User Manuals: Polaris RZR 570 2016 Off-road Vehicle

Manuals and User Guides for Polaris RZR 570 2016 Off-road Vehicle. We have 1 Polaris RZR 570 2016 Off-road Vehicle manual available for free PDF download: Service Manual

Polaris RZR 570 2016 Service Manual

Polaris RZR 570 2016 Service Manual (482 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 54 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Model Number Designation
  8
- Model Number Designation (2015 +)
  8
- Vehicle Identification
  8
- Vehicle Identification Number (Vin) Designation
  8
- Vehicle Identification Number (Vin) Designation (2015+)
  9
- Vehicle Information
  10
  - Replacement Keys
    10
  - Publication Numbers
    10
  - Special Tools
    11
- General Specifications
  12
  - 2013 Ranger Rzr 570
    12
  - 2013 Ranger Rzr 570 Le
    14
  - 2013 Ranger Rzr 570 Intl
    16
  - 2014 Rzr 570
    18
  - 2015 Rzr 570
    22
  - 2016 Rzr 570
    26
  - 2016 Rzr 570 Le
    28
- Misc. Specifications and Charts
  30
  - Master Torque Table
    30
  - Conversion Table
    33
  - Standard Bolt Torque Specification
    34
  - Metric Bolt Torque Specification
    34
  - Sae Tap / Drill Sizes
    35
  - Metric Tap / Drill Sizes
    35
  - Decimal Equivalents
    36
Chapter 2 Maintenance

37
- Break-In Period
  39
- Maintenance Chart Key
  39
- Periodic Maintenance Chart
  39
- Periodic Maintenance Overview
  39
- Maintenance Intervals
  40
- Maintenance Quick Reference
  42
- Grease Lubrication Points
  44
- Lubricants / Service Products
  45
- General Vehicle Inspection and Maintenance
  46
  - Pre-Ride / Daily Inspection
    46
  - Frame, Nuts, Bolts, and Fasteners
    46
- Engine
  47
  - Engine Oil Level
    47
  - Engine Oil and Filter Service
    47
  - Engine Breather Hose Inspection
    49
  - Engine and Transmission Mounts
    49
  - Compression Test Specification
    49
  - Valve Clearance Inspection
    50
  - Exhaust - Spark Arrestor
    51
- Cooling System
  52
  - Cooling System Overview
    52
  - Cooling System Exploded View
    52
  - Coolant Level Inspection
    53
  - Cooling System Pressure Test
    53
  - Coolant Strength / Type
    53
  - Cooling System
    54
  - Coolant Drain
    54
- Fuel System and Air Intake
  55
  - Fuel System
    55
  - Fuel Line
    55
  - Fuel Pump / Fuel Filters
    55
  - Vent Lines
    56
  - Throttle Pedal Inspection
    56
  - Throttle Freeplay Adjustment
    56
  - Engine and Pvt Intake Pre-Filter Service
    57
  - Air Filter Service
    58
- Pvt / Final Drive / Wheel and Tire
  59
  - Wheel and Hub Torque Table
    59
  - Wheel Removal
    59
  - Wheel Installation
    59
  - Tire Inspection
    60
  - Tire Pressure
    60
  - Drive Shaft Boot Inspection
    60
  - Belt Inspection
    60
- Transmission and Front Gearcase
  61
- Steering
  64
- Suspension
  67
  - Spring Preload Adjustment
    67
- Brake System
  68
- Electrical and Ignition System
  70
  - Battery Maintenance
    70
  - Battery Removal
    70
  - Battery Installation
    71
  - Battery off Season Storage
    71
  - Spark Plug Service
    71
  - Engine to Frame Ground
    72
Chapter 3 Engine / Cooling System

73
- Engine Lubrication Specifications
  76
- General Information
  76
- Oil Pressure Test
  76
- Special Tools
  76
- Engine Oil Flow Chart
  77
- Engine Service Specifications
  78
- Intake / Exhaust System
  87
  - Air Box / Air Filter Exploded View
    87
  - Exhaust System Assembly View
    88
- Engine Cooling System
  89
- Engine Service
  101
  - Accessible Engine Components
    101
  - Top-End Service (Engine in Chassis)
    101
  - Engine Removal
    101
  - Engine Installation
    105
  - Engine Break-In Period
    109
  - Engine Mounting and Torque Values
    110
  - Engine Lubrication Specifications
    110
- Engine Disassembly / Inspection - Top End
  111
  - Valve Cover Removal
    111
  - Camshaft / Carrier Removal
    111
  - Camshaft Sprocket Inspection
    112
  - Camshaft Inspection
    113
  - Exhaust Camshaft Decompression Mechanism
    113
- Engine / Cooling System
  113
  - Cam Chain and Guide Service
    113
  - Cylinder Head Removal
    114
  - Cylinder Head Disassembly
    114
  - Cylinder Head Inspection
    115
  - Cylinder Head Warp Inspection
    116
  - Valve Inspection
    116
  - Combustion Chamber Cleaning
    117
  - Valve Seat Reconditioning
    118
  - Cylinder Removal
    120
  - Cylinder Inspection
    120
  - Piston Removal
    121
  - Piston-To-Cylinder Clearance
    121
  - Piston / Rod Inspection
    122
  - Piston Ring Installed Gap
    123
  - Honing to Oversize
    123
  - Cylinder Hone Selection / Honing Procedure
    124
  - Cleaning the Cylinder after Honing
    124
  - Camshaft Installation / Timing
    124
  - Camshaft Timing - Quick Reference
    127
  - Valve Cover Installation
    128
- Engine Assembly - Top End
  129
  - Piston Ring Installation
    129
  - Piston / Connecting Rod Assembly
    130
  - Cylinder Installation
    131
  - Cylinder Head Assembly
    131
  - Valve Sealing Test
    132
  - Cylinder Head Installation - Black Bolts
    133
  - Cylinder Head Installation - Silver Bolts
    134
  - Valve Clearance Check / Adjustment
    135
  - Intake Valve Lash - Tappet Selection Matrix
    138
  - Exhaust Valve Lash - Tappet Selection Matrix
    139
- Engine Disassembly / Inspection - Bottom End
  140
  - Crankcase Disassembly
    140
  - Stator Cover Removal
    140
  - Starter One-Way Clutch Inspection
    140
  - Stator Removal
    142
  - Oil Pump Removal
    143
  - Oil Pump Assembly
    145
  - Crankcase Breather Service
    146
  - Crankcase Separation
    146
  - Balance Shaft Removal / Inspection
    147
  - Crankshaft Removal
    148
  - Crankshaft Inspection
    148
  - Pto Side Crankcase Bearing Service
    149
  - Mag Side Crankcase Bearing Service
    150
  - Oil Pickup Assembly Inspection
    151
  - Oil Pressure Regulator (Bypass) Valve Inspection
    151
Chapter 4 Fuel System

161
- General Information
  163
- Special Tools
  163
- Service Notes
  165
- Efi System Exploded View
  166
- Efi System Component Locations
  167
- Efi System Electrical Diagram
  169
- Efi Overview
  170
  - Principal Components
    170
  - Efi Operation Overview
    170
  - Initial Priming / Starting Procedure
    170
- Electronic Control Unit (Ecu)
  171
  - Operation Overview
    171
  - Ecu Service
    172
  - Ecu Replacement
    172
- Fuel Injectors
  173
  - Operation Overview
    173
  - Fuel Injector Troubleshooting
    173
  - Fuel Injector Test
    174
  - Fuel Injector Replacement
    174
- Fuel Tank
  176
  - Fuel Lines - Quick Connect
    176
  - Exploded View
    177
  - Operation Overview
    178
  - Fuel Sender Test
    179
  - Fuel Pump Test
    179
  - Fuel Pump Replacement
    181
  - Fuel Tank Removal
    184
  - Fuel Tank Installation
    186
- Temperature and Manifold Absolute Pressure Sensor (T-Map)
  187
  - Operation Overview
    187
  - T-Map Sensor Test
    187
  - T-Map Sensor Replacement
    187
- Idle Air Control (Iac)
  188
  - Operation Overview
    188
  - Iac Test
    188
  - Iac Replacement
    188
- Throttle Position Sensor (Tps)
  189
  - Operation Overview
    189
  - Tps Resistance Tests
    189
  - Tps Tester / Regulator
    190
  - Tps Replacement
    190
- Crankshaft Position Sensor (Cps)
  192
  - Operation Overview
    192
  - Cps Test
    192
  - Cps Replacement
    193
- Efi Diagnostics
  194
  - Instrument Cluster Trouble Code Display
    194
  - Efi Troubleshooting
    197
- Polaris Digital Wrench
  198
  - Digital Wrench® Diagnostic Software Overview
    198
  - Special Tools (Digital Wrench)
    198
  - Digital Wrench Software Version and Update
    198
  - Digital Wrench® Updates
    199
  - Digital Wrench® Communication Errors
    200
  - Digital Wrench® - Diagnostic Connector
    200
  - Guided Diagnostics
    201
  - Digital Wrench® Serial Number Location
    201
  - Digital Wrench® Feature Map
    202
  - Ecu Replacement
    203
  - Ecu Reprogramming (Reflash)
    203
- Polaris Mobile Digital Wrench (Pmdw)
  206
Chapter 5 Pvt System

207
- Base / Intl Models (Non-Ebs)
  209
- General Information
  209
  - Special Tools
    209
  - Pvt System Fastener Torques
    209
  - High Altitude Clutch Setup
    209
- Le Model (Ebs)
  209
- Pvt System Overview
  210
  - General Operation
    210
  - Drive Clutch Operation
    210
  - Driven Clutch Operation
    210
  - Pvt Break-In (Drive Belt / Clutches)
    211
  - Maintenance / Inspection
    211
  - Overheating / Diagnosis
    212
- Pvt System Service
  213
  - Pvt Covers and Ducting Components
    213
  - Pvt Disassembly
    214
  - Pvt Assembly
    215
- Drive Belt
  217
  - Belt Removal
    217
  - Belt Inspection
    217
  - Belt Installation
    218
  - Pvt Break-In (Drive Belt / Clutches)
    219
  - Clutch Center Distance
    219
    
    Inspection
    219
    
    Adjustment
    220
- Drive Clutch Service
  221
  - Drive Clutch Exploded View (All Models)
    221
  - Drive Clutch Disassembly
    222
  - Shift Weight Inspection
    223
  - Spider Removal
    224
  - Roller, Pin, and Thrust Washer Inspection
    225
  - Button to Tower Clearance Inspection
    225
  - Bearing Inspection
    226
  - Drive Clutch Inspection
    226
  - Bushing Service
    227
  - Drive Clutch Assembly
    229
- Driven Clutch Service
  231
  - Driven Clutch Service (Non-Ebs)
    231
    
    Exploded View
    231
    
    Clutch Disassembly / Inspection
    232
    
    Clutch Assembly
    233
  - Driven Clutch Service (Ebs)
    235
- Driven Clutch Disassembly
  235
- Pvt System
  235
- Driven Clutch Bushing Service
  237
- Clutch Bushing Removal
  238
- Driven Clutch Assembly
  239
- Driven Clutch Assembly View
  242
- Troubleshooting
  243
Chapter 6 Transmission

245
- General Information
  246
- Lubrication
  246
- Special Tools
  246
- Torque Specifications
  246
- Transmission Mounting and Torque Values
  247
- Shift Lever / Cable
  248
  - Shift Lever Removal
    248
  - Shift Lever Installation
    248
  - Shift Cable Inspection
    249
  - Shift Cable Adjustment
    249
- Transmission Service
  250
  - Transmission Removal
    250
  - Transmission Installation
    254
  - Servicing - no Differential
    258
    
    Transmission Disassembly
    258
    
    Gear / Shaft / Bearing Inspection
    264
    
    Snorkel Gear Backlash Procedure
    265
    
    Transmission Assembly View
    272
  - Servicing - with Differential
    274
    
    Differential Operation
    274
    
    Transmission Disassembly
    276
    
    Planetary Differential Disassembly
    281
    
    Planetary Differential Bushing Replacement
    282
    
    Planetary Differential Assembly
    284
    
    Gear / Shaft / Bearing Inspection
    286
    
    Snorkel Gear Backlash Procedure
    287
    
    Transmission Assembly View (Int
    295
- Troubleshooting
  297
  - Troubleshooting Checklist
    297
Chapter 7 Final Drive

299
- General Information
  300
- Special Tools
  300
- Torque Specifications
  300
- Bearing Carrier
  301
- Drive Shaft
  309
  - Drive Shaft Exploded View
    309
  - Front Drive Shaft Removal
    309
  - Front Drive Shaft Installation
    310
  - Rear Drive Shaft Removal
    312
  - Rear Drive Shaft Installation
    313
  - Drive Shaft / CV Joint Handling Tips
    315
  - Outer CV Joint / Boot Replacement
    316
  - Inner Plunging Joint / Boot Replacement
    318
  - Prop Shaft Removal / Installation
    320
  - Disassembly
    322
  - Assembly
    323
- Front Gearcase / Centralized Hilliard
  324
  - Centralized Hilliard Exploded View
    324
  - All Wheel Drive Operation
    325
  - Awd Diagnosis
    326
  - Gearcase Removal
    327
  - Gearcase Disassembly / Inspection
    328
  - Gearcase Assembly
    331
  - Gearcase Installation
    334
- Wheel Hubs
  335
  - Front Hub Exploded View
    335
  - Rear Hub Exploded View
    336
Chapter 8 Steering / Suspension

337
- General Information
  338
- Tool Part Numbers
  338
- Torque Specifications
  338
- Steering System
  339
- Front Suspension
  349
  - Removal / Replacement
    349
  - Exploded View
    351
  - Service Preparation
    352
  - Ball Joint Removal
    352
  - Ball Joint Installation
    353
  - Stabilizer Bar Linkage Removal
    354
  - Stabilizer Bar Removal
    355
  - Exploded View
    356
- Rear Suspension
  357
  - Rear A-Arm Removal
    357
  - Rear A-Arm Installation
    358
  - Exploded View
    358
  - Stabilizer Bar Removal / Installation
    359
- Shocks / Springs
  360
  - Exploded View
    360
  - Shock Removal / Installation
    361
  - Shock Replacement
    361
Chapter 9 Brake System

363
- General Specifications
  365
- Torque Specifications
  365
- Brake System Service Notes
  366
- Hydraulic Brake System Operation
  366
- Special Tools
  366
- Brake Bleeding / Fluid Change
  367
- Brake System Exploded View
  368
  - Rzr 570
    368
- Master Cylinder
  369
  - Removal
    369
  - Installation
    369
- Brake Pedal Lever
  370
  - Pedal Removal
    370
  - Pedal Installation
    370
- Parking Brake (Intl Model)
  371
  - Exploded View
    371
  - Parking Brake Inspection
    372
  - Parking Brake Cable Adjustment
    372
- Parking Brake Caliper Service (Intl Model)
  374
  - Caliper Exploded View
    374
  - Caliper Removal
    375
  - Caliper Disassembly / Inspection
    375
  - New Brake Pad Installation
    376
  - Caliper Installation
    377
- Parking Brake Disc (Intl Model)
  378
  - Disc Inspection
    378
  - Disc Replacement
    378
- Front Brake Pads
  379
  - Pad Removal
    379
  - Pad Inspection
    380
  - Pad Assembly / Installation
    380
  - Brake Burnishing Procedure
    381
- Front Caliper Service
  382
  - Caliper Exploded View
    382
  - Caliper Removal
    383
  - Caliper Disassembly
    383
  - Caliper Inspection
    384
  - Caliper Assembly
    385
  - Caliper Installation
    385
- Front Brake Disc
  387
  - Disc Runout
    387
  - Disc Inspection
    387
  - Disc Replacement
    388
- Rear Brake Pads
  389
  - Pad Removal
    389
  - Pad Inspection
    390
  - Pad Assembly / Installation
    391
  - Brake Burnishing Procedure
    392
- Rear Caliper Service
  393
  - Caliper Exploded View
    393
  - Caliper Removal
    394
  - Caliper Disassembly
    394
  - Caliper Inspection
    395
  - Caliper Assembly
    396
  - Caliper Installation
    396
- Rear Brake Disc
  397
  - Disc Inspection
    397
  - Disc Replacement
    397
- Troubleshooting
  399
  - Brake Noise Troubleshooting
    399
  - Brakes Squeal / Poor Brake Performance
    399
  - Pedal Vibration
    399
  - Caliper Overheats (Brakes Drag)
    399
  - Brakes Lock
    399
Chapter 10 Body / Frame

401
- General Information
  402
- Multi-Function Pliers
  402
- Torque Specifications
  402
- Cab Frame
  403
  - Assembly / Removal
    403
- Body Assembly Views
  404
  - Side Safety Nets
    404
  - Dash Instruments / Controls / Glovebox
    405
  - Hood / Front Body Work
    406
  - Front Bumper
    407
  - Rear Bumper
    408
  - Seat Assembly
    409
  - Seat Belts / Mounting
    410
  - Floor / Rocker Panels
    411
  - Rear Cargo Box / Fenders
    412
  - Chassis / Main Frame
    413
- Body Component Removal
  414
  - Seats
    414
  - Rear Service Panel
    414
  - Front Bumper
    414
  - Rear Bumper
    415
  - Hood and Front Body Work
    415
  - Rear Fender Flair Removal
    416
  - Cargo Box Assembly Removal
    417
  - Rocker Panels, Console and Floor
    418
- Decals
  419
  - Decal Replacement
    419
Chapter 11 Electrical

421
- Electrical Service Notes
  423
- General Information
  423
- Special Tools
  423
- Under-Dash Components
  423
- Instrument Cluster
  424
  - Overview
    424
  - Information Display Area
    426
  - Diagnostic Mode
    429
  - Instrument Cluster Removal
    430
  - Instrument Cluster Installation
    431
- Switches / Controls
  432
  - Ignition Key Switch / Headlamp Switch
    432
  - Ignition Key Switch (Intl)
    432
  - Awd / 2Wd Switch
    433
  - Awd / 2Wd / Turf Switch - Le / Intl
    433
  - Transmission (Gear Position) Switch
    434
  - Turn Signal Switch (Intl)
    434
  - Hazard Switch (Intl)
    435
  - Brake Light Switch
    436
  - Parking Brake Switch (Intl Model)
    436
  - Speed Sensor Location
    437
  - Speed Sensor Testing
    438
  - Differential Solenoid Overview
    438
  - Differential Solenoid Circuit Operation
    438
- All Wheel Drive Coil
  439
  - Operation Overview
    439
  - Diagnosing System Failures
    439
- Charging System
  440
  - Current Draw - Key off
    440
  - Charging System "Break Even" Test
    440
  - Charging System Stator (Alternator) Tests
    441
  - Stator (Alternator) Replacement
    442
  - Regulator / Rectifier
    442
  - Charging System Testing Flow Chart
    444
- Battery
  445
  - Battery Specifications
    445
  - General Battery Information
    445
  - Battery Activation
    446
  - Battery Removal / Installation
    446
  - Battery Testing
    447
  - Battery Conductance Analyzer
    447
  - Ocv - Open Circuit Voltage Test
    447
  - Load Test
    448
  - Specific Gravity Test
    449
  - Charging Procedure
    451
- Lighting System
  452
  - Headlight Adjustment
    452
  - Headlamp Bulb Replacement
    453
  - Headlamp Housing Removal
    453
  - Headlamp Housing Installation
    454
  - Bulb Replacement
    454
- Cooling System
  455
- Starting System
  457
  - Troubleshooting
    457
  - Voltage Drop Test
    457
  - Starter Motor Removal
    458
  - Starter Motor Installation
    458
  - Starter Solenoid Bench Test
    459
  - Starter Solenoid Operation
    459
  - Electrical Testing
    460
- Electronic Power Steering
  461
- Fuses / Relays
  465
  - Fuse Box
    465
  - Relays
    466
    
    Fan Relay
    466
    
    Efi Relay
    466
    
    Chassis Relay
    466
- Can System
  467
  - Can System Overview
    467
  - Can System Testing
    467

Advertisement

Advertisement

Related Products

Polaris Categories

Offroad Vehicle Swimming Pool Vacuum Snowmobiles Utility Vehicle Automobile Accessories

More Polaris Manuals