Polaris 2014 Sportsman 570 EF Manuals

Polaris 2014 Sportsman 570 EF Manuals

Manuals and User Guides for Polaris 2014 Sportsman 570 EF. We have 1 Polaris 2014 Sportsman 570 EF manual available for free PDF download: Service Manual

Polaris 2014 Sportsman 570 EF Service Manual

Polaris 2014 Sportsman 570 EF Service Manual (456 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 54.38 MB

Table of Contents

General Information Chapter 1 General Information

5
- Table of Contents
  5
- Chapter 1
  6
- Model Number Designation
  6
- Vehicle Identification
  6
- Vehicle Identification Number (Vin) Designation
  6
- Vehicle and Engine Serial Numbers
  7
- Transmission I.D. Location
  8
- Vehicle Information
  9
  - Publication Part Numbers
    9
  - Replacement Keys
    9
  - Special Tools
    9
- Vehicle Specifications
  10
- Clutching Specifications
  14
  - Clutching Chart
    14
- Misc. Specifications and Charts
  15
  - Conversion Table
    15
  - Standard Bolt Torque Specification
    16
  - Metric Bolt Torque Specification
    16
  - Sae Tap / Drill Sizes
    17
  - Metric Tap / Drill Sizes
    18
  - Decimal Equivalents
    19
Maintenance Chapter 2 Maintenance

21
- Special Tools
  23
- Break-In Period
  24
- Chapter 2
  24
- Inspection / Maintenance Intervals
  24
- Pre-Ride / Daily Inspection
  24
- Periodic Maintenance Chart
  26
- Vehicle Storage
  28
  - Storage Tips
    28
- Lubricants / Service Products
  29
  - Polaris Lubricants, Maintenance and Service Products
    29
  - Lubrication Components
    30
- Fuel System and Air Intake
  31
  - Fuel System
    31
  - Fuel Lines
    31
  - Vent Lines
    31
  - Throttle Inspection
    32
  - Throttle Cable / Throttle Release System (Trs Switch) Adjustment
    32
  - Air Filter/Pre-Filter Service
    33
  - Air Box Sediment Drain
    34
  - Crankcase Breather Valve / Hose
    35
- Engine
  36
  - Engine Oil Level
    36
  - Oil and Filter Change
    36
  - Compression Test Specification
    38
  - Engine Mounts
    38
  - Valve Clearance Inspection
    38
  - Exhaust Pipe
    40
- Transmission and Front Gearcase
  41
- Cooling System
  44
  - Liquid Cooling System Overview
    44
  - Coolant Level Inspection
    44
  - Radiator Coolant Level
    44
  - Cooling System Hoses
    45
  - Cooling System Pressure Test
    45
  - Coolant Strength / Type
    46
  - Coolant Drain / Fill
    46
  - Radiator/Grill Screen
    47
- Final Drive / Wheel and Tire
  48
  - Wheels
    48
  - Wheel, Hub, and Spindle Torque Table
    48
  - Tire Pressure
    48
  - Wheel Removal Front or Rear
    48
  - Wheel Installation
    48
  - Tire Inspection
    49
  - CV Shaft Boot Inspection
    49
  - Frame, Nuts, Bolts, Fasteners
    49
- Brake System
  50
  - Brake System Inspection
    50
  - Brake Pad Inspection
    50
  - Hose/Fitting Inspection
    50
  - Auxiliary Brake Testing
    51
  - Auxiliary Brake Adjustment (Hydraulic)
    51
- Electrical and Ignition System
  52
  - Battery Maintenance
    52
  - Battery Removal
    52
  - Battery Installation
    53
  - Spark Plug Service
    54
  - Engine to Frame Ground
    55
- Steering
  56
  - Tie Rod End/Steering Inspection
    56
  - Front Suspension
    57
  - Suspension Spring Preload Adjustment
    57
  - Toe Alignment Adjustment
    57
  - Camber and Caster
    57
  - Wheel Alignment
    57
Engine Chapter 3 Engine

59
- Chapter 3
  62
- Engine Lubrication Specifications
  62
- General Information
  62
- Special Tools
  62
- Oil Pressure Test
  63
- Engine Oil Flow Chart
  64
- Engine Service Specifications
  65
  - Engine Specifications
    65
- Engine Detail - Torque Values / Sequences / Assembly Notes
  67
- Engine Cooling System
  73
- Water Pump Service
  80
  - Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
    80
  - Water Pump Mechanical Seal / Oil Seal Replacement
    80
- Engine Service
  88
  - Accessible Engine Components
    88
  - Top-End Service (Engine in Chassis)
    88
  - Engine Removal
    89
  - Engine Installation
    92
  - Engine Break-In Period
    95
  - Engine Lubrication Specifications
    95
  - Engine Mounting and Torque Values
    96
  - Setting Tdc (Top-Dead-Center)
    97
- Engine Disassembly / Inspection - Top End
  98
  - Valve Cover Removal
    98
  - Camshaft / Carrier Removal
    98
  - Camshaft Sprocket Inspection
    100
  - Camshaft Inspection
    100
  - Exhaust Camshaft Decompression Mechanism
    101
  - Cam Chain and Guide Service
    101
  - Cylinder Head Removal
    101
  - Cylinder Head Disassembly
    102
  - Cylinder Head Inspection
    103
  - Cylinder Head Warp Inspection
    103
  - Valve Inspection
    104
  - Combustion Chamber Cleaning
    105
  - Valve Seat Reconditioning
    105
  - Cylinder Removal
    107
  - Cylinder Inspection
    107
  - Piston Removal
    108
  - Piston-To-Cylinder Clearance
    109
  - Piston / Rod Inspection
    109
  - Piston Ring Installed Gap
    110
  - Honing to Oversize
    111
  - Cylinder Hone Selection / Honing Procedure
    111
  - Cleaning the Cylinder after Honing
    111
- Engine Assembly - Top End
  112
  - Piston Ring Installation
    112
  - Piston / Connecting Rod Assembly
    113
  - Cylinder Installation
    113
  - Cylinder Head Installation
    114
  - Valve Sealing Test
    115
  - Valve Clearance Check / Adjustment
    116
  - Intake Valve Lash - Tappet Selection Matrix
    119
  - Exhaust Valve Lash - Tappet Selection Matrix
    120
  - Camshaft Installation / Timing
    121
  - Camshaft Timing - Quick Reference
    124
  - Valve Cover Installation
    125
- Engine Disassembly / Inspection - Lower End
  126
  - Crankcase Disassembly
    126
  - Flywheel / Stator Housing Removal
    126
  - Starter One-Way Clutch Inspection
    126
  - Starter One-Way Clutch Installation
    128
  - Flywheel Installation
    128
  - Stator Removal
    129
  - Stator / Stator Cover Installation
    129
  - Oil Pump Removal
    130
  - Oil Pump Assembly
    132
  - Crankcase Breather Valve / Hose
    133
  - Crankcase Separation
    134
  - Balance Shaft Removal / Inspection
    135
  - Crankshaft Removal
    136
  - Crankshaft Inspection
    136
  - Pto Side Crankcase Bearing Service
    137
  - Mag Side Crankcase Bearing Service
    139
  - Oil Pickup Assembly Inspection
    139
  - Oil Pressure Regulator (Bypass) Valve Inspection
    139
  - Crankcase Inspection
    140
- Engine Assembly - Lower End
  141
  - Crankcase Assembly - Pto Side
    141
  - Balance Shaft Installation / Timing
    143
  - Final Crankcase Assembly
    143
- Troubleshooting
  145
  - Engine
    145
  - Cooling System
    146
Fuel System - General Chapter 4 Fuel System - General

147
- Chapter 4
  149
- General Information
  149
- Service Notes
  149
- Efi System Exploded View
  150
- Electrical Diagram
  151
- Efi System Component Locations
  152
- Special Tools
  153
- Electronic Fuel Injection
  156
  - Principal Components
    156
  - Efi Operation Overview
    156
  - Initial Priming / Starting Procedure
    156
- Electronic Control Unit (Ecu)
  157
  - Operation Overview
    157
  - Ecu Service
    157
  - Ecu Replacement
    157
- Fuel Pump / Sender / Tank / Lines
  159
  - Operation Overview
    159
  - Fuel Pump Test
    160
  - Fuel Pump Replacement
    161
  - Fuel Tank Exploded View
    165
  - Fuel Sender Test
    166
  - Fuel Tank Removal
    166
  - Fuel Tank Installation
    167
  - Fuel Lines - Quick Connect
    167
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  168
  - Operation Overview
    168
  - T-Map Sensor Test
    168
  - T-Map Sensor Replacement
    168
- Crankshaft Position Sensor (Cps)
  169
  - Operation Overview
    169
  - Cps Test
    169
  - Cps Replacement
    170
- Fuel Injectors
  171
  - Operation Overview
    171
  - Fuel Injector Troubleshooting
    171
  - Fuel Injector Test
    172
  - Fuel Injector Replacement
    172
- Idle Air Control (Iac)
  174
  - Operation Overview
    174
  - Iac Test
    174
  - Iac Replacement
    174
- Throttle Position Sensor (Tps)
  175
  - Operation Overview
    175
  - Tps Resistance Tests
    175
  - Tps Tester / Regulator
    175
  - Tps Replacement
    175
- Engine Coolant Temperature Sensor (Ect)
  177
  - Operation Overview
    177
  - Ect Sensor Test
    177
  - Ect Sensor Replacement
    178
- Ignition Coil
  179
  - Operation Overview
    179
  - Ignition Coil / Wire Testing
    179
- Efi Diagnostics
  180
  - Instrument Cluster Trouble Code Display
    180
  - Efi Troubleshooting
    183
- Digital Wrench Operation
  185
  - Digital Wrench Diagnostic Software Overview
    185
  - Special Tools
    185
  - Diagnostic Software Version
    185
  - Ecu Replacement
    185
  - Guided Diagnostic Available
    185
  - Digital Wrench Communication Errors
    186
  - Digital Wrench - Diagnostic Connector
    186
  - Digital Wrench Serial Number Location
    186
  - Digital Wrench Version and Update
    187
  - Digital Wrench Updates
    187
  - Digital Wrench Feature Map
    189
  - Engine Controller Reprogramming (Reflash)
    190
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

195
- Chapter 5
  196
- General Information
  196
- Multi-Function Pliers
  196
- Torque Specifications
  196
- Body
  197
  - Side Panel Removal
    197
  - Front Storage Box Lid / Front Rack and Access Panel Removal / Installation
    197
  - Footwell Removal / Installation
    198
  - Front Bumper Removal / Installation
    199
  - Front Fender Removal / Installation
    200
  - Mud Guard Removal / Installation
    201
  - Front Rack / Storage Box Lid Assembly
    202
  - Front Bumper Assembly
    203
  - Front Cab Assembly
    204
  - Rear Rack Assembly
    206
  - Rear Cab, Seat, and Footwell Assembly
    210
  - Rear Storage Box Assembly
    216
  - Winch and Front Bumper Mounting
    217
  - Headlight Pod Exploded View
    218
- Steering
  219
  - Handlebar Block Installation Procedure
    220
  - Steering Post Removal
    220
  - Steering Post Assembly
    220
  - Eps Unit Removal (Eps Models)
    221
  - Eps Unit Installation (Eps Models)
    221
  - Steering Exploded View (Eps Models)
    224
- Steering Post and Lock (Intl.)
  219
  - Steering Assembly Exploded View
    219
- Suspension
  227
  - Steering / A-Arm Exploded View
    227
  - A-Arm Replacement
    228
  - Ball Joint Replacement
    228
  - Torsion Bar Exploded View
    230
  - Strut Assembly
    231
  - Front Strut Cartridge Replacement
    233
- Decal Replacement
  234
Clutching Chapter 6 Clutching

235
- Chapter 6
  237
- Clutching Chart
  237
- General Information
  237
- Pvt System Fastener Torques
  237
- Special Tools
  237
- Pvt System Overview
  238
  - General Operation
    238
  - Drive Clutch Operation
    238
  - Driven Clutch Operation
    238
  - Maintenance / Inspection
    239
  - Pvt Break-In (Drive Belt / Clutches)
    239
  - Overheating / Diagnosis
    240
- Pvt Exploded Views
  241
  - Drive Clutch Exploded Views (Ebs Vs. Non-Ebs)
    241
  - Pvt Sealing and Ducting Components
    242
- Pvt System Service
  244
  - Disassembly
    244
  - Assembly
    245
- Drive Belt
  246
  - Belt Removal
    246
  - Belt Inspection
    246
  - Belt Installation
    246
  - Pvt Break-In (Drive Belt / Clutches)
    246
- Clutch Alignment
  247
- Drive Clutch Service
  249
  - Drive Clutch Exploded View (All Models)
    249
  - Clutch Disassembly
    250
  - Shift Weight Inspection
    251
  - Spider Removal
    252
  - Roller, Pin, and Thrust Washer Inspection
    252
  - Button to Tower Clearance Inspection
    253
  - Bearing Inspection
    253
  - Clutch Inspection
    253
  - Bushing Service
    255
  - Clutch Assembly
    257
- Drive Clutch Bushing Service (Non Ebs and Ebs)
  259
  - Bushing Service
    259
- Driven Clutch Service (Non Ebs)
  262
  - Exploded View
    262
  - Clutch Disassembly / Inspection
    263
  - Bushing Service
    264
  - Moveable Sheave - Bushing Installation
    266
  - Clutch Assembly
    267
- Driven Clutch Service (Ebs)
  269
  - Exploded View
    269
  - Clutch Disassembly
    270
  - Bushing Service
    273
  - Clutch Assembly
    275
- Driven Clutch Bushing Service
  278
  - Bushing Service (Non Ebs and Ebs)
    278
- Troubleshooting
  280
Final Drive Chapter 7 Final Drive

283
- Chapter 7
  284
- Gearcase Fluid / Capacity
  284
- General Information
  284
- Torque Table
  284
- Front Hub
  285
  - Disassembly
    285
  - Assembly
    285
- Front Gearcase Removal and Installiation
  286
  - Gearcase Removal
    286
  - Gearcase Installation
    287
- Front Gearcase (Non-Adc)
  288
  - Exploded View
    288
  - Operation
    290
  - Disassembly / Inspection
    290
  - Reassembly / Inspection
    294
  - Troubleshooting, Front Gearcase (Non-Adc)
    297
  - Setting Ring Gear Backlash Non Adc
    298
- Front Drive (CV) Shaft
  299
  - Inspection
    299
  - Assembly
    304
  - Installation
    304
- Rear Drive (CV) Shaft
  306
  - Inspection
    306
  - Removal
    306
  - Installation
    306
- CV Drive Shaft Service
  308
- Prop Shaft - Front or Rear
  316
  - Removal and Installation
    316
- U-Joint Service
  317
  - Disassembly
    317
  - Assembly
    318
Transmission Chapter 8 Transmission

319
- Chapter 8
  320
- Lubrication
  320
- Transmission - General
  320
- Transmission Frame Mounts
  321
- Transmission Upper Frame Mount
  322
- Transmission Rear Stabilizer Mounts
  323
- Transmission Control Arm Bracket Mounts
  324
- Shift Linkage Inspection
  325
- Gear Selector Removal
  326
- Transmission Installation
  326
- Transmission Removal
  326
- Troubleshooting Checklist
  327
- Transmission Disassembly / Assembly
  328
  - Transmission Disassembly
    328
  - Snorkel / Output Gear Backlash Procedure
    334
  - Transmission Assembly
    336
- Sportsman Transmission Exploded View
  343
Brakes Chapter 9 Brakes

345
- Chapter 9
  347
- Component Service Limits
  347
- General Information
  347
- Torque Table
  347
- Special Tools
  348
- Hydraulic Brake System
  349
  - Operation Overview
    349
  - Brake Controls Overview
    350
  - Brake Noise Troubleshooting
    350
  - Brake Bleeding / Fluid Change
    351
- Brake System Exploded Views
  353
- Brake Caliper Exploded Views
  355
- Front Master Cylinder (All Models)
  358
  - Removal
    358
  - Installation
    358
- Front Brakes
  359
  - Pad Removal
    359
  - Assembly
    360
  - Brake Burnishing Procedure
    361
- Front Brake Disc
  362
  - Inspection
    362
  - Removal / Replacement
    363
- Front Caliper
  364
  - Removal
    364
  - Inspection
    365
  - Reassembly
    365
  - Installation
    366
- Rear Brake Pad
  367
  - Touring Pad Removal
    367
  - Touring Pad Installation
    368
  - Sportsman Rear Pad Removal
    369
  - Sportsman Rear Pad Installation
    370
  - Brake Burnishing Procedure
    371
- Sportsman Rear Caliper
  372
  - Removal and Inspection
    372
  - Assembly
    373
- Sportsman Touring Rear Caliper
  375
  - Removal
    375
  - Inspection
    376
  - Reassembly
    376
- Rear Brake Disc
  377
  - Inspection
    377
- Rear Master Cylinder
  378
Electrical Chapter 10 Electrical

381
- General Information
  383
- Chapter 10
  384
- Ignition System / Basic Electrical Components
  384
- Efi Component Testing
  385
- Electrical Service Notes
  385
- Troubleshooting
  385
- Instrument Cluster
  386
  - Overview
    386
  - Rider Information Display
    387
  - Information Display Area
    388
  - Diagnostic Mode
    393
- Controller Area Network (Can)
  395
  - Can Troubleshooting
    395
- Transmission (Gear Position) Switch
  396
- All Wheel Drive (Awd) Coil
  397
  - Operation Overview
    397
  - Diagnosing System Failures
    397
- Speed Sensor
  399
  - Speed Sensor Location
    399
  - Speed Sensor Testing
    399
  - Testing
    400
  - Replacement
    400
- Throttle Release Switch (Trs)
  401
- Cooling System Components
  402
  - Fan Control Circuit Operation
    402
  - Fan Control Bypass Test
    402
  - Fan Motor Current Draw Test
    402
  - Coolant Temperature Sensor
    403
- Electronic Power Steering (Eps)
  404
  - Eps Operation
    404
  - Proper Eps System Diagnosing
    404
  - Eps Circuit
    404
  - Eps Troubleshooting
    405
- Starter System
  406
  - Troubleshooting
    406
  - Voltage Drop Test
    406
  - Starter Motor Removal
    406
  - Starter Motor Installation
    406
  - Starter Solenoid Bench Test
    407
  - Starter Solenoid Operation
    407
- Starter System Testing Flow Chart
  408
- Charging System
  409
  - Current Draw - Key off
    409
  - Break Even Test
    409
  - Alternator Output Test
    410
  - Regulator / Rectifier
    411
  - Charging System Testing Flow Chart
    412
- Fuel Sender
  413
  - Testing
    413
- Lighting
  414
  - High Beam Headlight Bulb Replacement
    414
  - Headlight Housing Replacement
    414
  - High Beam Headlight Adjustment
    415
  - Lower Headlamp Removal / Installation
    416
  - Low Beam Headlight Adjustment (Non Intl)
    417
  - Lower Headlight Adjustment (Forest)
    417
  - Headlamp Switch Test
    418
  - Brake Light Replacement
    418
  - Brake Light Switch
    419
- Battery
  420
  - Battery Identification
    420
  - Battery Conductance Analyzer
    420
  - Battery Activation (Conventional)
    421
  - Battery Terminals/Bolts
    421
  - Conventional Battery Inspection / Removal
    421
  - Conventional Battery Installation
    422
  - Conventional Battery Testing
    422
  - Conventional Battery Ocv - Open Circuit Voltage Test
    422
  - Conventional Battery Specific Gravity Test
    423
  - Battery Load Test
    423
  - Off Season Storage
    423
  - Charging Procedure
    424
  - Low Maintenance Battery
    424
  - Low Maintenance Battery Charging
    425
  - Low Maintenance Battery Inspection / Removal
    425
  - Low Maintenance Battery Installation
    426
  - Low Maintenance Battery - Ocv- Open Circuit Voltage Test
    426
  - Low Maintenance Battery Load Test
    426
  - Low Maintenance Battery Charging Procedure
    427
  - Low Maintenance Battery Off-Season Storage
    427
- Sportsman 570 Efi Forest Electrical
  428
- Troubleshooting Diagrams
  431

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