2013-2016 Polaris RZR 570 Side by Side Service Manual

Description

This Official 2013 2014 2015 2016 Polaris RZR 570 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2013, 2014, 2015 2016 Polaris RZR 570 Razor side by sides.

Table of Contents

General Information
Maintenance
Engine
Fuel System – General
Steering / Suspension
Clutching
Final Drive
Transmission
Brakes
Body/frame
Electrical

Index of Topics

A
Air Box / Air Filter Exploded View
Air Filter Service
All Wheel Drive (AWD) Coil
Authorization
Reflash
AWD, Diagnosis
AWD, Operation
B
Balance Shaft Installation
Balance Shaft Removal / Inspection
Balance Shaft Timing
Ball Joint Service
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Battery Storage
Body Removal
Brake Burnishing
Brake Caliper Assembly, Front
Brake Caliper Assembly, Rear
Brake Caliper Inspection, Front
Brake Caliper Installation, Front
Brake Caliper Removal, Front
Brake Disc, Front
Brake Disc, Rear
Brake Hose and Fitting Inspection
Brake Pad Assembly, Front
Brake Pad Inspection
Brake Pad Thickness, Front
Brake Pads, Front
Brake Pads, Rear
Brake Pads, Removal, Front
Brake Pedal, Installation
Brake Pedal, Removal
Brake System Inspection
Brake System, Bleeding
Brake System, Exploded View
Brake System, Operation
Brake, Front Pad Assembly
Break-In Period
Break-In, PVT System (Belt)
Breather Hose Inspection
C
Cab Frame, Assembly / Removal (RZR / RZR S)
Caliper, Front
Caliper, Rear
Camshaft
Bore Inspection
Chain and Guide Service
Decompression Mechanism
Inspection
Installation / Timing
Removal
Sprocket Inspection
Timing – Quick Reference
Cargo Box Removal
Centralized Hilliard, Exploded View
Charging System
Charging System Testing Flow Chart
Charging System, Alternator Tests
Chassis (RZR / RZR S)
Clutch Center Distance
Clutch, Starter One Way
Compression Test
Console and Floor Panel Removal (RZR / RZR S)
Conversion Table
Coolant Drain / Fill
Coolant Drain / Radiator Removal
Coolant Level Inspection
Coolant Strength and Type
Cooling System Bleeding Procedure
Cooling System Exploded View
Cooling System Hoses
Cooling System Overview
Cooling System Pressure Cap Test
Cooling System Specifications
Cooling System, Pressure Test
Crankcase
Assembly
Separation
Crankcase Bearings
Crankcase Breather Service
Crankcase, Disassembly
Crankcase, Inspection
Crankshaft
Inspection
Removal
Crankshaft Position Sensor (CPS)
CV Joint / Boot
Replacement (Outer)
Cylinder Head
Combustion Chamber Cleaning
Disassembly
Inspection
Removal
Warp
Cylinder Head Assembly
D
Dash Instruments / Controls / Glovebox
Decal Replacement
Decimal Equivalent Chart
Decompression
Diagnostic Codes, Instrument Cluster
Digital Wrench
Communication Errors
Diagnostic Connector
ECU Reprogramming
Guided Diagnostics
Overview
Serial Number
Updates
Disassembly, Engine Lower End
Drive Belt
Installation
Drive Belt, Inspection
Drive Belt, Removal
Drive Clutch
Assembly
Exploded View
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Spring
Drive Shaft Boot Inspection
Driven Clutch
Disassembly
Driven Clutch Service
Driven Clutch, Assembly
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
Driveshaft / CV Joint, Handling Tips
E
ECU Replacement
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI System, Component Locations
EFI System, Exploded View
EFI, Service Notes
EFI, Troubleshooting
Electrical, Cooling System Breakout Diagram
Electronic Control Unit (ECU)
Engine:
Cam Chain and Guide Service
Cam Shaft Removal
Camshaft Bore Inspection
Camshaft Inspection
Camshaft Installation / Timing
Camshaft Sprocket Inspection
Camshaft Timing – Quick Reference
Combustion Chamber Cleaning
Cylinder Head Inspection
Cylinder Head Installation
Cylinder Head Removal
Cylinder Head Warp
Cylinder Honing
Cylinder Honing, Oversize
Cylinder Inspection
Cylinder Installation
Cylinder Removal
Decompression Mechanism
Installed Gap Measurement, Piston
Intake Valve Lash – Tappet Selection Matrix
Lower End Assembly
Lower End Disassembly
Piston / Connecting Rod Assembly
Piston / Rod Inspection
Piston Removal
Piston Ring Installation
Piston Ring Installed Gap
Piston-to-Cylinder Clearance
Top End Assembly
Top End Disassembly
Valve Clearance Check / Adjustment
Valve Cover Installation
Valve Cover Removal
Valve Inspection
Valve Sealing Test
Valve Seat Reconditioning
Valve Spring
Valve Spring Removal
Engine Break-In Period
Engine Coolant Temperature Sensor (ECT)
Engine Cooling System
ENGINE COOLING SYSTEM
Engine Exploded Views
Engine Installation
Engine Lubrication
Engine Mounting Exploded View
Engine Oil and Filter Change
Engine Oil Flow Chart
Engine Oil Level
Engine Removal
Engine Service
Engine Specifications
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Accessible Components
Engine, Cooling System Troubleshooting
Engine, Cylinder Head Assembly
Engine, Special Tools
Engine, Troubleshooting
EPS, Operation
EPS, Troubleshooting
Exhaust
Spark Arrestor
Exhaust Valve Lash – Tappet Selection Matrix (570)
F
Fan Control Circuit Bypass Test
Fan Control Circuit Operation
Floor (RZR / RZR S)
Flywheel Installation
Flywheel, Removal
Front A-arm, Replacement
Front Body / Dash Removal
Front Body Work
Front Bumper
Front Caliper, Piston Bore ID
Front Driveshaft, Installation
Front Driveshaft, Removal
Front Fender Flair Removal
Front Gearcase Lubrication
Front Gearcase, Assembly
Front Gearcase, Centralized Hilliard
Front Gearcase, Disassembly / Inspection
Front Gearcase, Installation
Front Gearcase, Removal
Front Stabilizer Bar (RZR, RZR S INT’L)
Fuel Filter
Fuel Injectors
Fuel Line
Fuel Lines Quick Connect
Fuel Pump Assembly
Fuel Pump Replacement
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel Tank Exploded View
Fuel Tank Replacement (RZR / RZR S)
G
General Specifications, Brakes
Ground, Engine
H
Head Lights
High Altitude Clutch Charts
Hood
Hood Removal
I
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Instrument Cluster
Instrument Cluster, Installation
Instrument Cluster, Removal
Intake Valve Clearance – Tappet Selection Matrix
K
Keys, Replacement
L
Leakdown Test
Lower Steering Shaft, Installation (EPS)
Lower Steering Shaft, Removal (EPS)
Lubrication Grease Points
Lubrication Specifications
Lubrication Transmission
M
MAG Side Crankcase Bearing Service
Main Frame (RZR / RZR S)
Maintenance Quick Reference Chart
Maintenance, Brake System
Maintenance, Cooling System
Maintenance, Electrical and Ignition
Maintenance, Engine
Maintenance, Final Drive
Maintenance, Fuel System
Maintenance, General Vehicle Inspection
Maintenance, Service Products and Lubricants
Maintenance, Steering
Maintenance, Transmission and Gearcases
Master Cylinder, Installation
Master Cylinder, Removal
Metric Bolt Torque Specification
Model Number Designation
Model Specifications, 2013 RANGER RZR 570
Model Specifications, 2013 RANGER RZR 570
International
Model Specifications, 2013 RANGER RZR 570LE
Model Specifications, 2014 RZR 570
Model Specifications, 2014 RZR 570 LE
N
Nets, Side
O
Oil Pickup Assembly Inspection
Oil Pressure Regulator (Bypass) Valve Inspection
Oil Pressure Specifications
Oil Pressure Test
Oil Pump Assembly
Oil Pump, Removal
P
Parking Brake Caliper, Disassembly / Inspection (INT’L)
Parking Brake Caliper, Exploded View (INT’L)
Parking Brake Caliper, Installation (INT’L)
Parking Brake Caliper, Pad Installation (INT’L)
Parking Brake Caliper, Removal (INT’L)
Parking Brake Disc (INT’L)
Parking Brake Pad Inspection (INT’L)
Parking Brake, Adjustment (INT’L)
Parking Brake, Exploded View (INT’L)
Parking Brake, Inspection (INT’L)
Periodic Maintenance Chart
Plunging Joint / Boot
Replacement (Inner)
Power Steering Unit, Installation
Power Steering Unit, Removal
Pre-Ride / Daily Inspection
Pressure Cap Test
Pressure Test, Oil
Propshaft Removal / Installation (RZR / RZR S)
Propshaft, U-Joint Service
Publication Numbers
PVT System Assembly
Disassembly
PVT System, Maintenance
PVT System, Overheating Diagnostics
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Button to Tower Clearance
PVT, Drive Clutch Bushing Service
PVT, Drive Clutch Cover Bushing
PVT, Drive Clutch Disassembly
PVT, Drive Clutch Spider Removal
PVT, Driven Clutch Assembly
PVT, Driven Clutch Bushing Service
PVT, Driven Clutch Disassembly
R
Radiator
Rear A-arm, Replacement
Rear Bumper
Rear Cargo Box (RZR / RZR S)
Rear Driveshaft, Installation
Rear Driveshaft, Removal
Rear Fender, Flair, and Tie Down Removal
Rear Fenders (RZR / RZR S)
Rear Service Panel (RZR / RZR S)
Rear Stabilizer Bar (RZR)
Reflash Authorization
Regulator / Rectifier Location
Rocker Panel Removal
Rocker Panels (RZR / RZR S)
S
Safety Nets
Seat Assembly
Seat Belts / Mounting (RZR / RZR S)
Seats
Sequence, Engine Cover Torque
Shift Cable Inspection and Adjustment
Shift Cable, Inspection
Shift Lever, Installation
Shift Lever, Removal
Shocks and Springs
Solenoid, Rear Differential (INT’L)
Spark Plug Service
Special Tools
Special Tools, Brakes
Special Tools, Clutching
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Special Tools, Transmission
Specification Chart, Maintenance
Specification, Coolant Sensor Resistance
Specification, Wheel Toe-Out
Specifications Camshaft
Cylinder Head Warp
Valve Seat Contact Width
Valve Spring
Valve Stem Diameter
Valve Stem Guide ID
Specifications, Cooling System
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Speed Sensor
Speedometer
Standard Bolt Torque Specification
Starter Assembly, Exploded View
Starter Drive, Removal
Starter Motor, Installation
Starter Motor, Removal
Starter Solenoid, Operation
Starter Solenoid, Test
Starter System Flow Chart
Starter System, Troubleshooting
Stator Housing Removal
Stator Installation
Stator Removal
Steering Shaft, Bearing Replacement
Steering Wheel Removal (EPS)
Steering Wheel Removal (Non-EPS)
Steering, Exploded View (Non-EPS)
Steering, Inspection
Suspension, Spring Preload Adjustment (Standard)
Sway Bar Linkage Removal
Switch, AWD/2WD
Switch, AWD/2WD/TURF (INT’L)
Switch, Brake Light
Switch, Gear Position
Switch, Hazard (INT’L)
Switch, Ignition
Switch, Ignition (INT’L)
Switch, Parking Brake (INT’L)
Switch, Turn Signal (INT’L)
T
Tail Lights
Tap / Drill Sizes (SAE)
Thermostat Replacement
Throttle Freeplay Adjustment
Throttle Pedal Inspection
Throttle Position Sensor (TPS)
Tie Rod End and Steering Inspection
Timing, Balance Shaft
Tire Inspection
Tire Pressure
Toe Adjustment
Torque Patterns, Engine Components
Torque Specifications Body / Frame
Clutching
Torque Specifications, Brakes
Torque Specifications, Transmission
Torque Specifications, Wheel and Hub
Transmission Disassembly
Transmission Disassembly (INT’L)
Transmission Gear Cluster Disassembly
Transmission Gear Cluster Disassembly (INT’L)
Transmission Installation
Transmission Lubrication
Transmission Mounting and Torque Value
Transmission Removal
Transmission Snorkel Shaft Removal / Disassembly
Transmission Snorkel Shaft Removal / Disassembly (INT’L)
Transmission, Assembly
Transmission, Assembly (INT’L)
Transmission, Exploded View
Transmission, Exploded View (INT’L)
Transmission, Output Shaft Backlash Procedure
ransmission, Output Shaft Backlash Procedure (INT’L)
Troubleshooting, Brake Noise
Troubleshooting, Brake System
Troubleshooting, Clutching
Troubleshooting, Transmission
U
Upper Steering Shaft Removal (EPS)
Upper Steering Shaft, Installation (EPS)
V
Valve Clearance Adjustment
Intake Valve Lash – Tappet Selection Matrix
Valve Clearance Inspection
Valve Cover Installation
Removal
Valve Sealing Test
Valve Seat Reconditioning
Valve Spring Removal
Vehicle Identification Model Number Designation
Vehicle Identification Number
Vent Lines
VIN
VIN Number
Voltage Drop Test
W
Water Pump Installation
Water Pump Mechanical Seal / Oil Seal
Water Pump Removal
Water Pump Service
Wheel Installation
Wheel Alignment
Wheel Hubs
Wheel, Removal