation
    83
  - Engine Break-In Period
    86
  - Engine Mounting and Torque Values
    87
  - Engine Lubrication Specifications
    87
- Setting Tdc (Top-Dead-Center)
  88
- Engine Disassembly / Inspection - Top End
  89
  - Valve Cover Removal
    89
  - Camshaft Removal
    89
  - Camshaft Sprocket Inspection
    91
  - Camshaft / Camshaft Bore Inspection
    91
  - Exhaust Camshaft Decompression Mechanism
    93
  - Cam Chain and Guide Service
    93
  - Cylinder Head Removal
    94
  - Cylinder Head Disassembly
    94
  - Cylinder Head Inspection
    96
  - Cylinder Head Warp Inspection
    96
  - Valve Inspection
    96
  - Combustion Chamber Cleaning
    97
  - Valve Seat Reconditioning
    98
  - Cylinder Removal
    100
  - Cylinder Inspection
    100
  - Piston Removal
    101
  - Piston-To-Cylinder Clearance
    102
  - Piston / Rod Inspection
    102
  - Piston Ring Installed Gap
    103
  - Honing to Oversize
    104
  - Cylinder Hone Selection / Honing Procedure
    104
  - Cleaning the Cylinder after Honing
    104
- Engine Assembly - Top End
  105
  - Piston Ring Installation
    105
  - Piston / Connecting Rod Assembly
    106
  - Cylinder Installation
    107
  - Cylinder Head Assembly
    108
  - Valve Sealing Test
    109
  - Cylinder Head Installation
    110
  - Valve Clearance Check / Adjustment
    111
  - Intake Valve Lash - Shim Selection Matrix
    113
  - Exhaust Valve Lash - Shim Selection Matrix
    114
  - Camshaft Installation / Timing
    115
  - Camshaft Timing - Quick Reference
    118
  - Valve Cover Installation
    119
- Engine Disassembly / Inspection - Lower End
  120
  - Crankcase Disassembly
    120
  - Flywheel / Stator Housing Removal
    120
  - Starter One-Way Clutch Inspection
    121
  - Starter One-Way Clutch Installation
    122
  - Flywheel Installation
    123
  - Stator Removal
    124
  - Stator / Stator Cover Installation
    125
  - Oil Pump Removal
    125
  - Oil Pump Assembly
    127
  - Crankcase Breather Service
    128
  - Crankcase Separation
    128
  - Balance Shaft Removal / Inspection
    129
  - Crankshaft Removal
    130
  - Crankshaft Inspection
    130
  - Pto Side Crankcase Bearing Service
    131
  - Mag Side Crankcase Bearing Service
    132
  - Oil Pickup Assembly Inspection
    133
  - Oil Pressure Regulator (Bypass) Valve Inspection
    133
  - Crankcase Inspection
    133
- Engine Assembly - Lower End
  134
  - Crankcase Assembly - Pto Side
    134
  - Balance Shaft Installation / Timing
    136
  - Final Crankcase Assembly
    136
- Troubleshooting
  138
  - Engine
    138
  - Cooling System
    139
Chapter 4 Electronic Fuel Injection

141
- General Information
  142
  - Service Notes
    144
  - Efi System Exploded View
    145
  - Efi System Component Locations
    146
- Electronic Fuel Injection
  148
- Fuel Tank
  148
- Efi Operation Overview
  150
- Initial Priming / Starting Procedure
  150
- Principal Components
  150
- Electronic Control Unit (Ecu)
  151
  - Operation Overview
    151
  - Ecu Service
    151
  - Ecu Replacement
    152
- Temp / Manifold Absolutepressure Sensor (T-Map)
  153
  - Operation Overview
    153
  - T-Map Sensor Test
    153
  - T-Map Sensor Replacement
    153
- Crankshaft Position Sensor (Cps)
  154
- Fuel Injectors
  155
  - Operation Overview
    155
  - Fuel Injector Troubleshooting
    155
  - Fuel Injector Test
    155
  - Cps Replacement
    155
  - Fuel Injector Replacement
    157
- Fuel Pump
  158
  - Operation Overview
    158
  - Fuel Sender Test
    159
  - Fuel Pump Test
    159
  - Fuel Pump Replacement
    161
  - Fuel Tank Removal
    164
  - Fuel Tank Installation
    167
- Idle Air Control (Iac)
  167
  - Throttle Position Sensor (Tps)
    168
  - Operation Overview
    168
  - Tps Resistance Tests
    169
  - Tps Tester / Regulator
    169
  - Tps Replacement
    169
- Engine Coolant Temperature Sensor (Ect)
  171
  - Operation Overview
    171
  - Ect Sensor Test
    171
  - Ect Sensor Replacement
    172
- Ignition Coil
  172
- Efi Diagnostics
  174
  - Efi Troubleshooting
    177
- Digital Wrench™ Operation
  178
  - Diagnostic Software Version
    178
  - Guided Diagnostic Available
    178
- Efi System Electrical Diagram
  187
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

189
- Body / Steering / Suspension
  189
  - Torque Specifications
    190
  - Special Tools
    190
  - Cab Frame
    191
- Chapter 5 Assembly / Removal
  191
- Body Exploded Views
  192
  - Side Safety Nets
    192
  - Dash Instruments / Controls / Glovebox
    193
  - Hood / Front Body Work
    194
  - Front Bumper
    195
  - Rear Bumper
    195
  - Seat Assembly
    196
  - Seat Belts / Mounting
    196
  - Floor / Rocker Panels
    197
  - Rear Cargo Box / Fenders
    198
  - Chassis / Main Frame
    199
- Body Component Removal
  200
  - Seats
    200
  - Rear Service Panel
    200
  - Front Bumper
    200
  - Rear Bumper
    200
  - Hood and Front Body Work
    201
  - Rear Fender Flair Removal
    202
  - Cargo Box Assembly Removal
    202
  - Rocker Panels, Console and Floor
    203
- Steering Assembly
  204
  - Exploded View
    204
  - Steering Wheel Removal
    205
  - Steering Shaft Bearing Replacement
    205
- Front A-Arms
  206
  - Removal / Replacement
    206
  - Exploded View
    207
- Ball Joint Service
  208
  - Removal
    208
  - Installation
    209
- Front Stabilizer Bar
  209
  - Stabilizer Bar Linkage Removal
    209
  - Stabilizer Bar Removal
    209
  - Exploded View
    211
- Rear A-Arms
  212
  - Removal
    212
  - Installation
    213
  - Exploded View
    213
- Rear Stabilizer Bar
  214
  - Removal / Installation
    214
- Shocks / Springs / Fasteners
  215
  - Exploded View
    215
  - Shock Removal / Installation
    215
  - Shock Replacement
    216
- Decal Replacement
  216
Clutching Chapter 6 Clutching

217
- Clutching
  217
  - Special Tools and Supplies
    218
  - Torque Specifications
    218
- Chapter 6 Pvt System Fastener Torques
  218
- Pvt System Overview
  218
  - General Operation
    218
  - Drive Clutch Operation
    219
  - Driven Clutch Operation
    219
  - Pvt Break-In (Drive Belt / Clutches)
    219
  - Maintenance / Inspection
    219
  - Overheating / Diagnosis
    220
- Pvt System Service
  221
  - Pvt Covers and Ducting Components
    221
  - Pvt Disassembly
    221
  - Pvt Assembly
    223
- Drive Belt
  224
  - Belt Removal
    224
  - Belt Inspection
    224
  - Belt Installation
    225
  - Pvt Break-In (Drive Belt / Clutches)
    225
- Clutch Center Distance
  226
  - Inspection
    226
  - Adjustment
    226
- Drive Clutch Service
  228
  - Drive Clutch Exploded View
    228
  - Clutch Disassembly
    229
  - Drive Clutch Spring Inspection
    230
  - Shift Weight Inspection
    230
  - Spider Removal
    231
  - Roller, Pin, and Thrust Washer Inspection
    232
  - Button to Tower Clearance Inspection
    232
  - Bearing Inspection
    232
  - Clutch Inspection
    233
  - Bushing Service
    234
  - Clutch Assembly
    236
- Driven Clutch Service
  237
  - Exploded View
    237
  - Clutch Disassembly / Inspection
    237
  - Clutch Assembly
    240
- Troubleshooting
  241
Final Drive Chapter 7 Final Drive

243
- Final Drive
  243
  - Special Tools
    244
  - Torque Specifications
    244
- Chapter 7 Wheel and Hub Torque Table
  244
- Front Bearing Carrier
  244
  - Bearing Carrier Inspection / Removal
    244
  - Bearing Replacement
    245
  - Bearing Carrier Installation
    246
- Front Drive Shaft
  248
  - Drive Shaft Removal
    248
  - Drive Shaft / CV Joint Handling Tips
    249
  - Outer CV Joint / Boot Replacement
    249
  - Inner Plunging Joint / Boot Replacement
    251
  - Drive Shaft Installation
    252
- Propshaft Service
  254
  - Removal / Installation
    254
- Transmission
  255
  - Propshaft U-Joint Service
    256
    
    Disassembly
    256
    
    Assembly
    257
  - Front Gearcase / Centralized Hilliard
    258
    
    Centralized Hilliard Exploded View
    258
    
    All Wheel Drive Operation
    259
    
    Awd Diagnosis
    260
    
    Gearcase Removal
    261
    
    Gearcase Disassembly / Inspection
    262
    
    Gearcase Assembly
    265
    
    Gearcase Installation
    267
  - Rear Bearing Carrier
    268
    
    Bearing Carrier Inspection / Removal
    268
- Brakes
  268
  - Bearing Replacement
    269
    
    Bearing Carrier Bushing Replacement
    270
    
    Bearing Carrier Installation
    271
  - Rear Drive Shaft
    272
    
    Drive Shaft Removal
    272
    
    Outer CV Joint / Boot Replacement
    274
    
    Inner Plunging Joint / Boot Replacement
    277
    
    Drive Shaft Exploded View
    279
    
    Drive Shaft Installation
    280
    
    Wheel Hub
    280
  - Wheel Hubs
    282
    
    Front Hub Exploded View
    282
    
    Rear Hub Exploded View
    282
Chapter 8 Transmission

283
- Lubrication
  284
- Special Tools
  284
- Specifications
  284
- Torque Specifications
  284
- Transmission Mounting and Torque Values
  284
- Shift Lever
  285
  - Removal
    285
  - Installation
    285
- Shift Cable
  286
  - Inspection
    286
  - Adjustment
    286
- Transmission Service
  287
  - Transmission Removal
    287
  - Transmission Installation
    290
  - Transmission Disassembly
    294
  - Gear / Shaft / Bearing Inspection
    300
  - Snorkel Gear Backlash Procedure
    301
  - Transmission Assembly
    303
- Electrical
  308
  - Transmission Disassembly
    309
    
    Planetary Differential Disassembly
    314
    
    Planetary Differential Bushing Replacement
    314
    
    Planetary Differential Assembly
    317
    
    Gear / Shaft / Bearing Inspection
    317
    
    Snorkel Gear Backlash Procedure
    318
    
    Transmission Assembly
    320
  - Troubleshooting
    325
  - Troubleshooting Checklist
    325
  - Transmission Exploded View
    326
  - Transmission Exploded View (Intl)
    328
Brakes Chapter 9 Brakes

331
- Transmission Service (Intl)
  308
  - Differential Operation
    308
- Chapter 9
  332
- General Specifications
  332
- Special Tools
  332
- Torque Specifications
  332
- Brake Noise Troubleshooting
  333
- Brake System Service Notes
  333
- Hydraulic Brake System Operation
  334
- Brake System Exploded View
  335
- Brake Pedal Lever
  336
  - Pedal Removal
    336
  - Pedal Installation
    336
- Master Cylinder
  336
- Brake Bleeding / Fluid Change
  337
- Parking Brake (Intl Model)
  338
- Parking Brake Caliper Service (Intl Model)
  340
- Parking Brake Disc (Intl Model)
  342
- Front Brake Pads
  343
  - Pad Removal
    343
  - Pad Inspection
    344
  - Pad Assembly / Installation
    344
  - Brake Burnishing Procedure
    345
- Front Caliper Service
  346
  - Caliper Exploded View
    346
  - Caliper Removal
    346
  - Caliper Disassembly
    347
  - Caliper Inspection
    348
  - Caliper Assembly
    348
  - Caliper Installation
    349
- Front Brake Disc
  350
  - Disc Runout
    350
  - Disc Inspection
    350
  - Disc Replacement
    351
- Rear Brake Pads
  352
  - Pad Removal
    352
  - Pad Inspection
    353
  - Pad Assembly / Installation
    353
  - Brake Burnishing Procedure
    354
- Rear Caliper Service
  355
  - Caliper Exploded View
    355
  - Caliper Removal
    355
  - Caliper Disassembly
    356
  - Caliper Inspection
    357
  - Caliper Assembly
    357
  - Caliper Installation
    358
- Rear Brake Disc
  358
  - Disc Inspection
    358
  - Disc Replacement
    359
- Troubleshooting
  360
  - Pedal Vibration
    360
  - Brakes Lock
    360
Electrical Chapter 10 Electrical

361
- Chapter 10
  363
- Electrical Service Notes
  363
- General Information
  363
- Special Tools
  363
- Under-Dash Components
  363
- Switches / Controls
  364
  - Ignition Key Switch / Headlamp Switch
    364
  - Ignition Key Switch (Intl)
    364
  - Awd / 2Wd Switch
    365
  - Awd / 2Wd / Turf Switch (Intl)
    365
  - Transmission (Gear Position) Switch
    366
  - Turn Signal Switch (Intl)
    366
  - Hazard Switch (Intl)
    366
  - Brake Light Switch
    367
  - Parking Brake Switch (INTL Model)
    367
- Rear Diff Solenoid (Intl)
  368
  - Differential Solenoid Overview
    368
  - Differential Solenoid Circuit Operation
    368
- Vehicle Speed Sensor
  369
  - Speed Sensor Location
    369
  - Speed Sensor Testing
    369
- Instrument Cluster
  370
  - Overview
    370
  - Rider Information Display
    371
  - Information Display Area
    371
  - Diagnostic Mode
    375
  - Instrument Cluster Pinouts
    376
  - Instrument Cluster Removal
    376
  - Instrument Cluster Installation
    377
- All Wheel Drive Coil
  377
  - Operation Overview
    377
  - Diagnosing System Failures
    377
- Head Lights
  378
  - Headlight Adjustment
    378
  - Headlamp Bulb Replacement
    378
  - Headlamp Housing Removal
    379
  - Headlamp Housing Installation
    379
- Tail / Brake Lights
  379
  - Bulb Replacement
    379
- Cooling System
  380
- Efi Diagnostics
  382
  - Efi Component Testing
    382
- Fuel Sender
  382
  - Testing
    382
- Charging System
  383
  - Current Draw - Key off
    383
  - Charging System "Break Even" Test
    383
  - Charging System Stator (Alternator) Tests
    384
  - Stator (Alternator) Replacement
    384
  - Regulator / Rectifier
    385
  - Charging System Testing Flow Chart
    386
- Battery Service
  387
  - Battery Specifications
    387
  - General Battery Information
    387
  - Battery Activation
    388
  - Battery Removal / Installation
    388
  - Battery off Season Storage
    389
  - Battery Testing
    389
  - Battery Conductance Analyzer
    389
  - Ocv - Open Circuit Voltage Test
    390
  - Load Test
    390
  - Specific Gravity Test
    390
  - Charging Procedure
    391
- Starting System
  391
  - Troubleshooting
    391
  - Voltage Drop Test
    391
  - Starter Motor Removal
    392
  - Starter Motor Installation
    392
  - Starter Solenoid Bench Test
    393
  - Starter Solenoid Operation
    393
- Starting System Testing Flow Chart
  394
- Electrical System Breakouts
  395
  - Awd
    395
  - Vehicle Speed Sensor
    395
  - Cooling Fan
    396
  - Charging System
    397
  - Chassis Power
    397
  - Lights
    398

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