Polaris RZR 570 2013 Service manual

Table of Contents

• 7. Table of Contents
• 8. VEHICLE IDENTIFICATION
• 9. VEHICLE IDENTIFICATION NUMBER (VIN) DESI...
• 10. VEHICLE INFORMATION
• 11. SPECIAL TOOLS
• 12. GENERAL SPECIFICATIONS
• 14. 2013 RANGER RZR 570 LE
• 16. 2013 RANGER RZR 570 INTL
• 18. 2014 RZR 570
• 22. 2015 RZR 570
• 26. 2016 RZR 570
• 28. 2016 RZR 570 LE
• 30. MISC. SPECIFICATIONS AND CHARTS
• 33. CONVERSION TABLE
• 34. STANDARD BOLT TORQUE SPECIFICATION
• 35. SAE TAP / DRILL SIZES
• 36. DECIMAL EQUIVALENTS
• 39. PERIODIC MAINTENANCE CHART
• 40. MAINTENANCE INTERVALS
• 42. MAINTENANCE QUICK REFERENCE
• 44. GREASE LUBRICATION POINTS
• 45. LUBRICANTS / SERVICE PRODUCTS
• 46. GENERAL VEHICLE INSPECTION AND MAINTENAN...
• 47. ENGINE
• 49. ENGINE BREATHER HOSE INSPECTION
• 50. VALVE CLEARANCE INSPECTION
• 51. EXHAUST - SPARK ARRESTOR
• 52. COOLING SYSTEM
• 53. COOLANT LEVEL INSPECTION
• 54. COOLING SYSTEM
• 55. FUEL SYSTEM AND AIR INTAKE
• 56. VENT LINES
• 57. ENGINE AND PVT INTAKE PRE-FILTER SERVICE
• 58. AIR FILTER SERVICE
• 59. PVT / FINAL DRIVE / WHEEL AND TIRE
• 60. TIRE INSPECTION
• 61. TRANSMISSION AND FRONT GEARCASE
• 62. SHIFT CABLE INSPECTION / ADJUSTMENT
• 64. STEERING
• 65. WHEEL TOE ALIGNMENT INSPECTION
• 67. SUSPENSION
• 68. BRAKE SYSTEM
• 69. BRAKE HOSE AND FITTING INSPECTION
• 70. ELECTRICAL AND IGNITION SYSTEM
• 71. BATTERY INSTALLATION
• 72. ENGINE TO FRAME GROUND
• 76. GENERAL INFORMATION
• 77. ENGINE OIL FLOW CHART
• 78. ENGINE SERVICE SPECIFICATIONS
• 80. TORQUE SEQUENCE
• 81. CRANKCASE / TIMING CHAIN GUIDES / OIL PI...
• 82. CYLINDER / OIL FILTER / OIL PUMP / BREAT...
• 83. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / S...
• 84. CAMS / CYL HEAD / FLYWHEEL / STATOR COVE...
• 85. SPARK PLUGS / STARTER / THROTTLE BODY / ...
• 86. PISTON / CRANKSHAFT / BALANCE SHAFT
• 87. INTAKE / EXHAUST SYSTEM
• 88. EXHAUST SYSTEM ASSEMBLY VIEW
• 89. ENGINE COOLING SYSTEM
• 90. COOLING SYSTEM SPECIFICATIONS
• 91. PRESSURE CAP TEST
• 92. COOLANT DRAIN / RADIATOR REMOVAL
• 93. THERMOSTAT REPLACEMENT
• 94. WATER PUMP MECHANICAL SEAL / OIL SEAL RE...
• 100. COOLING SYSTEM BLEEDING PROCEDURE
• 101. ENGINE SERVICE
• 105. ENGINE INSTALLATION
• 109. ENGINE BREAK-IN PERIOD
• 110. ENGINE MOUNTING AND TORQUE VALUES
• 111. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
• 112. CAMSHAFT SPROCKET INSPECTION
• 113. CAMSHAFT INSPECTION
• 114. CYLINDER HEAD REMOVAL
• 115. CYLINDER HEAD INSPECTION
• 116. CYLINDER HEAD WARP INSPECTION
• 117. COMBUSTION CHAMBER CLEANING
• 118. VALVE SEAT RECONDITIONING
• 120. CYLINDER REMOVAL
• 121. PISTON REMOVAL
• 122. PISTON / ROD INSPECTION
• 123. PISTON RING INSTALLED GAP
• 124. CYLINDER HONE SELECTION / HONING PROCEDU...
• 127. CAMSHAFT TIMING - QUICK REFERENCE
• 128. VALVE COVER INSTALLATION
• 129. ENGINE ASSEMBLY - TOP END
• 130. PISTON / CONNECTING ROD ASSEMBLY
• 131. CYLINDER INSTALLATION
• 132. VALVE SEALING TEST
• 133. CYLINDER HEAD INSTALLATION - BLACK BOLTS
• 134. CYLINDER HEAD INSTALLATION - SILVER BOLT...
• 135. VALVE CLEARANCE CHECK / ADJUSTMENT
• 138. INTAKE VALVE LASH - TAPPET SELECTION MAT...
• 139. EXHAUST VALVE LASH - TAPPET SELECTION MA...
• 140. ENGINE DISASSEMBLY / INSPECTION - BOTTOM...
• 142. STATOR REMOVAL
• 143. OIL PUMP REMOVAL
• 145. OIL PUMP ASSEMBLY
• 146. CRANKCASE BREATHER SERVICE
• 147. BALANCE SHAFT REMOVAL / INSPECTION
• 148. CRANKSHAFT REMOVAL
• 149. PTO SIDE CRANKCASE BEARING SERVICE
• 150. MAG SIDE CRANKCASE BEARING SERVICE
• 151. OIL PICKUP ASSEMBLY INSPECTION
• 163. GENERAL INFORMATION
• 165. SERVICE NOTES
• 166. EFI SYSTEM EXPLODED VIEW
• 167. EFI SYSTEM COMPONENT LOCATIONS
• 169. EFI SYSTEM ELECTRICAL DIAGRAM
• 170. EFI OVERVIEW
• 171. ELECTRONIC CONTROL UNIT (ECU)
• 172. ECU SERVICE
• 173. FUEL INJECTORS
• 174. FUEL INJECTOR TEST
• 176. FUEL TANK
• 177. EXPLODED VIEW
• 178. OPERATION OVERVIEW
• 179. FUEL SENDER TEST
• 181. FUEL PUMP REPLACEMENT
• 184. FUEL TANK REMOVAL
• 186. FUEL TANK INSTALLATION
• 187. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSU...
• 188. IDLE AIR CONTROL (IAC)
• 189. THROTTLE POSITION SENSOR (TPS)
• 190. TPS TESTER / REGULATOR
• 192. CRANKSHAFT POSITION SENSOR (CPS)
• 193. CPS REPLACEMENT
• 194. EFI DIAGNOSTICS
• 197. EFI TROUBLESHOOTING
• 198. POLARIS DIGITAL WRENCH
• 199. DIGITAL WRENCH® UPDATES
• 200. DIGITAL WRENCH® COMMUNICATION ERRORS
• 201. GUIDED DIAGNOSTICS
• 202. DIGITAL WRENCH® FEATURE MAP
• 203. ECU REPLACEMENT
• 206. POLARIS MOBILE DIGITAL WRENCH (PMDW)
• 209. GENERAL INFORMATION
• 210. PVT SYSTEM OVERVIEW
• 211. PVT BREAK-IN (DRIVE BELT / CLUTCHES)
• 212. OVERHEATING / DIAGNOSIS
• 213. PVT SYSTEM SERVICE
• 214. PVT DISASSEMBLY
• 215. PVT ASSEMBLY
• 217. DRIVE BELT
• 218. BELT INSTALLATION
• 219. PVT BREAK-IN (DRIVE BELT / CLUTCHES)
• 220. ADJUSTMENT
• 221. DRIVE CLUTCH SERVICE
• 222. DRIVE CLUTCH DISASSEMBLY
• 223. SHIFT WEIGHT INSPECTION
• 224. SPIDER REMOVAL
• 225. ROLLER, PIN, AND THRUST WASHER INSPECTIO...
• 226. BEARING INSPECTION
• 227. BUSHING SERVICE
• 229. DRIVE CLUTCH ASSEMBLY
• 231. DRIVEN CLUTCH SERVICE
• 232. CLUTCH DISASSEMBLY / INSPECTION
• 233. CLUTCH ASSEMBLY
• 235. DRIVEN CLUTCH SERVICE (EBS)
• 237. DRIVEN CLUTCH BUSHING SERVICE
• 238. CLUTCH BUSHING REMOVAL
• 239. DRIVEN CLUTCH ASSEMBLY
• 242. DRIVEN CLUTCH ASSEMBLY VIEW
• 243. TROUBLESHOOTING
• 246. GENERAL INFORMATION
• 247. TRANSMISSION MOUNTING AND TORQUE VALUES
• 248. SHIFT LEVER / CABLE
• 249. SHIFT CABLE INSPECTION
• 250. TRANSMISSION SERVICE
• 254. TRANSMISSION INSTALLATION
• 258. SERVICING - NO DIFFERENTIAL
• 264. GEAR / SHAFT / BEARING INSPECTION
• 265. SNORKEL GEAR BACKLASH PROCEDURE
• 272. TRANSMISSION ASSEMBLY VIEW
• 274. SERVICING - WITH DIFFERENTIAL
• 276. TRANSMISSION DISASSEMBLY
• 281. PLANETARY DIFFERENTIAL DISASSEMBLY
• 282. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
• 284. PLANETARY DIFFERENTIAL ASSEMBLY
• 286. GEAR / SHAFT / BEARING INSPECTION
• 287. SNORKEL GEAR BACKLASH PROCEDURE
• 295. TRANSMISSION ASSEMBLY VIEW (INT
• 297. TROUBLESHOOTING
• 300. GENERAL INFORMATION
• 301. BEARING CARRIER
• 302. FRONT BEARING REPLACEMENT
• 303. FRONT BEARING CARRIER INSTALLATION
• 304. REAR BEARING CARRIER INSPECTION / REMOVA...
• 306. REAR BEARING REPLACEMENT
• 307. REAR BEARING CARRIER BUSHING REPLACEMENT
• 309. DRIVE SHAFT
• 310. FRONT DRIVE SHAFT INSTALLATION
• 312. REAR DRIVE SHAFT REMOVAL
• 313. REAR DRIVE SHAFT INSTALLATION
• 315. DRIVE SHAFT / CV JOINT HANDLING TIPS
• 316. OUTER CV JOINT / BOOT REPLACEMENT
• 318. INNER PLUNGING JOINT / BOOT REPLACEMENT
• 320. PROP SHAFT REMOVAL / INSTALLATION
• 322. DISASSEMBLY
• 323. ASSEMBLY
• 324. FRONT GEARCASE / CENTRALIZED HILLIARD
• 325. ALL WHEEL DRIVE OPERATION
• 326. AWD DIAGNOSIS
• 327. GEARCASE REMOVAL
• 328. GEARCASE DISASSEMBLY / INSPECTION
• 331. GEARCASE ASSEMBLY
• 334. GEARCASE INSTALLATION
• 335. WHEEL HUBS
• 336. REAR HUB EXPLODED VIEW
• 338. GENERAL INFORMATION
• 339. STEERING SYSTEM
• 340. STEERING WHEEL REMOVAL (NON-EPS MODELS)
• 342. EXPLODED VIEW (EPS MODELS)
• 343. UPPER STEERING SHAFT REMOVAL (EPS MODELS...
• 344. STEERING WHEEL REMOVAL (EPS MODELS)
• 345. POWER STEERING UNIT REMOVAL
• 346. LOWER STEERING SHAFT REMOVAL (EPS MODELS...
• 347. POWER STEERING UNIT INSTALLATION
• 348. UPPER STEERING SHAFT INSTALLATION (EPS M...
• 349. FRONT SUSPENSION
• 351. EXPLODED VIEW
• 352. SERVICE PREPARATION
• 353. BALL JOINT INSTALLATION
• 354. STABILIZER BAR LINKAGE REMOVAL
• 355. STABILIZER BAR REMOVAL
• 356. EXPLODED VIEW
• 357. REAR SUSPENSION
• 358. REAR A-ARM INSTALLATION
• 359. STABILIZER BAR REMOVAL / INSTALLATION
• 360. SHOCKS / SPRINGS
• 361. SHOCK REMOVAL / INSTALLATION
• 365. GENERAL SPECIFICATIONS
• 366. SPECIAL TOOLS
• 367. BRAKE BLEEDING / FLUID CHANGE
• 368. BRAKE SYSTEM EXPLODED VIEW
• 369. MASTER CYLINDER
• 370. BRAKE PEDAL LEVER
• 371. PARKING BRAKE (INTL MODEL)
• 372. PARKING BRAKE INSPECTION
• 374. PARKING BRAKE CALIPER SERVICE (INTL MODE...
• 375. CALIPER REMOVAL
• 376. NEW BRAKE PAD INSTALLATION
• 377. CALIPER INSTALLATION
• 378. PARKING BRAKE DISC (INTL MODEL)
• 379. FRONT BRAKE PADS
• 380. PAD INSPECTION
• 381. BRAKE BURNISHING PROCEDURE
• 382. FRONT CALIPER SERVICE
• 383. CALIPER REMOVAL
• 384. CALIPER INSPECTION
• 385. CALIPER ASSEMBLY
• 387. FRONT BRAKE DISC
• 388. DISC REPLACEMENT
• 389. REAR BRAKE PADS
• 390. PAD INSPECTION
• 391. PAD ASSEMBLY / INSTALLATION
• 392. BRAKE BURNISHING PROCEDURE
• 393. REAR CALIPER SERVICE
• 394. CALIPER REMOVAL
• 395. CALIPER INSPECTION
• 396. CALIPER ASSEMBLY
• 397. REAR BRAKE DISC
• 399. TROUBLESHOOTING
• 402. GENERAL INFORMATION
• 403. CAB FRAME
• 404. BODY ASSEMBLY VIEWS
• 405. DASH INSTRUMENTS / CONTROLS / GLOVEBOX
• 406. HOOD / FRONT BODY WORK
• 407. FRONT BUMPER
• 408. REAR BUMPER
• 409. SEAT ASSEMBLY
• 410. SEAT BELTS / MOUNTING
• 411. FLOOR / ROCKER PANELS
• 412. REAR CARGO BOX / FENDERS
• 413. CHASSIS / MAIN FRAME
• 414. BODY COMPONENT REMOVAL
• 415. REAR BUMPER
• 416. REAR FENDER FLAIR REMOVAL
• 417. CARGO BOX ASSEMBLY REMOVAL
• 418. ROCKER PANELS, CONSOLE AND FLOOR
• 419. DECALS
• 423. GENERAL INFORMATION
• 424. INSTRUMENT CLUSTER
• 426. INFORMATION DISPLAY AREA
• 429. DIAGNOSTIC MODE
• 430. INSTRUMENT CLUSTER REMOVAL
• 431. INSTRUMENT CLUSTER INSTALLATION
• 432. SWITCHES / CONTROLS
• 433. AWD / 2WD SWITCH
• 434. TRANSMISSION (GEAR POSITION) SWITCH
• 435. HAZARD SWITCH (INTL)
• 436. BRAKE LIGHT SWITCH
• 437. SPEED SENSOR LOCATION
• 438. SPEED SENSOR TESTING
• 439. ALL WHEEL DRIVE COIL
• 440. CHARGING SYSTEM
• 441. CHARGING SYSTEM STATOR (ALTERNATOR) TEST...
• 442. STATOR (ALTERNATOR) REPLACEMENT
• 444. CHARGING SYSTEM TESTING FLOW CHART
• 445. BATTERY
• 446. BATTERY ACTIVATION
• 447. BATTERY TESTING
• 448. LOAD TEST
• 449. SPECIFIC GRAVITY TEST
• 451. CHARGING PROCEDURE
• 452. LIGHTING SYSTEM
• 453. HEADLAMP BULB REPLACEMENT
• 454. HEADLAMP HOUSING INSTALLATION
• 455. COOLING SYSTEM
• 456. FAN CONTROL CIRCUIT OPERATION / TESTING
• 457. STARTING SYSTEM
• 458. STARTER MOTOR REMOVAL
• 459. STARTER SOLENOID BENCH TEST
• 460. ELECTRICAL TESTING
• 461. ELECTRONIC POWER STEERING
• 462. EPS TROUBLESHOOTING (POWER STEERING NON-...
• 463. EPS TROUBLESHOOTING (POWER STEERING NON-...
• 464. EPS TROUBLESHOOTING (USING DIGITAL WRENC...
• 465. FUSES / RELAYS
• 466. RELAYS
• 467. CAN SYSTEM