Polaris RZR S 570 2017 Manuals

Manuals and User Guides for Polaris RZR S 570 2017. We have 1 Polaris RZR S 570 2017 manual available for free PDF download: Service Manual

Polaris RZR S 570 2017 Service Manual (460 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 73 MB

Safety Warnings
2
Revision Index
4
Feedback Form
4
Table of Contents
7
Chapter 1 General Information
7
Vehicle Identification
8
Model Number Designation (2015 +)
8
Vehicle Identification Number (Vin) Designation (2015+)
8
Vehicle and Engine Serial Number Locations
8
Reference Information
9
Replacement Keys
9
Publication Numbers
9
Special Tools
10
Master Torque Table
14
General Specifications
18
2017 Rzr 570 / Eu
18
Rzr 570 Clutch Chart
19
2017 Rzr 570 Eps
20
Rzr 570 Eps Clutch Chart
21
2018 Rzr 570
22
Rzr 570 Clutch Chart
23
2018 Rzr 570 Eps
24
Rzr 570 Eps Clutch Chart
25
2019 Rzr 570
26
Rzr 570 Clutch Chart
27
2019 Rzr 570 Eps
28
Rzr 570 Eps Clutch Chart
29
2020 Rzr 570
30
Rzr 570 Clutch Chart
31
2020 Rzr 570 Eps
32
Rzr 570 Eps Clutch Chart
33
2021 Rzr 570
34
Rzr 570 Clutch Chart
35
2021 Rzr 570 Eps
36
Rzr 570 Eps Clutch Chart
37
Misc. Specifications and Charts
38
Conversion Table
38
Sae Tap / Drill Sizes
39
Metric Tap / Drill Sizes
39
Decimal Equivalents
40
Maintenance
43
Periodic Maintenance Chart
43
Periodic Maintenance Overview
43
Break-In Period
43
Pre-Ride Inspection
44
Maintenance Intervals
45
Maintenance Quick Reference
65
Grease Lubrication Points
67
Lubricants / Service Products
68
General Vehicle Inspection and Maintenance
69
Pre-Ride / Daily Inspection
69
Frame, Nuts, Bolts, and Fasteners
69
Heat Shield Inspection
69
Engine
70
Engine Oil Level
70
Engine Oil and Filter Service
70
Engine Breather Hose Inspection
72
Engine and Transmission Mounts
72
Compression Test Specification
72
Valve Clearance Inspection
72
Exhaust - Spark Arrestor
74
Cooling System
75
Cooling System Overview
75
Cooling System Exploded View
75
Coolant Level Inspection
76
Cooling System Pressure Test
76
Coolant Strength / Type
76
Coolant Drain
77
Fuel System and Air Intake
79
Fuel System
79
Fuel Pump / Fuel Filters
79
Throttle Pedal Inspection
80
Engine and Pvt Intake Pre-Filter Service
80
Air Filter Service
80
Pvt / Final Drive / Wheel and Tire
82
Wheel and Hub Torque Table
82
Wheel Removal
82
Wheel Installation
82
Tire Inspection
82
Tire Pressure
83
Drive Shaft Boot Inspection
83
Belt Inspection
83
Transmission and Front Gearcase
84
Specification Chart
84
Transmission Lubrication
84
Shift Cable Inspection / Adjustment
85
Front Gearcase Lubrication
85
Steering
87
Steering Inspection
87
Tie Rod End / Wheel Bearing Inspection
87
Wheel Toe Alignment Inspection
87
Wheel Toe Adjustment
88
Suspension
90
Spring Preload Adjustment
90
Brake System
91
Brake Fluid Inspection
91
Brake Pad / Disc Inspection
91
Brake Hose and Fitting Inspection
91
Parking Brake Cable Adjustment
92
Electrical and Ignition System
94
Battery Maintenance
94
Battery off Season Storage
94
Chapter 3 Engine / Cooling System
97
General Information
99
Special Tools
99
Engine Lubrication Specifications
99
Oil Pressure Test
99
Engine Oil Flow Chart
100
Engine Service Specifications
101
Engine Specifications
101
Engine Assembly Views
103
Cooling System Exploded View and Coolant Flow Diagram
103
Torque Sequence
104
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
106
Cylinder / Oil Filter / Oil Pump / Breather
107
Camshafts / Cylinder Head / Flywheel / Stator Cover - Black Head Bolts
108
Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts
109
Spark Plugs / Starter / Throttle Body / Valve Cover
110
Piston / Crankshaft / Balance Shaft
111
Intake System
112
Intake System Assembly View
112
Exhaust System
113
Exhaust System Assembly View
113
Engine Cooling System
114
Cooling System Specifications
114
Pressure Cap Test
114
Coolant Drain / Radiator Removal
115
Thermostat Replacement
116
Water Pump Cover and Impeller Service
117
Water Pump Mechanical Seal / Oil Seal Replacement
117
Cooling System Bleeding Procedure
123
Engine Service
124
Accessible Engine Components
124
Top-End Service (Engine in Chassis)
124
Engine Removal
124
Engine Installation
128
Engine Break-In Period
132
Engine Mounting and Torque Values
133
Engine Lubrication Specifications
133
Engine Disassembly / Inspection - Top End
134
Valve Cover Removal
134
Camshaft / Carrier Removal
134
Camshaft Sprocket Inspection
135
Camshaft Inspection
136
Exhaust Camshaft Decompression Mechanism
136
Cam Chain and Guide Service
136
Cylinder Head Removal
137
Cylinder Head Disassembly
137
Cylinder Head Warp Inspection
138
Valve Inspection
138
Combustion Chamber Cleaning
140
Valve Seat Reconditioning
140
Cylinder Removal
142
Cylinder Inspection
143
Piston Removal
143
Piston-To-Cylinder Clearance
144
Piston / Rod Inspection
144
Piston Ring Installed Gap
145
Honing to Oversize
145
Cylinder Hone Selection / Honing Procedure
146
Cleaning the Cylinder after Honing
146
Camshaft Installation / Timing
146
Camshaft Timing - Quick Reference
149
Valve Cover Installation
150
Engine Assembly - Top End
151
Piston Ring Installation
151
Piston / Connecting Rod Assembly
152
Cylinder Installation
152
Cylinder Head Assembly
153
Valve Sealing Test
154
Cylinder Head Installation - Silver Bolts
156
Valve Clearance Check / Adjustment
157
Valve Lash - Tappet Selection
159
Exhaust Valve Lash - Tappet Selection Matrix
160
Engine Disassembly / Inspection - Bottom End
161
Crankcase Disassembly
161
Starter One-Way Clutch Inspection
161
Stator Removal
163
Oil Pump Removal
164
Oil Pump Assembly
166
Crankcase Breather Service
166
Crankcase Separation
167
Balance Shaft Removal / Inspection
168
Crankshaft Removal
169
Crankshaft Inspection
169
Pto Side Crankcase Bearing Service
170
Mag Side Crankcase Bearing Service
171
Oil Pickup Assembly Inspection
172
Oil Pressure Regulator (Bypass) Valve Inspection
172
Crankcase Inspection
172
Engine Assembly - Bottom End
173
Crankcase Assembly - Pto Side
173
Balance Shaft Installation / Timing
175
Final Crankcase Assembly
175
Starter One-Way Clutch Installation
176
Flywheel Installation
177
Stator / Stator Cover Installation
178
Troubleshooting
179
Chapter 4 Engine Electrical
181
General Information
183
Digital Wrench - Diagnostic Connector
183
Service Notes
184
Efi Overview
185
Efi System View
185
Efi Operation Overview
186
Initial Priming / Starting Procedure
186
Electronic Control Unit (Ecu)
187
Operation Overview
187
Ecu Service
188
Ecu Replacement
188
Temperature and Manifold Absolute Pressure Sensor (T-Map)
189
T-Map Overview
189
T-Map Sensor Test
189
T-Map Sensor Replacement
189
Crankshaft Position Sensor (Cps)
190
Cps Overview
190
Cps Test
190
Resistance Test
190
Cps Replacement
192
Electronic Throttle Control (Etc)
193
Etc Operation Overview
193
Etc Test
193
Etc Replacement
193
Etc Learn Procedure
194
Pedal Position Sensor (Pps)
195
Operation Overview
195
Location
195
Pps Test
195
Pps Replacement
195
Efi Diagnostics
197
Instrument Cluster Trouble Code Display
197
Efi Troubleshooting
200
Polaris Digital Wrench
201
Digital Wrench® Diagnostic Software Overview
201
Special Tools (Digital Wrench)
201
Digital Wrench Software Version and Update
201
Digital Wrench® Updates
202
Digital Wrench® Communication Errors
203
Digital Wrench - Diagnostic Connector
203
Guided Diagnostics
203
Digital Wrench® Serial Number Location
203
Digital Wrench® Feature Map
204
Ecu Replacement
205
Ecu Reprogramming (Reflash)
205
Additional Information
208
Chapter 5 Fuel System
209
General Information
210
Special Tools
210
Service Notes
211
Fuel Injectors
212
Fuel Injector Overview
212
Fuel Injector O-Rings
212
Fuel Injector Troubleshooting
213
Fuel Injector Test
213
Fuel Injector Replacement
214
Fuel Tank / Lines
215
Fuel Supply Line Routing
215
Fuel Vent Line Routing
216
Vent Line Termination Fitting
217
Fuel Lines - Quick Connect
217
Exploded View
219
Operation Overview
220
Fuel Pump Test
220
Fuel Pump Replacement
222
Fuel Tank Removal
226
Fuel Tank Installation
228
Chapter 6 Pvt System
231
General Information
232
Special Tools
232
Rzr 570 Clutch Chart
232
Rzr 570 Eps Clutch Chart
232
Rzr S 570 Clutch Chart
232
Pvt System Overview
233
General Operation
233
Drive Clutch Operation
233
Driven Clutch Operation
233
Pvt Break-In (Drive Belt / Clutches)
233
Overheating / Diagnosis
235
Pvt System Service
236
Pvt Covers and Ducting Components
236
Pvt Disassembly
237
Pvt Assembly
238
Drive Belt
240
Belt Removal
240
Belt Installation
241
Pvt Break-In (Drive Belt / Clutches)
241
Clutch Center Distance
241
Inspection
241
Adjustment
242
Drive Clutch Service
244
Drive Clutch Exploded View (All Models)
244
Drive Clutch Disassembly
245
Shift Weight Inspection
246
Spider Removal
247
Button to Tower Clearance Inspection
248
Roller, Pin, and Thrust Washer Inspection
248
Drive Clutch Inspection
249
Bushing Service
250
Drive Clutch Assembly
252
Driven Clutch Service
255
Driven Assembly View
255
Clutch Disassembly / Inspection
256
Clutch Assembly
257
Driven Clutch Service (Ebs)
259
Driven Clutch Exploded View (Ebs)
259
Driven Clutch Disassembly
260
Clutch Inspection
261
Driven Clutch Assembly
263
Troubleshooting
265
Chapter 7 Transmission
267
General Information
268
Special Tools
268
Lubrication
268
Shift Lever / Cable
269
Shift Lever Removal
269
Shift Lever Installation
269
Transmission Service
271
Transmission Removal
271
Transmission Installation
274
Transmission Disassembly
277
Differential Operation
281
Planetary Differential Disassembly (Turf Mode Models Only)
284
Planetary Differential Bushing Replacement (Turf Mode Models Only)
285
Planetary Differential Assembly
287
Gear / Shaft / Bearing Inspection
288
Transmission Assembly / Snorkel Gear Backlash Procedure
289
Transmission Assembly View
295
Transmission Assembly View (Int
297
Transmission / Rear Gearcase Vent Line
299
Troubleshooting
300
Troubleshooting Checklist
300
Chapter 8 Final Drive
301
General Information
302
Special Tools
302
Bearing Carrier
303
Front Bearing Replacement
304
Front Bearing Carrier Installation
305
Rear Bearing Carrier Bushing Replacement
308
Drive Shaft
310
Front Drive Shaft Removal
310
Front Drive Shaft Installation
311
Rear Drive Shaft Removal
312
Rear Drive Shaft Installation
313
Drive Shaft / CV Joint Handling Tips
315
Outer CV Joint / Boot Replacement
315
Inner Plunging Joint / Boot Replacement
317
Prop Shaft
320
U-Joint Disassembly
321
U-Joint Assembly
322
Front Gearcase / Centralized Hilliard
323
Front Gearcase Assembly View
323
Front Gearcase Vent Line Routing
324
All Wheel Drive Operation
325
Awd Diagnosis
325
Gearcase Removal
326
Front Gearcase Disassembly / Inspection
327
Front Gearcase Assembly
330
Gearcase Installation
332
Wheel Hubs
333
Front Hub Exploded View
333
Rear Hub Exploded View
333
Chapter 9 Steering / Suspension
335
General Information
336
Tool Part Numbers
336
Steering System
337
Steering System Assembly View (Non-Eps)
337
Steering Wheel Removal (Non-Eps Models)
338
Steering Shaft Removal (Non-Eps)
338
Steering Shaft Bearing Replacement
339
Steering Assembly View (Eps Models)
341
Upper Steering Shaft Removal (Eps Models)
342
Steering Wheel Removal (Eps)
342
Power Steering Unit Removal
343
Lower Steering Shaft Removal (Eps Models)
343
Lower Steering Shaft Installation (Eps)
344
Power Steering Unit Installation
344
Upper Steering Shaft Installation (Eps)
345
Front Suspension
346
Front Suspension Assembly View
346
Ball Joint Removal
348
Ball Joint Installation
349
Stabilizer Bar Replacement
350
Rear Suspension
352
Rear Suspension Assembly View
352
Stabilizer Bar Removal / Installation
354
Shocks / Springs
356
Shock Assembly Views
356
Shock Removal / Installation
357
Shock / Spring Replacement
357
Chapter 10 Brake System
359
General Specifications
361
Special Tools
361
Brake System Service Notes
362
Hydraulic Brake System Operation
362
Brake Bleeding / Fluid Change
363
Brake System Assembly View
364
Rzr 570 Brake System
364
Brake Line Routing
365
Master Cylinder
367
Brake Pedal Lever
368
Brake Pedal Removal
368
Brake Pedal Installation
368
Parking Brake (Int'l)
369
Parking Brake Assembly View
369
Caliper Installation
371
Caliper Removal
371
Front Brakes
373
Front Brake Caliper Assembly View
373
Front Caliper / Pad Removal
374
Front Caliper Disassembly
375
Front Caliper Inspection
376
Front Caliper Assembly
376
Front Pad Inspection
377
Front Brake Disc Inspection
377
Front Brake Disc Runout
377
Front Disc Replacement
378
Front Caliper / Pad Assembly / Installation
378
Brake Burnishing Procedure
379
Rear Brakes
380
Rear Caliper Assembly View
380
Rear Caliper / Pad Removal
381
Rear Caliper Disassembly
382
Rear Caliper Inspection
382
Rear Caliper Assembly
383
Rear Brake Pad Inspection
383
Rear Disc Inspection
384
Rear Disc Replacement
384
Rear Caliper / Pad Assembly / Installation
385
Brake Burnishing Procedure
385
Troubleshooting
386
Brake Noise Troubleshooting
386
Brakes Squeal / Poor Brake Performance
386
Pedal Vibration
386
Caliper Overheats (Brakes Drag)
386
Chapter 11 Body / Frame
387
General Information
388
Multi-Function Pliers
388
Decal Replacement
388
Body Assembly Views
389
Cab Frame Assembly
389
Side Safety Nets
390
Dash Instruments / Glovebox
391
Hood / Front Bumper
392
Rear Bumper
393
Seat Assembly
394
Seat Belts / Mounting
395
Floor / Rocker Panels
396
Rear Cargo Box / Fenders
397
Chassis / Main Frame
398
Body Component Removal
399
Rear Service Panel
399
Front Bumper
399
Rear Bumper Removal
399
Hood and Front Body Work
400
Rear Fender Flair Removal
401
Cargo Box Assembly Removal
402
Rocker Panels, Console and Floor
403
Chapter 12 Chassis Electrical
405
General Information
407
Special Tools
407
Electrical Service Notes
407
Under-Dash Components
407
Break-Out Diagram Viewing
408
Instrument Cluster
409
Diagnostic Mode
409
Instrument Cluster Pinouts
410
Instrument Cluster Removal
410
Instrument Cluster Installation
410
Switches / Controls
411
Ignition Key Switch / Headlamp Switch
411
Ignition Key Switch (Intl)
411
Awd / 2Wd Switch
412
Transmission / Gear Position Switch
413
Turn Signal Switch (Intl)
413
Hazard Switch (Intl)
414
Brake Light Switch
414
Parking Brake Switch (Intl Model)
415
Speed Sensor
416
Differential Solenoid Overview
416
Differential Solenoid Circuit Operation
417
Chassis Harness
418
Main Harness Component Locations
418
Main Harness Routing
419
Main Harness Retention Locations
420
All Wheel Drive Coil
421
Operation Overview
421
Diagnosing System Failures
421
Charging System
422
Current Draw - Key off
422
Testing Procedure
422
Stator Replacement
424
Regulator / Rectifier
424
Charging System Testing Flow Chart
425
Battery
426
Battery Specifications
426
General Battery Information
426
Battery Activation
426
Battery Installation
427
Battery Removal
427
Battery Testing
428
Battery Conductance Analyzer
428
Ocv - Open Circuit Voltage Test
428
Load Test
428
Specific Gravity Test
429
Charging Procedure
430
Lighting System
431
Headlights
431
Taillights
432
Bulb Replacement
432
Cooling System
434
Fan Control Circuit Operation / Testing
434
Fan Control Circuit Bypass Test
434
Coolant Temperature Sensor
434
Starting System
435
Troubleshooting
435
Voltage Drop Test
435
Starter Motor Removal
435
Starter Motor Installation
436
Starter Solenoid Bench Test
436
Starter Solenoid Operation
436
Electrical Testing
436
9850074 R01 - 2017-2021 RZR 570 / S 570 Service Manual
436
Electronic Power Steering
438
Eps Operation
438
Proper Eps System Diagnosing
438
Eps Troubleshooting (Power Steering Non-Functional with Mil On)
439
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
440
Eps Troubleshooting (Using Digital Wrench)
441
Fuses / Relays
442
Fuse Box
442
Relay / Fuse / Circuit Breaker Details
448
Can System
449
Can System Overview
449
Can System Testing
449

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Polaris RZR S 570 2017 Service Manual (460 pages)

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