Polaris RANGER 500 2017 Service Manual

Table of Contents

• 9. Table of Contents
• 12. VEHICLE INFORMATION
• 13. REFERENCE INFORMATION
• 14. PUBLICATION PART NUMBERS
• 16. SPECIAL TOOLS
• 17. MASTER SPECIAL TOOLS TABLE
• 25. MASTER TORQUE TABLE
• 27. CLUTCHING CHART
• 28. GENERAL SPECIFICATIONS
• 32. 2017-2018 RANGER 570 4X4 (INTL.)
• 60. MISC. SPECIFICATIONS AND CHARTS
• 61. SAE TAP / DRILL SIZES
• 62. METRIC TAP / DRILL SIZES
• 63. DECIMAL EQUIVALENTS
• 65. GENERAL DIAGNOSTICS
• 66. GUIDED SYMPTOM REFERENCES
• 67. ENGINE AND DRIVABILITY DIAGNOSTIC PROCED...
• 70. ENGINE CRANKS BUT DOES NOT START
• 72. NO CRANK NO START OR SLOW CRANK
• 73. OVER HEATING
• 74. WARNING LIGHTS
• 75. ENGINE TROUBLESHOOTING
• 77. COOLING TROUBLESHOOTING
• 78. DIGITAL WRENCH
• 79. DIGITAL WRENCH® SOFTWARE INSTALLATION AN...
• 80. DIGITAL WRENCH® COMMUNICATION ERRORS
• 81. DIGITAL WRENCH® FEATURE MAP
• 82. ENGINE CONTROLLER REPROGRAMMING (REFLASH...
• 83. ENGINE ELECTRICAL DIAGNOSTICS
• 84. MASTER TROUBLE CODE LIST
• 95. CYLINDER MISFIRE DETECTION
• 96. FLUID LEAKS
• 97. FUEL SYSTEM DIAGNOSTICS
• 99. PVT SYSTEM DIAGNOSTICS
• 101. PVT SYSTEM OVERHEATING / DIAGNOSIS
• 102. TRANSMISSION DIAGNOSTICS
• 103. FINAL DRIVE DIAGNOSTICS
• 104. BRAKE SYSTEM DIAGNOSTICS
• 105. CALIPER OVERHEATS (BRAKES DRAG)
• 106. STEERING / SUSPENSION DIAGNOSTICS
• 107. EPS TROUBLESHOOTING (POWER STEERING NON-...
• 108. EPS TROUBLESHOOTING (USING DIGITAL WRENC...
• 109. SHOCK ANALYSIS
• 110. ELECTRICAL DIAGNOSTICS
• 112. TESTING FOR A SHORT TO GROUND
• 113. TESTING FOR A SHORT TO VOLTAGE
• 114. TESTING FOR INTERMITTENT CONDITIONS
• 115. CURRENT DRAW - KEY OFF
• 119. MAINTENANCE
• 120. BREAK-IN PERIOD
• 121. PERIODIC MAINTENANCE CHART KEY
• 124. GREASE LUBRICATION POINTS
• 125. COMPONENT QUICK REFERENCE
• 126. STORAGE TIPS
• 127. LUBRICANTS / SERVICE PRODUCTS
• 128. ENGINE
• 129. BREATHER HOSE
• 130. 500 SOHC
• 132. COOLING SYSTEM
• 134. 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE
• 135. COOLANT STRENGTH / TYPE
• 136. RADIATOR INSPECTION / CLEANING
• 138. FUEL SYSTEM AND AIR INTAKE
• 139. ENGINE AIR INTAKE INSPECTION
• 140. TRANSMISSION AND GEARCASE
• 141. FRONT GEARCASE LUBRICATION
• 143. FINAL DRIVE / WHEEL / TIRE
• 144. WHEEL INSTALLATION
• 145. STEERING
• 146. WHEEL TOE ALIGNMENT INSPECTION
• 147. CAMBER AND CASTER
• 148. SUSPENSION
• 149. SUSPENSION PIVOT POINT LUBRICATION
• 150. SHOCK ANALYSIS
• 151. BRAKE SYSTEM
• 152. BRAKE DISC INSPECTION
• 153. ELECTRICAL AND IGNITION SYSTEM
• 154. BATTERY INSTALLATION
• 155. 570 DOHC
• 156. MAIN FRAME/ENGINE GROUND
• 161. GENERAL ENGINE INFORMATION
• 162. OIL PRESSURE TEST
• 163. ENGINE OIL FLOW CHART
• 164. ENGINE SPECIFICATIONS
• 166. ENGINE SERVICE
• 169. ENGINE INSTALLATION
• 172. ENGINE BREAK-IN PERIOD
• 173. ENGINE MOUNTING AND TORQUE VALUES
• 174. SETTING TDC (TOP-DEAD-CENTER)
• 176. COOLING SYSTEM
• 177. COOLING SYSTEM SPECIFICATIONS
• 178. RADIATOR
• 179. THERMOSTAT REPLACEMENT
• 180. COOLING SYSTEM BLEEDING PROCEDURE
• 181. WATER PUMP COVER AND IMPELLER SERVICE (S...
• 187. TROUBLESHOOTING
• 188. COOLING SYSTEM
• 189. 500CC SOHC ENGINE
• 191. ENGINE TORQUE SEQUENCES
• 193. CRANKCASE SEALANT PATH
• 194. CRANKCASE / TIMING CHAIN GUIDES / OIL PI...
• 195. CYLINDER / OIL FILTER / OIL PUMP / BREAT...
• 197. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / I...
• 199. SPARK PLUGS / STARTER / THROTTLE BODY / ...
• 201. PISTON / CRANKSHAFT / BALANCE SHAFT
• 204. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
• 205. CAMSHAFT SPROCKET INSPECTION
• 206. EXHAUST CAMSHAFT DECOMPRESSION MECHANISM
• 207. CYLINDER HEAD REMOVAL
• 208. CYLINDER HEAD INSPECTION
• 210. COMBUSTION CHAMBER CLEANING
• 211. CYLINDER REMOVAL
• 212. CYLINDER INSPECTION
• 213. PISTON-TO-CYLINDER CLEARANCE
• 214. PISTON RING INSTALLED GAP
• 215. ENGINE ASSEMBLY - TOP END
• 216. PISTON / CONNECTING ROD ASSEMBLY
• 217. CYLINDER HEAD INSTALLATION
• 218. VALVE SEALING TEST
• 220. VALVE LASH - TAPPET SELECTION MATRIX
• 221. CAMSHAFT INSTALLATION / TIMING
• 223. CAMSHAFT TIMING - QUICK REFERENCE
• 224. VALVE COVER INSTALLATION
• 225. ENGINE DISASSEMBLY / INSPECTION - LOWER ...
• 227. STATOR REMOVAL
• 228. OIL PUMP REMOVAL
• 230. OIL PUMP ASSEMBLY
• 231. CRANKCASE BREATHER SERVICE
• 232. BALANCE SHAFT REMOVAL / INSPECTION
• 233. CRANKSHAFT REMOVAL
• 234. PTO SIDE CRANKCASE BEARING SERVICE
• 235. MAG SIDE CRANKCASE BEARING SERVICE
• 236. OIL PICKUP ASSEMBLY INSPECTION
• 237. ENGINE ASSEMBLY - LOWER END
• 239. BALANCE SHAFT INSTALLATION / TIMING
• 241. STARTER ONE-WAY CLUTCH INSTALLATION
• 243. STATOR / STATOR COVER INSTALLATION
• 244. 570CC DOHC ENGINE
• 246. TORQUE SEQUENCE
• 248. CRANKCASE - TIMING / SEALING PATH
• 249. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
• 250. CAMSHAFT SPROCKET INSPECTION
• 251. CAMSHAFT INSPECTION
• 252. CAM CHAIN AND GUIDE SERVICE
• 253. CYLINDER HEAD DISASSEMBLY
• 254. CYLINDER HEAD INSPECTION
• 255. COMBUSTION CHAMBER CLEANING
• 256. VALVE SEAT RECONDITIONING
• 258. CYLINDER REMOVAL
• 259. PISTON REMOVAL
• 260. PISTON / ROD INSPECTION
• 261. PISTON RING INSTALLED GAP
• 262. ENGINE ASSEMBLY - TOP END
• 263. PISTON / CONNECTING ROD ASSEMBLY
• 264. CYLINDER INSTALLATION
• 265. CRANKCASE IDENTIFICATION
• 266. CYLINDER HEAD INSTALLATION - BLACK BOLTS
• 267. CYLINDER HEAD INSTALLATION - SILVER BOLT...
• 268. VALVE SEALING TEST
• 271. VALVE LASH - TAPPET SELECTION
• 272. CAMSHAFT INSTALLATION / TIMING
• 275. CAMSHAFT TIMING - QUICK REFERENCE
• 276. VALVE COVER INSTALLATION
• 277. ENGINE DISASSEMBLY / INSPECTION - LOWER ...
• 279. STATOR REMOVAL
• 280. OIL PUMP REMOVAL
• 282. OIL PUMP ASSEMBLY
• 283. CRANKCASE BREATHER SERVICE
• 285. CRANKSHAFT REMOVAL
• 286. PTO SIDE CRANKCASE BEARING SERVICE
• 287. MAG SIDE CRANKCASE BEARING SERVICE
• 288. OIL PICKUP ASSEMBLY INSPECTION
• 289. ENGINE ASSEMBLY - LOWER END
• 291. BALANCE SHAFT INSTALLATION / TIMING
• 292. STARTER ONE-WAY CLUTCH INSTALLATION
• 293. FLYWHEEL INSTALLATION
• 294. STATOR / STATOR COVER INSTALLATION
• 298. ELECTRONIC CONTROL UNIT (ECU)
• 299. ECU REPLACEMENT
• 300. ELECTRONIC THROTTLE BODY (ETC)
• 301. TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE...
• 302. PEDAL POSITION SENSOR (PPS)
• 303. CRANKSHAFT POSITION SENSOR
• 305. CPS REPLACEMENT
• 306. ENGINE COOLANT TEMPERATURE SENSOR (ETC)
• 307. ECT SENSOR REPLACEMENT
• 311. GENERAL INFORMATION
• 312. PRINCIPAL COMPONENTS
• 313. SPECIAL TOOLS
• 314. DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR
• 315. DIGITAL WRENCH® DIAGNOSTIC SOFTWAREPU-47...
• 316. EFI COMPONENT LOCATIONS
• 317. EFI COMPONENT LOCATIONS - RIGHT VIEW
• 318. LINE / HOSE ROUTING
• 319. VENT LINE TERMINATION FITTING
• 320. AIR BOX / INTAKE SYSTEM
• 322. AIR BOX REMOVAL / INSTALLATION
• 323. FUEL TANK / PUMP / SENDING UNIT
• 324. FUEL TANK INSTALLATION
• 325. FUEL PUMP TEST
• 326. FUEL PUMP REPLACEMENT
• 330. IGNITION COIL OVERVIEW
• 331. FUEL INJECTOR
• 332. FUEL INJECTOR REPLACEMENT
• 333. FUEL INJECTOR TROUBLESHOOTING
• 334. EFI DIAGNOSIS
• 335. TROUBLE CODE DISPLAY (DTC)
• 342. FUEL SYSTEM TROUBLESHOOTING
• 344. GENERAL INFORMATION
• 345. PVT SYSTEM OVERVIEW
• 346. DRIVE CLUTCH OPERATION
• 347. OVERHEATING / DIAGNOSIS
• 348. PVT SYSTEM SERVICE
• 349. PVT DISASSEMBLY
• 350. PVT ASSEMBLY
• 351. DRIVE BELT
• 352. BELT INSTALLATION
• 353. CLUTCH ALIGNMENT / OFFSET / CENTER DISTA...
• 354. ADJUSTMENT
• 355. DRIVE CLUTCH SERVICE
• 356. CLUTCH DISASSEMBLY
• 357. SHIFT WEIGHT INSPECTION
• 358. SPIDER REMOVAL
• 359. BUTTON TO TOWER CLEARANCE INSPECTION
• 361. BUSHING SERVICE
• 364. CLUTCH ASSEMBLY
• 365. DRIVEN CLUTCH SERVICE
• 366. CLUTCH DISASSEMBLY / INSPECTION
• 367. CLUTCH ASSEMBLY
• 368. PVT SYSTEM TROUBLESHOOTING
• 372. GENERAL INFORMATION
• 373. SPECIAL TOOLS
• 374. TRANSMISSION GEARS
• 375. TRANSMISSION MOUNTING AND TORQUE VALUES
• 376. ASSEMBLY VIEW
• 378. SHIFT LEVER
• 379. SHIFT CABLE
• 380. ADJUSTMENT
• 381. TRANSMISSION SERVICE
• 383. TRANSMISSION INSTALLATION
• 386. TRANSMISSION INTERNALS SERVICE
• 387. TRANSMISSION DISASSEMBLY
• 392. PLANETARY DIFFERENTIAL DISASSEMBLY
• 393. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
• 395. PLANETARY DIFFERENTIAL ASSEMBLY
• 396. GEAR / SHAFT / BEARING INSPECTION
• 397. SNORKEL GEAR BACKLASH PROCEDURE
• 405. TROUBLESHOOTING
• 409. GENERAL INFORMATION
• 410. FRONT HUB / BEARING
• 411. HUB INSTALLATION
• 413. FRONT HUB/WHEEL EXPLODED VIEW
• 414. FRONT DRIVE SHAFT
• 415. FRONT DRIVE SHAFT INSTALLATION
• 416. FRONT GEARCASE
• 418. FRONT GEARCASE (NON-ADC)
• 419. ALL WHEEL DRIVE OPERATION
• 420. AWD DIAGNOSIS
• 421. FRONT GEARCASE DISASSEMBLY / INSPECTION
• 424. FRONT GEARCASE ASSEMBLY
• 427. FRONT GEARCASE (ADC)
• 429. OPERATION, FRONT GEARCASE (4WDC)
• 430. DISASSEMBLY / INSPECTION, FRONT GEARCASE...
• 434. REASSEMBLY, FRONT GEARCASE (ADC)
• 437. TROUBLESHOOTING, FRONT GEARCASE (ADC)
• 441. REAR BEARING CARRIER
• 442. DISASSEMBLY
• 443. INSTALLATION
• 444. REAR DRIVE SHAFT
• 445. DRIVE SHAFT SERVICE
• 448. INNER PLUNGING JOINT / BOOT REPLACEMENT
• 450. DRIVE SHAFT ASSEMBLY VIEW
• 451. PROPSHAFT U-JOINT SERVICE
• 452. SUPPORT BEARING REPLACEMENT (CREW)
• 453. DISASSEMBLY
• 454. ASSEMBLY
• 456. GENERAL INFORMATION
• 457. SHOCK ANALYSIS
• 458. STEERING ASSEMBLY
• 460. STEERING ASSEMBLY VIEW (EPS)
• 462. STEERING WHEEL REMOVAL (NON-EPS MODELS)
• 463. STEERING SHAFT / STEERING RACK REMOVAL (...
• 464. STEERING WHEEL / UPPER STEERING SHAFT RE...
• 465. POWER STEERING UNIT REMOVAL
• 467. STEERING RACK REMOVAL / INSTALLATION (EP...
• 469. FRONT STRUT
• 470. FRONT STRUT CARTRIDGE REPLACEMENT
• 472. REAR A-ARMS
• 473. INSTALLATION
• 474. ASSEMBLY VIEW
• 475. REAR STABALIZER BAR / LINKAGE
• 476. ASSEMBLY VIEW
• 479. GENERAL INFORMATION
• 480. BRAKE SYSTEM NOTES
• 481. HYDRAULIC BRAKE SYSTEM OPERATION
• 482. BRAKE SYSTEM ASSEMBLY VIEWS
• 483. RANGER CREW
• 484. MASTER CYLINDER
• 485. BRAKE PEDAL
• 486. BRAKE SERVICE PROCEDURES
• 487. BRAKE BURNISHING PROCEDURE
• 488. FRONT BRAKE PADS
• 489. PAD ASSEMBLY / INSTALLATION- RANGER
• 490. CREW
• 491. PAD INSPECTION
• 492. FRONT CALIPER
• 493. FRONT CALIPER REMOVAL- RANGER
• 494. FRONT CALIPER INSPECTION- RANGER
• 495. FRONT CALIPER INSTALLATION
• 496. CREW
• 497. FRONT CALIPER REMOVAL- CREW
• 498. FRONT CALIPER INSPECTION - CREW
• 499. FRONT CALIPER ASSEMBLY - CREW
• 501. FRONT BRAKE DISC
• 502. DISC REMOVAL / REPLACEMENT
• 503. BRAKE PAD INSPECTION
• 504. REAR PAD INSTALLATION
• 505. REAR CALIPERS
• 506. CALIPER REMOVAL
• 507. REAR CALIPER INSPECTION
• 508. REAR CALIPER INSTALLATION
• 509. REAR BRAKE DISC
• 510. DISC REMOVAL / REPLACEMENT
• 511. TROUBLESHOOTING
• 512. BRAKE WARNING SYSTEM INSPECTION (INTL MO...
• 514. GENERAL INFORMATION
• 515. CHASSIS / BODY ASSEMBLY VIEWS
• 516. CREW FRAME ASSEMBLY VIEW
• 519. DASH INSTRUMENTS / CONTROLS
• 520. HOOD / DASH / FRONT FASCIA
• 521. FLOOR / REAR FENDERS
• 522. SEAT MOUNTING / SEAT BELTS
• 523. CREW FLOOR / REAR FENDERS
• 524. CREW SEAT MOUNTING / SEAT BELTS
• 525. REAR CARGO BOX
• 527. BOX REMOVAL
• 528. BODY COMPONENT REMOVAL
• 529. HOOD / DASH
• 530. FLOORS
• 531. DECALS
• 535. GENERAL INFORMATION
• 536. COMPONENTS UNDER HOOD
• 537. SWITCHES / CONTROLS
• 538. DIFFERENTIAL SOLENOID
• 539. ALL WHEEL DRIVE (AWD) COIL
• 540. VEHICLE SPEED SENSOR
• 541. INSTRUMENT CLUSTER
• 542. RIDER INFORMATION DISPLAY
• 543. INFORMATION DISPLAY AREA
• 545. DIAGNOSTIC MODE
• 546. INSTRUMENT CLUSTER PINOUTS
• 547. HEADLIGHTS
• 548. HEADLIGHT BULB REPLACEMENT
• 549. TAIL LIGHT / BRAKE LIGHT
• 550. COOLING SYSTEM
• 551. IGNITION COIL
• 552. IGNITION COIL AND HT LEAD REPLACEMENT
• 553. RELAYS
• 555. FUSES / CIRCUIT BREAKER
• 556. OPERATION (INTL.)
• 557. CHARGING SYSTEM
• 558. CHARGING SYSTEM ALTERNATOR TESTS
• 560. CHARGING SYSTEM TESTING FLOW CHART
• 561. BATTERY SERVICE
• 562. BATTERY INSPECTION
• 563. BATTERY REMOVAL / INSTALLATION
• 564. LOAD TEST
• 565. STARTER SYSTEM
• 566. STARTER SOLENOID BENCH TEST
• 567. STARTING SYSTEM TESTING FLOW CHART