2015 – 2016 Polaris Ranger 570 ETX CREW Side by Side Service Manual

Description

This Official 2015 – 2016 Polaris Ranger 570 UTV Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for Polaris Ranger 570 Side by Sides.

Table of Contents

Chapter 1: General Information
Chapter 2: Maintenance
Chapter 3: Engine
Chapter 4: Electronic Fuel Injection
Chapter 5: Body / Steering / Suspension
Chapter 6: Clutching
Chapter 7: Final Drive
Chapter 8: Transmission
Chapter 9: Brakes
Chapter 10: Electrical

Index of Topics

Chapter 1: General Information
Chapter 2: Maintenance
Chapter 3: Engine
Chapter 4: Electronic Fuel Injection
Chapter 5: Body / Steering / Suspension
Chapter 6: Clutching
Chapter 7: Final Drive
Chapter 8: Transmission
Chapter 9: Brakes
Chapter 10: Electrical

Chapter 1 General Information
Vehicle Information
Model Number Designation
Vehicle Identification Number (vin) Designation
Engine Designation Number
Vin / Engine Number Location
Publication Numbers
Replacement Keys
Special Tools
General Specifications
Model: Ranger 570 / 570 Eps / Int’l
Ranger 570 / 570 Eps / Int’l
Model: Ranger 570 Crew / 570 Crew Eps
Ranger 570 Crew
Misc Specifications And Charts
Conversion Table
Standard Bolt Torque Specification
Metric Bolt Torque Specification
Sae Tap/drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents

Chapter 2 Maintenance
Special Tools
Periodic Maintenance Chart
Periodic Maintenance Overview
Break-in Period
Maintenance Chart Key
Pre-ride – 25 Hour Maintenance Interval
50- 100 Hour Maintenance Interval
100 – 300 Hour Maintenance Interval
Grease Lubrication Points
Service Products And Lubricants
Polaris Lubricants, Maintenance And Service Products
Fluid Maintenance References
Component Quick Reference
Component Quick Reference, Continued
General Maintenance
Pre-ride / Daily Inspection
Frame, Nuts, Bolts, And Fasteners
Shift Cable Inspection
Shift Cable Adjustment
Fuel System And Air Intake
Fuel System
Fuel Lines
Fuel Pump/filter
Vent Lines
Throttle Pedal Inspection
Throttle Freeplay Adjustment
Air Filter Service
Engine Air Intake Inspection
Pvt Air Intake Inspection
Engine
Compression And Leakdown Test
Breather Valve Inspection
Breather Hose
Engine Oil Level
Engine Oil And Filter Change
Valve Clearance
Transmission And Gearcases
Transmission Lubrication
Front Gearcase Lubrication
Cooling System
Liquid Cooling System Overview
Coolant Level Inspection
Coolant Strength / Type
Cooling System Hoses
Radiator Inspection / Cleaning
Coolant Drain / Radiator Removal
Final Drive / Wheel And Tire
Wheel And Hub Torque Table
Cv Shaft Boot Inspection
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
Electrical And Ignition System
Battery Maintenance
Battery Fluid Level (conventional Battery)
Battery Removal
Battery Installation
Battery Storage
Battery Charging
Spark Plug Service
Main Frame/engine Ground
Steering
Steering Inspection Note
Tie Rod End / Steering Inspection
Wheeltoe Alignment Inspection
Toe Adjustment
Suspension
Suspension Inspection
Spring Pre-load Adjustment
Stabilizer Bar Pivot Lubrication
Suspension Pivot Point Lubrication
Brake System
Brake Fluid Inspection
Brake Hose And Fitting Inspection
Brake Pad / Disc Inspection

Chapter 3 Engine
General Information
Special Tools
Engine Lubrication Specifications
Oil Pressure Test
Engine Oil Flow Chart
Engine Specifications
Engine Detail – Torque Values / Sequences / Assembly Notes
Main Engine Components – Torque Specification And Sequence
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
Cylinder / Oil Filter / Oil Pump / Breather
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
Spark Plug / Starter / Throttle Body / Valve Cover
Piston / Crankshaft / Balance Shaft
Engine Cooling System
Cooling System Assembly View And Coolant Flow Diagram
Cooling System Specifications
Cooling System Pressure Test
Pressure Cap Test
Radiator
Coolant Drain / Radiator Removal
Thermostat Replacement
Cooling System Bleeding Procedure
Water Pump Cover And Impeller Service (stator Cover Remains On Engine)
Water Pump Mechanical Seal / Oil Seal Replacement
Engine Service
Accessible Engine Components
Top-end Service (engine In Chassis)
Engine Removal
Engine Installation
Engine Break-in Period
Engine Mounting And Torque Values
Engine Lubrication Specifications
Setting Tdc (top-dead-center)
Engine Disassembly / Inspection – Top End
Valve Cover Removal
Camshaft Removal
Camshaft Sprocket Inspection
Camshaft / Camshaft Bore Inspection
Exhaust Camshaft Decompression Mechanism
Cam Chain And Guide Service
Cylinder Head Removal
Cylinder Head Disassembly
Cylinder Head Inspection
Cylinder Head Warp Inspection
Valve Inspection
Combustion Chamber Cleaning
Valve Seat Reconditioning
Cylinder Removal
Cylinder Inspection
Piston Removal
Piston-to-cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Honing To Oversize
Cylinder Hone Selection / Honing Procedure
Cleaning The Cylinder After Honing
Camshaft Installation / Timing
Camshaft Timing – Quick Reference
Valve Cover Installation
Engine Assembly- Top End
Piston Ring Installation
Piston / Connecting Rod Assembly
Cylinder Installation
Cylinder Head Assembly
Valve Sealing Test
Cylinder Head Installation
Valve Clearance Check / Adjustment
Intake Valve Lash – Tappet Selection Matrix
Exhaust Valve Lash – Tappet Selection Matrix
Engine Disassembly / Inspection – Lower End
Crankcase Disassembly
Flywheel/stator Housing Removal
Starter One-way Clutch Inspection
Stator Removal
Oil Pump Removal
Oil Pump Assembly
Crankcase Breather Service
Crankcase Separation
Balance Shaft Removal / Inspection
Crankshaft Removal
Crankshaft Inspection
Pto Side Crankcase Bearing Service
Mag Side Crankcase Bearing Service
Oil Pickup Assembly Inspection
Oil Pressure Regulator (bypass) Valve Inspection
Crankcase Inspection
Engine Assembly-lower End
Crankcase Assembly-pto Side
Balance Shaft Installation / Timing
Final Crankcase Assembly
Starter One-way Clutch Installation
Flywheel Installation
Stator / Stator Cover Installation
Troubleshooting
Engine
Cooling System

Chapter 4 Electronic Fuel Injection
General Information
Special Tools
Service Notes
Efi Operation Overview
Efi System Assembly View
Efi System Component Locations
Principal Components
Initial Priming / Starting Procedure
Electronic Control Unit (ecu)
Operation Overview
Ecu Service
Ecu Replacement
Fuel Tank
Operation Overview
Assembly View
Fuel Lines-quick Connect
Fuel Tank Removal
Fuel Tank Installation
Fuel Sender Test
Fuel Pump Test
Fuel Pump Replacement
Temp / Manifold Absolute Pressure Sensor (t-map)
Operation Overview
T-map Sensor Test
T-map Sensor Replacement
Crankshaft Position Sensor (cps)
Operation Overview
Cps Test
Cps Replacement
Fuel Injector
Operation Overview
Fuel Injector Troubleshooting
Fuel Injector Test
Fuel Injector Replacement
Idle Air Control (iac)
Operation Overview
Iac Test
Iac Replacement
Throttle Position Sensor (tps)
Operation Overview
Tps Resistance Tests
Tps Tester / Regulator
Tps Replacement
Engine Coolant Temperature Sensor (ect)
Operation Overview
Ect Sensor Test
Ect Sensor Replacement
Efi Diagnostics
Instrument Cluster Trouble Code Display
Diagnostic Trouble Code Chart
Efi Troubleshooting
Digital Wrench® Operation
Digital Wrench® Diagnostic Software Overview
Special Tools (also Refer To The Beginning Of This Chapter)
Diagnostic Software Version
Ecu Replacement
Guided Diagnostic Available
Digital Wrench® Communication Errors
Digital Wrench® – Diagnostic Connector
Digital Wrench® Serial Number Location
Digital Wrench® Version And Update Id
Digital Wrench® Updates
Digital Wrench® Feature Map
Engine Controller Reprogramming (reflash)
Efi System Electrical Diagram

Chapter 5 Body / Steering / Suspension
Torque Specifications
Special Tools
Chassis /body
570 Efi Frame Assembly View
570 Efi Crew Frame Assembly View
570 Cab Frame
570 Crew Cab Frame
Dash Instruments / Controls:
Hood / Dash / Front Fascia
570 Efi Floor / Rear Fenders
570 Efi Seat Mounting / Seat Belts
570 Efi Crew Floor / Rear Fenders
570 Efi Crew Seat Mounting / Seat Belts
Rear Cargo Box
Cargo Box – Tailgate / Box Support
Box Removal
Box Installation
Body Component Removal
Lower Seat Base
Front Bumper
Wheel Well Panels
Fenders/foot Pads
Hood/dash
Floors
Decal Replacement
Steering Assembly
Assembly View (non-eps)
Assembly View (eps)
Steering Wheel Removal (non-eps Models)
Steering Shaft Removal (non-eps Models)
Steering Shaft Bearing Replacement
Steering Wheel Removal (eps Models)
Power Steering Unit Removal
Power Steering Unit Installation
Front Strut
Assembly View
Front Strut Cartridge Replacement
Ball Joint Replacement
Rear A-arms
Removal/replacement
Installation
Assembly View
Rear Stabilizer Bar / Linkage
Removal / Installation
Assembly View
Shocks /springs
Assembly View
Shock Removal / Installation
Shock Replacement

Chapter 6 Clutching
Special Tools And Supplies
Torque Specifications
Pvt System Fastener Torques
Pvt System Overview
Clutching Chart
General Operation
Drive Clutch Operation
Driven Clutch Operation
Pvt Break-in (drive Belt / Clutches)
Maintenance / Inspection
Overheating /diagnosis
Pvt System Service
Pvt Sealing, Guard, And Duct Components
Pvt Disassembly
Pvtassembly
Drive Belt
Belt Removal
Belt Inspection
Belt Installation
Pvt Break-in (drive Belt / Clutches)
Clutch Alignment / Offset / Center Distance
Inspection
Adjustment
Drive Clutch Service
Drive Clutch Assembly View
Clutch Disassembly
Shift Weight Inspection
Spider Removal
Roller, Pin, And Thrust Washer Inspection
Button To Tower Clearance Inspection
Bearing Inspection
Clutch Inspection
Bushing Service
Clutch Assembly
Driven Clutch Service
Assembly View
Clutch Disassembly / Inspection
Clutch Assembly
Troubleshooting

Chapter 7 Final Drive
Special Tools
Torque Specifications
Wheel And Hub Torque Table
Front Hub/bearing
Hub Removal/inspection
Hubstrut Bearing Replacement
Hub Installation
Front Hub/wheel Exploded View
Front Drive Shaft
Removal
Installation
Front Gearcase / Centralized Hilliard
Centralized Hilliard Assembly View
All Wheel Drive Operation
Awd Diagnosis
Gearcase Removal
Gearcase Disassembly / Inspection
Gearcase Assembly
Gearcase Installation
Rear Bearing Carrier
Inspection
Removal
Disassembly
Assembly
Installation
Rear Drive Shaft
Removal
Installation
Drive Shaft Service
Drive Shaft / Cv Joint Handling Tips
Outer Cv Joint / Boot Replacement
Inner Plunging Joint / Boot Replacement
Drive Shaft Assembly View
Propshaft U-joint Service
Removal / Installation
Front Propshaft Components
Removal / Installation (crew)
Support Bearing Replacement (crew)
Disassembly
Assembly

Chapter 8 Transmission
Specifications
Torque Specifications
Special Tools
Lubrication
Transmission Mounting And Torque Values
Shift Lever
Removal
Installation
Shift Cable
Inspection
Adjustment
Transmission Removal
Transmission Installation
Transmission Service
Differential Operation
Transmission Disassembly
Planetary Differential Disassembly
Planetary Differential Bushing Replacement
Planetary Differential Assembly
Gear / Shaft / Bearing Inspection
Snorkel Gear Backlash Procedure
Troubleshooting
Troubleshooting Checklist
Transmission
Transmission Assembly View

Chapter 9 Brakes
General Specifications
Torque Specifications
Special Tools
Brake System Notes
Brake System Service Notes
Brake Noise Troubleshooting
Hydraulic Brake System Operation
Brake System Assembly View
Ranger 570 Efi
Ranger 570 Efi Crew
Master Cylinder
Removal
Installation
Brake Pressure Switch
Foot Brake Pedal
Pedal Removal
Pedal Installation
Brake Procedures
Brake Bleeding / Fluid Change
Brake Burnishing Procedure
Front Brake Pads – 570 Efi
Pad Removal / Disassembly
Pad Inspection-570 Efi
Pad Assembly / Installation- 570 Efi
Pad Adjustment- 570 Efi
Front Caliper-570 Efi
Front Caliper Assembly View
Front Caliper Removal-570 Efi
Front Caliper Disassembly- 570 Efi
Front Caliper Inspection- 570 Efi
Front Caliper Assembly
Front Caliper Installation
Front Brake Pads – 570 Efi Crew
Pad Removal – 570 Efi Crew
Pad Inspection
Pad Assembly / Installation- 570 Efi Crew
Front Caliper – 570 Efi Crew
Front Caliper Assembly View
Front Caliper Removal- 570 Efi Crew
Front Caliper Disassembly- 570 Efi Crew
Front Caliper Inspection – 570 Efi Crew
Front Caliper Assembly- 570 Efi Crew
Front Caliper Installation – 570 Efi Crew
Front Brake Disc
Disc Inspection
Disc Removal / Replacement
Rear Brake Pad Service
Pad Removal
Pad Inspection
Rear Pad Installation
Rear Caliper
Caliper Assembly View
Caliper Removal
Rear Caliper Disassembly
Rear Caliper Inspection
Rear Caliper Assembly
Rear Caliper Installation
Rear Brake Disc
Disc Runout
Disc Inspection
Disc Removal / Replacement
Troubleshooting
Brakes Squeal / Poor Brake Performance
Pedal Vibration
Caliper Overheats (brakes Drag)
Brakes Lock

Chapter 10 Electrical
General Information
Special Tools
Electrical Service Notes
Battery Conductance Analyzer
Components Under Hood
Switches / Controls
Ignition / Headlight Switch
Awd / 2wd / Turf Switch
Differential Solenoid
Brake Pressure Switch
All Wheel Drive (awd) Coil
Operation Overview
Diagnosing System Failures
Vehicle Speed Sensor
Speed Sensor Location
Speed Sensor Testing
Instrument Cluster
Overview
Rider Information Display
Information Display Area
Diagnostic Mode
Instrument Cluster Pinouts
Instrument Cluster Removal
Instrument Cluster Installation
Headlights
Headlight Adjustment
Headlight Bulb Replacement
Headlight Housing Removal
Headlight Housing Installation
Tail Light / Brake Light
Led Lamp Replacement
Cooling System
Fan Control Circuit Operation
Fan Control Circuit Bypass Test
Cooling System Break-out Diagram
Ignition Coil
Operation Overview
Ignition Coiltests
Ignition Coil And Ht Lead Replacement
Relays
Operation
Fuses / Circuit Breaker
Operation
Charging System
Current Draw – Key Off
Charging System “break Even” Test
Charging System Alternator Tests
Charging System Testing Flow Chart
Battery Service
Battery Terminals/bolts
Battery Terminal Block
Battery Activation
Battery Inspection
Battery Removal / Installation
Conventional Battery Testing
Ocv – Open Circuit Voltage Test
Voltage Drop Test
Specific Gravity Test
Load Test
Charging Procedure
Off Season Storage
Starter System
Troubleshooting
Starter Drive
Starter Solenoid Bench Test
Starter Solenoid Operation
Starting System Testing Flow Chart