Polaris RZR 570 2013 Service Manual
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Polaris RZR 570 2013 Service Manual

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Table of Contents

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2013-2016 RZR 570
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed March 2016 (PN 9926813 R04)
© Copyright 2016 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris RZR 570 2013

  • Page 1 Publication Printed March 2016 (PN 9926813 R04) © Copyright 2016 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. REVISION INDEX DATE...
  • Page 5 2013-2016 RZR 570 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10:...

  • Page 7: Table Of Contents

    ................1.30 DECIMAL EQUIVALENTS 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 8: Vehicle Identification

    VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS WORLD MFG. ID INDIVIDUAL SERIAL NO. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 9: Vehicle Identification Number (Vin) Designation (2015+)

    WORLD MFG. ID INDIVIDUAL SERIAL NO. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 10: Vehicle Information

    Z16VHA57A2 9926399 2016 RZR 570 EPS Z16VHE57AK 9926398 2016 RZR 570 EU Z16VHA57FJ 9926383 NOTE Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 11: Special Tools

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.

  • Page 12: General Specifications

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 Circuit Breaker Fuses (Fuse/Relay Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse EFI: 30 Amp Holder) Chassis: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 14: 2013 Ranger Rzr 570 Le

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 Circuit Breaker Fuses (Fuse/Relay Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse EFI: 30 Amp Holder) Chassis: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 16: 2013 Ranger Rzr 570 Intl

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 Fuses (Fuse/Relay Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse EFI: 30 Amp Holder) Chassis: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.11 © Copyright Polaris Industries Inc.

  • Page 18: 2014 Rzr 570

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 Fuses (Fuse/Relay Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.13 © Copyright Polaris Industries Inc.
  • Page 20 Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.14 © Copyright Polaris Industries Inc.
  • Page 21 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Engine Control: 30 Amp Fuses (Power Fuse Chassis: 30 Amp Holder) EPS: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: 2015 Rzr 570

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.16 © Copyright Polaris Industries Inc.
  • Page 23 Fuses (Fuse/Relay Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.17 © Copyright Polaris Industries Inc.
  • Page 24 Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.18 © Copyright Polaris Industries Inc.
  • Page 25 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Engine Control: 30 Amp Fuses (Power Fuse Chassis: 30 Amp Holder) EPS: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.19 © Copyright Polaris Industries Inc.

  • Page 26: 2016 Rzr 570

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.20 © Copyright Polaris Industries Inc.
  • Page 27 Fuses (Fuse/Relay Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Engine Control: 30 Amp Holder) Chassis: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.21 © Copyright Polaris Industries Inc.

  • Page 28: 2016 Rzr 570 Le

    Maximum Weight Capacity (Includes rider(s), cargo, (Payload) accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.22 © Copyright Polaris Industries Inc.
  • Page 29 Drive / Fuel Pump: 10 Amp Box) Lights / EFI / Accessory: 20 Amp Engine Control: 30 Amp Fuses (Power Fuse Chassis: 30 Amp Holder) EPS: 30 Amp 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.23 © Copyright Polaris Industries Inc.

  • Page 30: Misc. Specifications And Charts

    Cylinder Head Bolts - Front Gearcase Drain/Fill 10 ft-lbs (14 Nm) Black Step 1: 21 ft-lbs (28 Nm) Plugs Step 2: 26 ft-lb (35 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.24 © Copyright Polaris Industries Inc.
  • Page 31 12 ft-lbs (16 Nm) Plugs 17 ft-lbs (23 Nm) Shift Cable Bracket Bolts Transmission Isolator 40 ft-lbs (54 Nm) Bolts (Rear) 37 ft-lb (50 Nm) Shock Mount Bolts 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.25 © Copyright Polaris Industries Inc.
  • Page 32 (Front) Wheel Hub Castle Nuts 110 ft-lbs (149 Nm) (Rear) Steel Rims: 27 ft-lbs (37 Wheel Lug Nuts Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.26 © Copyright Polaris Industries Inc.

  • Page 33: Conversion Table

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.27 © Copyright Polaris Industries Inc.

  • Page 34: Standard Bolt Torque Specification

    103 (140) 151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.28 © Copyright Polaris Industries Inc.

  • Page 35: Sae Tap / Drill Sizes

    5/16–18 2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.29 © Copyright Polaris Industries Inc.

  • Page 36: Decimal Equivalents

    0.6094″ 0.625″ 16 mm = 0.6299″ 41/64 0.6406″ 21/32 0.6563″ 17 mm = 0.6693″ 0.6719″ 43/64 11/16 0.6875″ 45/64 0.7031″ 18 mm = 0.7087″ 23/32 0.7188″ 9926813 R04 - 2013-2016 RZR 570 Service Manual 1.30 © Copyright Polaris Industries Inc.
  • Page 37 ................. . .2.24 TIRE INSPECTION 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 38 ................2.36 ENGINE TO FRAME GROUND 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 39: Periodic Maintenance Chart

    Have an authorized Polaris dealer perform these Severe Use Definition services. • Frequent immersion in mud, water or sand •...

  • Page 40: Maintenance Intervals

    Fuel System 600 (1000) 100 H 12 M fuel pump. Replace lines every two years. ■ Spark Plug 600 (1000) Inspect; replace as needed 100 H 12 M 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 41 ▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 42: Maintenance Quick Reference

    Check level during pre-ride “MAX and “MIN” lines on the inspection; change fluid every Brake Fluid Polaris DOT 4 Brake Fluid master cylinder reservoir two years * More often under severe use, such as operated in water or under severe loads.
  • Page 43 Add lubricant until it is visible Transmission change lubricant yearly Gearcase Lubricant at the fill hole threads * More often under severe use, such as operated in water or under severe loads. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 44: Grease Lubrication Points

    Grease fittings every 500 of storage, and after A-arm Pivot Bushings Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or Stabilizer Bar Bushings submerging the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 45: Lubricants / Service Products

    3 oz tube (24) 2871515 U-Joint Grease 14 oz cartridge 2871551 2871326 12 oz bottle (12) Carbon Clean 16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) 2872280 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 46: General Vehicle Inspection And Maintenance

    • Engine coolant - check for proper level at the recovery bottle • Check all front and rear suspension components for wear or damage. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.10 © Copyright Polaris Industries Inc.

  • Page 47: Engine

    2. Place the transmission in PARK (P). 3. If needed, start the engine and allow it to idle for three minutes until warm. Stop the engine. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.11 © Copyright Polaris Industries Inc.
  • Page 48 16. Verify the transmission is still positioned in PARK (P). 17. Start the engine and let it idle for two minutes. 18. Stop the engine and inspect for leaks. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.12 © Copyright Polaris Industries Inc.

  • Page 49: Engine Breather Hose Inspection

    Less than 20% the engine crankcase to the air intake baffle box on the left-hand rear fender panel. NOTE Make sure line is not kinked or pinched. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.13 © Copyright Polaris Industries Inc.

  • Page 50: Valve Clearance Inspection

    (feeler) gauge. Record the measurement if clearance is out of specification. 6. Remove the outer PVT cover and drive belt as shown in chapter 6. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.14 © Copyright Polaris Industries Inc.

  • Page 51: Exhaust - Spark Arrestor

    16. Reinstall the cargo box access panel and seats (see Chapter 10) . Spark Arrestor Fastener 8 ft-lbs (11 Nm) Head Pipe Fasteners 18 ft-lb (25 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.15 © Copyright Polaris Industries Inc.

  • Page 52: Cooling System

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. COOLING SYSTEM EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.16...

  • Page 53: Coolant Level Inspection

    MAINTENANCE COOLANT LEVEL INSPECTION 8. Fill recovery bottle to MAX level with Polaris 50/50 Extended Life Anti Freeze/Coolant as required for The pressure cap and recovery bottle are located freeze protection in your area. under the front hood of the vehicle. The coolant level must be maintained between the minimum and 9.

  • Page 54: Cooling System

    4. Drain the coolant from the radiator by removing the 2871323 - Gallon lower coolant hose from the radiator as shown. Properly dispose of the coolant. 5. Allow coolant to completely drain. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.18 © Copyright Polaris Industries Inc.

  • Page 55: Fuel System And Air Intake

    Make sure line is not kinked or pinched. Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System. 3. Replace fuel line every two years. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.19 © Copyright Polaris Industries Inc.

  • Page 56: Vent Lines

    Check throttle pedal freeplay periodically in accordance with the Periodic Maintenance Chart. Adjust the freeplay if necessary (see Chapter 2 – Throttle Freeplay Adjustment, page 2.20). 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.20 © Copyright Polaris Industries Inc.

  • Page 57: Engine And Pvt Intake Pre-Filter Service

    9. Reinstall the cargo box access panel. 3. Reinstall the dry pre-filters and install the pre-filter cover. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.21 © Copyright Polaris Industries Inc.

  • Page 58: Air Filter Service

    Be sure not to let the air box cover contact the air filter element during removal. 8. Reinstall the clean intake hose and tighten hose clamp (A). 9. Reinstall the cargo box access cover . 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.22 © Copyright Polaris Industries Inc.

  • Page 59: Pvt / Final Drive / Wheel And Tire

    If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.23 © Copyright Polaris Industries Inc.

  • Page 60: Tire Inspection

    3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.24 © Copyright Polaris Industries Inc.

  • Page 61: Transmission And Front Gearcase

    3. If lubricant level is not even with the bottom threads, add the recommended lubricant as needed. Do not 12. Check for leaks. Dispose of used lubricant properly. overfill. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.25 © Copyright Polaris Industries Inc.

  • Page 62: Shift Cable Inspection / Adjustment

    3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.26 © Copyright Polaris Industries Inc.
  • Page 63 Maintain the fluid level even with the bottom threads of the fill plug hole. FLUID CAPACITY Recommended Front Gearcase Fluid: Polaris Demand Drive 2877922 (Quart) Capacity: 6.75 oz. (200 ml) 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 64: Steering

    Whenever steering components are replaced, check front end alignment. Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. Use only genuine Polaris replacement parts.

  • Page 65: Wheel Toe Alignment Inspection

    (A) - (B) = 1/8 - 1/4" (3 to 6 mm) • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.29 © Copyright Polaris Industries Inc.
  • Page 66 Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 13 ft-lbs (18 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 67: Suspension

    Shock Spanner Wrench 2871095 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 68: Brake System

    MEASUREMENT Brake Disc Thickness Service Limit: .170″ (4.32 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 69: Brake Hose And Fitting Inspection

    / shift cable bracket. The mount bracket is located on the right-hand side of the transmission. Adjustment Procedure: Refer to Chapter 9 “Brakes” for complete adjustment procedure. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.33 © Copyright Polaris Industries Inc.

  • Page 70: Electrical And Ignition System

    10-30% of full potential. Charge battery according to “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 71: Battery Installation

    NOTE 1. Ensure the battery is fully charged. Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to 2. Place the battery in the battery holder and secure make up for normal self-discharge.

  • Page 72: Engine To Frame Ground

    11. Install spark plug wire into spark plug / engine. 12. Reinstall cargo box access panel. 13. Reinstall the (-) negative battery cable and driver’s seat. 9926813 R04 - 2013-2016 RZR 570 Service Manual 2.36 © Copyright Polaris Industries Inc.
  • Page 73 ..........3.41 EXHAUST CAMSHAFT DECOMPRESSION MECHANISM 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 74 ..........3.79 OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 75 ..............3.88 LEAK AT WATER PUMP WEEP HOLE 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 76: General Information

    Installation Kit Test results are based on the use of the recommended Bosch Automotive Service Solutions : 1-800-328- engine oil (Polaris PS-4) at operating temperature, and 6657 or http://polaris.service-solutions.com/ may vary considerably if any other oil is used or if engine is not up to temperature.

  • Page 77: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 78: Engine Service Specifications

    3.8976" ± 0.0003" (99.0 mm ± 0.008 mm) Cylinder Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 79 Crankshaft See Service Procedure Listed Crankshaft Runout Limit (PTO and MAG) In This Chapter 1.1798” - 1.1802" (29.969 - Bearing Journal O.D. (Standard) Balance Shaft 29.979 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 80: Torque Sequence

    ENGINE / COOLING SYSTEM TORQUE SEQUENCE 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 81: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve

    ENGINE / COOLING SYSTEM CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 82: Cylinder / Oil Filter / Oil Pump / Breather

    ENGINE / COOLING SYSTEM CYLINDER / OIL FILTER / OIL PUMP / BREATHER 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.10 © Copyright Polaris Industries Inc.

  • Page 83: Camshafts / Cylinder Head / Flywheel / Stator Cover - Black Head Bolts

    CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER - BLACK HEAD BOLTS Apply a drop of Loctite 641 (Yellow) to the crankshaft taper before assembly. Loctite 603 (Green) can be used if 641 is not available. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 84: Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts

    ENGINE / COOLING SYSTEM CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 85: Spark Plugs / Starter / Throttle Body / Valve Cover

    ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 86: Piston / Crankshaft / Balance Shaft

    ENGINE / COOLING SYSTEM PISTON / CRANKSHAFT / BALANCE SHAFT 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 87: Intake / Exhaust System

    FILTER, AIRBOX, MAIN SCREW CLIP, AIRBOX DECAL, FILTER MAINTENANCE NUT, U BRACKET, MOUNT, BLACK BOX, INTAKE SCREW GROMMET FILTER, ENGINE IN HOSE, INTAKE FILTER, CLUTCH IN 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 88: Exhaust System Assembly View

    EXHAUST SYSTEM ASSEMBLY VIEW Muffler Exhaust Seal Spring Spark Arrestor Exhaust Pipe Isolator Mount Silencer Screw Exhaust Gasket 8 ft-lbs (11 Nm) Exhaust Flange Bolts 18 ft-lb (25 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 89: Engine Cooling System

    ENGINE / COOLING SYSTEM ENGINE COOLING SYSTEM COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 90: Cooling System Specifications

    Polaris Premium 50/50 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

  • Page 91: Pressure Cap Test

    CAUTION Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.19 © Copyright Polaris Industries Inc.

  • Page 92: Coolant Drain / Radiator Removal

    6. Place a suitable drain pan underneath the lower engine hose on the right-hand rear side of the vehicle. 7. Remove the hose and completely drain the engine. Radiator Removal 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.20 © Copyright Polaris Industries Inc.

  • Page 93: Thermostat Replacement

    11. Using an 8mm socket, remove the water pump impeller NOTE The water pump impeller uses reverse (LH) threads. 12. Inspect the water pump cover and impeller for damage. Replace as necessary. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.21 © Copyright Polaris Industries Inc.

  • Page 94: Water Pump Mechanical Seal / Oil Seal Replacement

    8. Raise and safely support the vehicle. Remove the right-hand rear wheel. 9. Disconnect the stator wire connector and cut the tie strap securing the wiring to the front engine mount bracket. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.22 © Copyright Polaris Industries Inc.
  • Page 95 15. Remove the thirteen bolts securing the stator cover engine oil during stator cover service. to the engine. 18. Bring the stator cover assembly to a clean work bench. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.23 © Copyright Polaris Industries Inc.
  • Page 96 PU-50869 Item #1. 21. Press out the water pump drive shaft bearing from the stator cover. Discard bearing and replace with new. Water Pump Assembly 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 97 27. Lubricate the new water pump oil seal with clean engine oil. 28. Use the water pump oil seal installation tool in kit 31. Install a new stator cover gasket onto the engine. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.25 © Copyright Polaris Industries Inc.
  • Page 98 35. If needed, install the stator cover removal handles TORQUE tool PA-49317 to the water cover bolt holes to aid in Stator Cover and Water Pump Cover: stator cover installation. 9 ft-lb (12 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 99 50. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 51. Check for leaks. 40. Install a new water pump cover gasket. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.27 © Copyright Polaris Industries Inc.

  • Page 100: Cooling System Bleeding Procedure

    11. Remove the pressure cap. Add the necessary 3. Remove the recovery bottle cap and fill the bottle amount of Polaris Premium Antifreeze to the radiator to the MAX line. filler neck. 12. Open the bleed screw to allow any trapped air to escape.

  • Page 101: Engine Service

    Manual. Failing to do so may lead to possible injury. 1. If vehicle was recently operated, allow it to cool down before attempting to perform any work. 2. Thoroughly clean the engine and chassis. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.29 © Copyright Polaris Industries Inc.
  • Page 102 / intake hoses / engine crankcase vent tube an needed. assembly as shown below. 8. Elevate the rear of the vehicle off the ground using a suitable lift and remove the left rear wheel. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.30 © Copyright Polaris Industries Inc.
  • Page 103 16. Move fuel line to the left-hand side of the engine compartment. Make note of line routing for installation. 17. Disconnect the ignition coil harness connector and remove the spark plug wire from the engine. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.31 © Copyright Polaris Industries Inc.
  • Page 104 (I) and ECT (J) harness connector. 28. Use an overhead or portable engine hoist and suitable engine straps to secure the engine in its current position. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.32 © Copyright Polaris Industries Inc.

  • Page 105: Engine Installation

    (B) and instal the eight bolts and washers (C). Do not tighten fasteners at this time. Engine Stand Adapter PU-50824 NOTE DO NOT torque fasteners at this time. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.33 © Copyright Polaris Industries Inc.
  • Page 106 2014-16 2015-16 ACE 570 2015-16 RGR ETX 2013–16 RZR 570 2014–16 RANGER 570 2015-16 RANGER 570 Full-Size 2014-16 RANGER 900 2015-16 RZR 900 2016 RZR 1000 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.34 © Copyright Polaris Industries Inc.
  • Page 107 Exhaust Head Pipe Bolts: 18 ft-lb (25 Nm) 13. Install the two springs securing the muffler to the head pipe. 14. Install the three coolant hoses onto the engine. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.35 © Copyright Polaris Industries Inc.
  • Page 108 21. Connect the fuel line (H) to the fuel rail. 29. Install the rear bumper and cargo box assembly as outlined in the body chapter. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 109: Engine Break-In Period

    / coolant. 32. If the engine oil was completely drained, add approximately 2 quarts (1.9 L) of Polaris PS-4 Synthetic Engine Oil into the crankcase. 33. Install a new oil filter. Lubricate the seal with engine oil prior to installation (see Chapter 2 –...

  • Page 110: Engine Mounting And Torque Values

    PU-50105 or 2.5” (64 mm) Oil Type Polaris PS-4 Synthetic Engine Oil Oil Pressure Minimum Specification (using Polaris PS-4 Plus at operating temperature) 10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.38...

  • Page 111: Engine Disassembly / Inspection - Top End

    6. Remove the spark plug . Stuff spark plug hole with a shop towel to prevent anything from falling into the combustion chamber (if further engine disassembly is required). 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 112: Camshaft Sprocket Inspection

    6. Mark the intake and exhaust camshafts to ensure proper assembly. TORQUE Intake Camshaft Sprocket Bolt: 33 ft-lb (45 Nm)Replace intake camshaft sprocket bolt if loosened or removed. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.40 © Copyright Polaris Industries Inc.

  • Page 113: Camshaft Inspection

    3. Remove the fastener that secure the lower cam chain guide to the crankcase. 4. Inspect the cam chain guides and replace if excessive wear is evident. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 114: Cylinder Head Removal

    Cam Chain Guide Fasteners: 9 ft-lb (12 Nm) CYLINDER HEAD DISASSEMBLY CAUTION Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.42 © Copyright Polaris Industries Inc.

  • Page 115: Cylinder Head Inspection

    PV-43513-A or grease upon assembly. Clean sealing surfaces with rubbing alcohol or electrical contact cleaner. Do not touch sealing surfaces of the new head gasket. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.43 © Copyright Polaris Industries Inc.

  • Page 116: Cylinder Head Warp Inspection

    5. Inspect split keeper groove for wear or flaring in the keeper seat area. NOTE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.44 © Copyright Polaris Industries Inc.

  • Page 117: Combustion Chamber Cleaning

    Valve Guide I.D.: 0.2165" - 0.2171" (5.500 - 5.515 mm) 8. Be sure to measure each guide and valve combination individually. NOTE The valve guides cannot be replaced. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 118: Valve Seat Reconditioning

    The valve may overheat and warp, resulting in burnt valves. 6. Insert valve into guide and tap valve lightly into place a few times. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.46 © Copyright Polaris Industries Inc.
  • Page 119 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.47 © Copyright Polaris Industries Inc.

  • Page 120: Cylinder Removal

    (1/2" down from top, in the middle, and 1/2” up from bottom). 6. Remove and discard cylinder base gasket. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.48 © Copyright Polaris Industries Inc.

  • Page 121: Piston Removal

    4. Repeat procedure for second ring. 5. Remove oil control ring top rail first, then bottom rail. 6. Remove oil control ring expander. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 122: Piston / Rod Inspection

    Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm) Service Limit: 0.0042" (0.108 mm) Second Ring: Std.: 0.0007 - 0.0029" (.020 - 0.076 mm) Service Limit: 0.0035" (0.89 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.50 © Copyright Polaris Industries Inc.

  • Page 123: Piston Ring Installed Gap

    NOTE Do not allow cylinder to heat up during honing. NOTE Always check piston ring installed gap after re-boring a cylinder or when installing new rings. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.51 © Copyright Polaris Industries Inc.

  • Page 124: Cylinder Hone Selection / Honing Procedure

    3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Place the exhaust cam into the cylinder head and align the timing marks as shown below.
  • Page 125 Intake cam sprocket should have “I” marks aligned with PU-50563 gasket surface and the exhaust cam sprocket should have “E” marks aligned with gasket surface. 7. Carefully install the camshaft carrier onto the camshafts. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.53 © Copyright Polaris Industries Inc.
  • Page 126 13. If needed, install the camshaft carrier and bolts. TORQUE Cam Chain Tensioner: 30 ft-lb (40 Nm) 17. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 127: Camshaft Timing - Quick Reference

    Stator Cover/Flywheel Installed. “V” marked on the down and insert a 1/4” drive socket extension through flywheel is aligned with the CPS mounting hole. the crankcase and into the crankshaft locating hole 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 128: Valve Cover Installation

    5. Install the three valve cover shoulder bolts isolators using a T40 driver. 6. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 129: Engine Assembly - Top End

    Second Ring Gap Position Top Ring Gap Position 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 130: Piston / Connecting Rod Assembly

    Do not tap on pin or cause any sideways force to connecting rod. Warm piston crown with a heat gun if pin cannot be installed by hand, or use a piston pin installation tool. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.58 © Copyright Polaris Industries Inc.

  • Page 131: Cylinder Installation

    5. Dip the seat , valve spring and retainer clean engine oil. 6. Install the valve spring seat 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 132: Valve Sealing Test

    10. Install split keepers with gap even on both sides. 11. Repeat this procedure for remaining valves. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 133: Cylinder Head Installation - Black Bolts

    4. Carefully set the cylinder head in place on alignment pins. NOTE Install new cylinder head bolts. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.61 © Copyright Polaris Industries Inc.

  • Page 134: Cylinder Head Installation - Silver Bolts

    5. Install and finger tighten the four new cylinder head bolts evenly. 6. Install and finger tighten the two new outer M6 bolts evenly. 7. Torque the new cylinder head bolts in sequence to specification. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.62 © Copyright Polaris Industries Inc.

  • Page 135: Valve Clearance Check / Adjustment

    (10 ± 1 Nm) shafts. 3. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head. The camshaft lobes should face out. 5. Carefully install the camshaft carrier onto the camshafts.
  • Page 136 NOTE If all valve clearance measurements are within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.64 © Copyright Polaris Industries Inc.
  • Page 137 19. If valve clearance is not within specification, repeat this procedure. 20. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 138: Intake Valve Lash - Tappet Selection Matrix

    0.926-0.950 520 522 525 528 530 532 535 538 540 542 545 0.951-0.975 522 525 528 530 532 535 538 540 542 545 0.976-1.000 525 528 530 532 535 538 540 542 545 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.66 © Copyright Polaris Industries Inc.

  • Page 139: Exhaust Valve Lash - Tappet Selection Matrix

    0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.67 © Copyright Polaris Industries Inc.

  • Page 140: Engine Disassembly / Inspection - Bottom End

    2. Place flywheel on work bench. Grasp gear and rotate clockwise. It should turn smoothly without binding. 3. Rotate gear counterclockwise. The gear should immediately lock in position and not slip. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.68 © Copyright Polaris Industries Inc.
  • Page 141 9. Inspect drive surface of starter gear and bearing surface for wear, damage, or uneven surface. If any starter clutch component is worn or damaged, replace clutch, clutch hub, and starter gear. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.69 © Copyright Polaris Industries Inc.

  • Page 142: Stator Removal

    4. Remove the two bolts that secure the stator wire routing bracket to the stator cover. 5. Remove the stator from the stator cover. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.70 © Copyright Polaris Industries Inc.

  • Page 143: Oil Pump Removal

    ENGINE / COOLING SYSTEM OIL PUMP REMOVAL DESCRPITION NOTES Screw Cover, Oil Pump Washer Pin, Solid Shaft, Oil Pump ASM., Gerotor 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.71 © Copyright Polaris Industries Inc.
  • Page 144 8. Remove the oil pump geroter that is in the engine case (if needed). 9. Clean the geroters to remove oil. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 145: Oil Pump Assembly

    4. Slide the gerotor onto the drive shaft and lock Minimum Specification them into position on the drive pin. (using Polaris PS-4 at operating temperature) 5. Install the washer onto the drive shaft. 10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.73...

  • Page 146: Crankcase Breather Service

    1. Rotate the engine on the engine stand so the magneto side is facing upward. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.74 © Copyright Polaris Industries Inc.

  • Page 147: Balance Shaft Removal / Inspection

    The inner race should be firm with minimal side to side movement and no detectable up and down (radial) movement. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 148: Crankshaft Removal

    Small End I.D. Standard: 4. Remove all special tools from the crankcase. 0.8665 - 0.8670″ (22.010 - 22.023 mm) Service Limit: 0.08682″ (22.053 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.76 © Copyright Polaris Industries Inc.

  • Page 149: Pto Side Crankcase Bearing Service

    Replace with new for assembly. Bearing Spacer 2. If not already performed, remove the screws that secure the bearing retainer to the case. Retaining Ring 3. Remove the retaining ring. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.77 © Copyright Polaris Industries Inc.

  • Page 150: Mag Side Crankcase Bearing Service

    2. Clean all bearing bores and inspect for excessive wear. 3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.78 © Copyright Polaris Industries Inc.

  • Page 151: Oil Pickup Assembly Inspection

    4. Thoroughly clean the valve. 5. Replace the o-ring and lubricate with clean engine oil. 6. Press the oil pressure valve into the crankcase until fully seated. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.79 © Copyright Polaris Industries Inc.
  • Page 152 6. With the help of an assistant, slowly tighten the nut until the crankshaft is completely seated into the crankcase bearings. 7. Remove the crankshaft removal / installation tool from the crankcase. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.80 © Copyright Polaris Industries Inc.
  • Page 153 Be sure seal lip does not fold back when moving over the crankshaft flange. 11. Drive seal until flush with seal bore. 12. Turn PTO crankcase over and support with crankshaft upright. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.81 © Copyright Polaris Industries Inc.
  • Page 154 4. Tap crankcase evenly until fully seated with a soft sided hammer. 5. Install the new crankcase bolts finger tight in MAG side crankcase. 6. Tighten all bolts evenly until snug. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.82 © Copyright Polaris Industries Inc.
  • Page 155 9. Select the proper engine stand sleeve adapter and install it onto the engine stand adapter. Sleeve adapter for a 2″ bore engine stand: PU-50625 Sleeve adapter for a 2.375″ bore engine stand: PW-47054 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.83 © Copyright Polaris Industries Inc.
  • Page 156 9 ft-lbs (12 Nm) Apply Loctite® 272™ 4. Apply a drop of Loctite® 641 (yellow) to the tapers before assembly. Loctite® 603 (green) can be used if 641 is not available. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.84 © Copyright Polaris Industries Inc.
  • Page 157 Fully install the flywheel until seated on the crankshaft taper. 9. Install the flywheel washer. 10. Hold flywheel with commercially available strap wrench. 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.85 © Copyright Polaris Industries Inc.
  • Page 158 8. Install the stator cover screws and torque to specification. TORQUE Stator Mounting Bolts: 9 ft-lbs (12 Nm)Apply Loctite® 242™ TORQUE Stator Wire Retainer: 6 ft-lbs (9 Nm) Apply Loctite® 242™ 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.86 © Copyright Polaris Industries Inc.
  • Page 159 • Sheared flywheel key compression) • PVT not operating properly • Restricted exhaust muffler • Cam worn excessively PISTON FAILURE - SCORING • Lack of lubrication 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.87 © Copyright Polaris Industries Inc.
  • Page 160 • Thermostat stuck open LEAK AT WATER PUMP WEEP HOLE • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9926813 R04 - 2013-2016 RZR 570 Service Manual 3.88 © Copyright Polaris Industries Inc.
  • Page 161 .................4.30 TPS REPLACEMENT 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 162 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........

  • Page 163: General Information

    PU-47469 and PC Interface Cable PU-47470. This pressure test. module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier SPX at (1-800-328-6657) or Fuel Pressure Gauge Kit - PU-43506-A http://polaris.spx.com...
  • Page 164 Digital Wrench® - Download Website Located at: www.polaris.diagsys.com Download Digital Wrench® Updates: NOTE For the most recent information on Digital Wrench® software and update downloads please visit the website: www.polaris.diagsys.com 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 165: Service Notes

    • Do not charge battery with key switch "on." • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 166: Efi System Exploded View

    FUEL SYSTEM EFI SYSTEM EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 167: Efi System Component Locations

    - Attached to the fuel rail located in the intake track of Sensor (T-MAP) the cylinder head. - Located in the rubber intake boot between the throt- tle body and the cylinder head. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 168 - Located on the right-hand side of the throttle body below the IAC motor. 8. Idle Air Control Motor (IAC) - Located on the upper right-hand side of the throttle body above the TPS. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 169: Efi System Electrical Diagram

    FUEL SYSTEM EFI SYSTEM ELECTRICAL DIAGRAM 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 170: Efi Overview

    (load), engine temperature, speed (RPM), and throttle position. These primary signals are compared to 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 171: Electronic Control Unit (Ecu)

    This process repeats it self in rapid succession, limiting operation to the preset maximum. RZR 570 EFI RPM Limit: Max RPM Limit - Injector and ignition suppression. • 7750 RPM (All Gears) 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.11 © Copyright Polaris Industries Inc.

  • Page 172: Ecu Service

    TPS to the throttle body is altered, the TPS must be adjusted. For the purpose of troubleshooting, a known-good ECU from another Polaris RZR 570 of the same model may be used without system or engine component damage. ECU REPLACEMENT...

  • Page 173: Fuel Injectors

    Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.13 © Copyright Polaris Industries Inc.

  • Page 174: Fuel Injector Test

    Take care not to damage the fuel injector ends during removal. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 175 15. Reinstall the fuel line to the fuel rail. 16. Connect the harness lead to the fuel injector. 17. Reconnect the negative battery cable and reinstall the driver’s seat. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.15 © Copyright Polaris Industries Inc.

  • Page 176: Fuel Tank

    1. Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.16 © Copyright Polaris Industries Inc.

  • Page 177: Exploded View

    EXPLODED VIEW ITEM DESCRIPTION PFA Nut 70 ft-lbs (95 Nm) Fuel Pump Preliminary Fuel Filter Fuel Sender Float Arm Gasket (replace if removed) Fuel Tank Assembly 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.17 © Copyright Polaris Industries Inc.

  • Page 178: Operation Overview

    4 cranking revolutions if system function start-up. is OK. Once the engine is running, the fuel pump remains 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.18 © Copyright Polaris Industries Inc.

  • Page 179: Fuel Sender Test

    Gauge Adaptor (PV-48656). Route the clear hose Fuel Sender Resistance Specifications: into a portable gasoline container or the vehicle’s Full: 6 ± 1 Ω fuel tank. Empty: 90 ± 4.5 Ω 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.19 © Copyright Polaris Industries Inc.
  • Page 180 “3” and “4”' at the white fuel pump connector to check for continuity within the fuel pump. NOTE If there was no continuity between the pump terminals, replace the fuel pump assembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.20 © Copyright Polaris Industries Inc.

  • Page 181: Fuel Pump Replacement

    A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container. NOTE Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.21 © Copyright Polaris Industries Inc.
  • Page 182 It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel. Do not use water or any other chemicals to remove debris. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.22 © Copyright Polaris Industries Inc.
  • Page 183 Pull on fuel line lightly to confirm connection. 21. Connect the fuel pump electrical harness. 22. Connect battery. 23. Install the driver and passenger seat. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.23 © Copyright Polaris Industries Inc.

  • Page 184: Fuel Tank Removal

    NOTE A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.24 © Copyright Polaris Industries Inc.
  • Page 185 RH portion of the fuel tank. Once removed, place the mechanism in the rear cargo box to keep it out of the way. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.25 © Copyright Polaris Industries Inc.

  • Page 186: Fuel Tank Installation

    Check for leaks. 12. Finally, install the rear service panel along with the seats. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.26 © Copyright Polaris Industries Inc.

  • Page 187: Temperature And Manifold Absolute Pressure Sensor (T-Map)

    The T-MAP sensor provides the ECU with engine load data. 7. Install the retaining bolt and torque to specification. TORQUE T-MAP Retaining Bolt: 24 in-lbs (2.8 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.27 © Copyright Polaris Industries Inc.

  • Page 188: Idle Air Control (Iac)

    6. Reconnect the vehicle harness to the IAC motor. 7. Reinstall the cargo box access panel, connect the negative (-) battery cable and install the drivers seat. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.28 © Copyright Polaris Industries Inc.

  • Page 189: Throttle Position Sensor (Tps)

    The stop screw controls the air flow calibration of the throttle body. If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.29 © Copyright Polaris Industries Inc.

  • Page 190: Tps Tester / Regulator

    5. Assemble SmartLink Module and connect the diagnostic interface cable to the vehicle to allow Digital Wrench® use (see Chapter 4 – Digital Wrench® - Diagnostic Connector, page 4.40). 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.30 © Copyright Polaris Industries Inc.
  • Page 191 7. Loosen the TPS mounting screws. 8. Rotate the TPS until your display reading is within specification. TPS Output Reading (Digital Wrench®): 0.46 ± 0.03 Vdc 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 192: Crankshaft Position Sensor (Cps)

    If the sensor fails or becomes disconnected for any reason, the engine will stop running. CPS Resistance Specification: 1000 Ω ± 10% 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.32 © Copyright Polaris Industries Inc.

  • Page 193: Cps Replacement

    5. If the resistance is incorrect, follow theCPS 4. Torque the CPS and heat shield retaining bolts (if Replacement, page 4.33 procedure. equipped) to specification. TORQUE CPS Retaining Bolt: 9 ft-lb (12 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.33 © Copyright Polaris Industries Inc.

  • Page 194: Efi Diagnostics

    MODE button or turn the ignition key OFF once the codes are recorded. 2. Press and hold the MODE button to enter the diagnostics code menu. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.34 © Copyright Polaris Industries Inc.
  • Page 195 Driver Circuit Short to B+ P1692 (INTL) Driver Circuit Grounded P1693 Driver Circuit Open / Grounded P1481 Fan Relay Driver Circuit 1071 Driver Circuit Short to B+ P1482 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.35 © Copyright Polaris Industries Inc.
  • Page 196 Driver Circuit Open / Grounded P1535 Idle Air Control Valve (IAC) 520270 Driver Circuit Short to B+ P1539 M17; IAC Stepper Pin 6 Driver Circuit Grounded P1538 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.36 © Copyright Polaris Industries Inc.

  • Page 197: Efi Troubleshooting

    • Ignition timing incorrect • Belt dragging • Dirty air cleaner • Engine worn • Spark Plug fouled • Throttle stop screw set incorrectly (out of sync with ECU) 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.37 © Copyright Polaris Industries Inc.

  • Page 198: Polaris Digital Wrench

    Refer to Section 2, 3 and 4 in the Instruction Manual • Perform output state control tests (some models) provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the...

  • Page 199: Digital Wrench® Updates

    FUEL SYSTEM DIGITAL WRENCH® UPDATES 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. Updates are released for Digital Wrench® via the Internet at: http://polaris. diagsys. com. The Digital Wrench® website can also be accessed through the dealer website at: www.polarisdealers.com.

  • Page 200: Digital Wrench® Communication Errors

    If you experience problems connecting to a vehicle or Wrench®. any Digital Wrench® related problem, visit the Digital Wrench® Knowledge Base for the most current troubleshooting information, FAQs, downloads and software updates at: http://polaris.diagsys.com/. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.40 © Copyright Polaris Industries Inc.

  • Page 201: Guided Diagnostics

    DIGITAL WRENCH® SERIAL NUMBER LOCATION Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.41 © Copyright Polaris Industries Inc.

  • Page 202: Digital Wrench® Feature Map

    Screen. Perform specialized testing and Run the Help System. adjustment functions service reports. Prints the current screen as a Open the ASSERT ASK form. formatted printout. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.42 © Copyright Polaris Industries Inc.

  • Page 203: Ecu Replacement

    To successfully reprogram the ECU, an Authorization Key must be obtained by entering • Proceed to http://polaris.diagsys.com for specific a Request Code in the box provided on the Reflash information and FAQs on how to troubleshoot communication problems.
  • Page 204 7. Select the file you want to load into the ECU then 10. Enter or paste the Request Code into the box. click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.44 © Copyright Polaris Industries Inc.
  • Page 205 13. Enter or paste the Authorization Key in the box located on the Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 9926813 R04 - 2013-2016 RZR 570 Service Manual 4.45 © Copyright Polaris Industries Inc.

  • Page 206: Polaris Mobile Digital Wrench (Pmdw)

    (PMDW) • An electronic user’s guide is provided within the app. Polaris Mobile Digital Wrench (PMDW) is a diagnostic To access the user’s guide, launch the app, and then software application (app) designed specifically for click on the “Help” button in the Settings/Preferences Android™...
  • Page 207 ..............5.29 DRIVEN CLUTCH SERVICE (EBS) 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 208 ..................5.37 TROUBLESHOOTING 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 209: General Information

    (Rear) 225 ft-lb (305 Nm) (Apply 0.4 mL Drive Clutch Spider Loctite® 7088 Primer and 0.4 mL Loctite® 620™) 100 in-lb (12 Nm) Drive Clutch Cover Plate 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 210: Pvt System Overview

    During the development of resistance at the transmission input shaft is greater than the Polaris vehicle, the PVT system is matched first to the the load from the drive belt, the drive belt is kept at the engine power curve;...

  • Page 211: Pvt Break-In (Drive Belt / Clutches)

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 212: Overheating / Diagnosis

    PVT system. 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD Clutch malfunction. certified technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or Poor engine performance.

  • Page 213: Pvt System Service

    HOSE, INTAKE, CLUTCH RTV SILICONE O-RING DECAL, BELT, CAUTION/CHECK CLAMP, NARROW BAND SCREW ASM., COVER, CLUTCH, OUTER ASM., BOLT/WASHER PLUG, DRAIN CLAMP, VINYL COATED ASM., COVER, CLUTCH, INNER BOLT 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 214: Pvt Disassembly

    Drive Clutch Puller: PA-48595 Drive Clutch Holder: 9314177 NOTE Be sure to use the correct Drive Clutch Puller to prevent damage to crankshaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 215: Pvt Assembly

    9. Apply a light film of grease to the splines on the shaft. 10. LE Model: Install the driven clutch assembly, washer and retaining bolt. Torque to specification. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 216 Steel Rims: 27 ft-lbs (37 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 18. Reconnect the battery cable. 19. Install engine service panel and both seats. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 217: Drive Belt

    2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.11 © Copyright Polaris Industries Inc.

  • Page 218: Belt Installation

    TORQUE PVT Outer Clutch Cover bolts: 100 in-lbs (12 Nm) NOTE Make sure the tool is square with the moveable sheave surface of the driven clutch. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 219: Pvt Break-In (Drive Belt / Clutches)

    3. If the tool fits as shown above, the clutch center to center distance is correct. 4. If the tool does not fit as shown above, adjustment is needed. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.13 © Copyright Polaris Industries Inc.

  • Page 220: Adjustment

    Tool (PU-50658) as shown in the inspection process. reassemble the PVT system as outlined in this chapter. TORQUE Rear Trans. Isolator Bolts: 40 ft-lbs (54 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 221: Drive Clutch Service

    (Apply 0.4 mL Loctite® 7088 Primer and 0.4 mL Loctite® 620™) Cover Bolt Shift Weight 100 in-lb (12 Nm) Shift Weight Bolt 20 in-lb (2 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 222: Drive Clutch Disassembly

    3. Remove the six cover bolts evenly in a cross pattern 7. Remove the limiter spacer and inspect for wear. and remove cover plate. Replace if excessive wear is evident. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 223: Shift Weight Inspection

    Distortion of the spring indicates stress fatigue, requiring replacement. CAUTION The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly! 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 224: Spider Removal

    Clutch Spider SeeRoller, Pin, and Thrust Washer Inspection, page Removal Tool with a breaker bar. 5.19 ITEM DESCRIPTION 2871358–B Clutch Holding Fixture 2870341 Spider Removal Tool 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 225: Roller, Pin, And Thrust Washer Inspection

    Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. Button to Tower Clearance: .000-.012” 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 226: Bearing Inspection

    2. Verify there is no binding or rough spots. If problems are noted continue with disassembly. 2. Remove the moveable clutch sheave . Inspect for damage and wear. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 227: Bushing Service

    Measure the thickness and compare to specification. Number Two Puller 5020633 Replace if worn or damaged. Adapter MEASUREMENT PTFE Washer Thickness: Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.21 © Copyright Polaris Industries Inc.
  • Page 228 3. Remove nut from puller rod and set aside. seated. 4. Install puller adapter (10 from kit PN 2871226). 18. Remove nut from puller rod and set aside. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.22 © Copyright Polaris Industries Inc.

  • Page 229: Drive Clutch Assembly

    4. Apply 0.4 mL of Loctite® 620™ and 0.4 mL of Loctite® 7088™ Primer in 90º apart in vertical stripes to the shaft threads. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.23 © Copyright Polaris Industries Inc.
  • Page 230 Spider: 225 ft-lb (305 Nm)(Apply 0.4 mL Loctite® 7088 Primer and 0.4 mL Loctite® 620™) 7. Install shift weights using new lock nuts on the bolts. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.24 © Copyright Polaris Industries Inc.

  • Page 231: Driven Clutch Service

    Installing the later build spring in early build clutch may cause additional belt heat and high engine RPM resulting in shortened belt life and cord pop-out. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.25 © Copyright Polaris Industries Inc.

  • Page 232: Clutch Disassembly / Inspection

    2. Remove the driven clutch from the vehicle. (See PVT Disassembly, page 5.8). 8. Separate the stationary and the moveable sheaves. Keep track of the number of thrust washers between the sheaves. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.26 © Copyright Polaris Industries Inc.

  • Page 233: Clutch Assembly

    Do not apply oil or grease to the bearings. 13. Lube splines with a light film of grease. Do not lubricate the bearings! 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.27 © Copyright Polaris Industries Inc.
  • Page 234 Apply and hold downward pressure on the spring cup. Torque the retaining ring screws specification. TORQUE Clutch Spring Retaining Ring Bolts: 11 ft-lbs (15 Nm) 7. Install driven clutch assembly and drive belt. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.28 © Copyright Polaris Industries Inc.

  • Page 235: Driven Clutch Service (Ebs)

    Universal Clutch Compressor: PU-50518-A 5. Press down on the top of the spider assembly, pushing the spider onto the shaft. Remove snap ring and slowly release the assembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.29 © Copyright Polaris Industries Inc.
  • Page 236 12. Press the shaft and bearing out of the outer sheave using an arbor press. 8. Remove the E-clips , washers , and the clutch rollers . Inspect the rollers for wear; replace if worn. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.30 © Copyright Polaris Industries Inc.

  • Page 237: Driven Clutch Bushing Service

    Main Adapter 15. Inspect the sheaves for excessive wear or damage. 51320- Bushing Removal Tool DRIVEN CLUTCH BUSHING SERVICE NOTE Special Tools Required for this service 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.31 © Copyright Polaris Industries Inc.

  • Page 238: Clutch Bushing Removal

    11. Remove nut (left hand thread) from puller rod and set aside. 12. Remove adapters from puller. 13. Remove bushing and removal tool from adapters. Discard bushing. 5. Install adapter reducer 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.32 © Copyright Polaris Industries Inc.

  • Page 239: Driven Clutch Assembly

    6. Install left hand thread nut onto puller rod and hand tighten against installation tool. NOTE Press only on the outer race of the bearing during installation to prevent damaging the bearing. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.33 © Copyright Polaris Industries Inc.
  • Page 240 The flat side of the roller pin faces towards the sheaves. 9. Install the spider dampener inside the spider and install the inside spider plate 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.34 © Copyright Polaris Industries Inc.
  • Page 241 Helix Retaining Screws: aligned. Once the spider passes the retaining ring 48 in-lb (5 Nm) notch on the shaft, install the retaining ring 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.35 © Copyright Polaris Industries Inc.

  • Page 242: Driven Clutch Assembly View

    DRIVEN CLUTCH ASSEMBLY VIEW Snap Ring Spring Bearing Spider Insert Stationary Sheave Spider Dampener E-Clip Roller Washer Helix (Cam) Moveable Sheave Helix Screws Clutch Shaft 48 in-lb (5 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.36 © Copyright Polaris Industries Inc.

  • Page 243: Troubleshooting

    Inspect brake system. spots Slow, easy clutch engagement. Fast, effective use of throttle for efficient engagement. PVT cover Plugged air intake or outlet. Clear obstruction. overheating (melting) 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.37 © Copyright Polaris Industries Inc.
  • Page 244 Thin spots on belt, worn belt . Replace belt. Refer to belt burnt troubleshooting Engagement and instruct operator. erratic or stabby Drive clutch bushings stick. Inspect and repair clutches. 9926813 R04 - 2013-2016 RZR 570 Service Manual 5.38 © Copyright Polaris Industries Inc.
  • Page 245 ..............6.53 TROUBLESHOOTING CHECKLIST 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 246: General Information

    Backlash Procedure” Snorkel Tube Locking 8 ft-lbs (11 Nm) Screw Starter Mounting Bolts 7 ft-lb (10 Nm) Support and Shift Cable 17 ft-lbs (23 Nm) Bracket Bolts 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 247: Transmission Mounting And Torque Values

    TRANSMISSION TRANSMISSION MOUNTING AND TORQUE VALUES 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 248: Shift Lever / Cable

    SHIFT LEVER INSTALLATION the lever. 1. Perform the removal steps in reverse order to install the gear shift lever (lever, cable, console, shift knob). 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 249: Shift Cable Inspection

    4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 250: Transmission Service

    10. Pull sharply forward to remove the propshaft from transmission shaft. 11. Remove the rear bumper and cargo box as an assembly (see Chapter 10 – BODY COMPONENT REMOVAL, page 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 251 Be sure dirt and debris do not enter the engine, air box or throttle body. Use clean shop towels to plug engine and air box intake holes. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 252 (G) harness connectors. Cut tie strap (H). Note harness routings for reassembly. 22. Remove the transmission vent tube (I). 23. INTL - Remove the parking break cable and asm. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 253 28. Place a support in-between the main frame and the engine crankcase to support the engine in its current position. Do not pinch brake line. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 254: Transmission Installation

    1. With the help of an assistant lift transmission into the vehicle frame through the left rear wheel well area as shown below. 2. Carefully rotate the top of the transmission upward into its proper location. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.10 © Copyright Polaris Industries Inc.
  • Page 255 Torque fasteners to specification as outlined in Chapter 10. Be sure wires are routed correctly. TORQUE Starter Mounting Bolts: 7 ft-lb (10 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.11 © Copyright Polaris Industries Inc.
  • Page 256 Torque fasteners to specification. 13. Torque the two shift cable bracket bolts to specification. 19. Lubricate the transmission splines with Polaris All Purpose Grease. Install the propshaft onto the TORQUE transmission splines. Shift Cable Bracket Bolts: 20.
  • Page 257 40 ft-lb (54 Nm) the (-) negative battery cable. 31. Install the engine service panel and seats. 32. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris AGL (see Chapter 2 – Transmission Lubrication, page 2.25). FLUID CAPACITY...

  • Page 258: Servicing - No Differential

    (G). NOTE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.14 © Copyright Polaris Industries Inc.
  • Page 259 12. Lift up on the shift shaft rail (Q) and move the rail assembly rearward to allow the shift fork pins to be removed from the shift drum (R). Remove the shift drum (R) from the transmission housing. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.15 © Copyright Polaris Industries Inc.
  • Page 260 53T gear and needle bearing off the reverse shaft (see Figure 8-1). 20. Remove the retaining ring and engagement dog from the reverse shaft (see Figure 8-1). 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.16 © Copyright Polaris Industries Inc.
  • Page 261 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. Snorkel Shaft Removal / Disassembly 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 262 31. Lightly tap on the bearing from the opposite side to snorkel shaft. remove it from the snorkel tube. 29. Use an arbor press to remove the snorkel tube from the snorkel shaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.18 © Copyright Polaris Industries Inc.
  • Page 263 TRANSMISSION 32. Remove the retaining ring to remove the remaining washer, bearing and gear from the snorkel shaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.19 © Copyright Polaris Industries Inc.

  • Page 264: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.20 © Copyright Polaris Industries Inc.

  • Page 265: Snorkel Gear Backlash Procedure

    NOTE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.21 © Copyright Polaris Industries Inc.
  • Page 266 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.22 © Copyright Polaris Industries Inc.
  • Page 267 The snorkel shaft snorkel tube. cannot be installed after assembling the transmission. 17. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.23 © Copyright Polaris Industries Inc.
  • Page 268 19. Install the idler gear shaft assembly (A) and gear assembly previously disassembled (see cluster assembly (B) into the transmission housing, illustrations). all at the same time. 20. Install the rear output shaft assembly (C). 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.24 © Copyright Polaris Industries Inc.
  • Page 269 25. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to the left hand transmission mating surface. NOTE Shift fork pins should be offset towards the input shaft as shown above. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.25 © Copyright Polaris Industries Inc.
  • Page 270 Seals should be installed just past the case lead-in chamfer (.070 in. or 1.8 mm from the outer face of the bore). 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.26 © Copyright Polaris Industries Inc.
  • Page 271 TORQUE Bell Crank Nut: 15 ft-lbs (20 Nm) 39. Refer to Chapter 8 – Transmission Installation, page 6.10to complete the repair. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.27 © Copyright Polaris Industries Inc.

  • Page 272: Transmission Assembly View

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 273 Shaft, Idler 29T Washer, Thrust Shaft, Front Output Seal, Dual Lip Shaft, Input, Helical Seal, Triple Lip Shim Shaft, Reverse, 27T Sensor, Speed Shim Bearing, Needle Cage Bellcrank 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.29 © Copyright Polaris Industries Inc.

  • Page 274: Servicing - With Differential

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.30 © Copyright Polaris Industries Inc.
  • Page 275 TRANSMISSION 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.31 © Copyright Polaris Industries Inc.

  • Page 276: Transmission Disassembly

    (G). NOTE Removal can be aided by using your thumbs to press in on the shafts while pulling out the cover with your fingers. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.32 © Copyright Polaris Industries Inc.
  • Page 277 13. Lift up on the shift shaft rail (Q) and move the rail assembly rearward to allow the shift fork pins to be removed from the shift drum (R). Remove the shift drum (R) from the transmission housing. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.33 © Copyright Polaris Industries Inc.
  • Page 278 53T gear and needle bearing off the housing. reverse shaft (see Figure 8-1). 23. Remove the retaining ring and engagement dog from the reverse shaft (see Figure 8-1). 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.34 © Copyright Polaris Industries Inc.
  • Page 279 Failure to remove pinion shaft, will result in damage to the snorkel shaft. 28. Extract the seal from the snorkel shaft to access the snorkel tube for removal. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.35 © Copyright Polaris Industries Inc.
  • Page 280 31. Remove the snap ring (Y) and shim (Z) from the snorkel shaft. 32. Use an arbor press to remove the snorkel tube from the snorkel shaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.36 © Copyright Polaris Industries Inc.

  • Page 281: Planetary Differential Disassembly

    If the gearcase is completely assembled, perform the Gearcase Disassembly / Inspection, page 7.30 procedure. 1. Use a scribe to mark the differential cover and ring gear prior to disassembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.37 © Copyright Polaris Industries Inc.

  • Page 282: Planetary Differential Bushing Replacement

    Ring Gear Bushing Replacement 1. Press the old bushing out of the ring gear. 2. Thoroughly clean the bore of the ring gear and check for any unwanted burs. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.38 © Copyright Polaris Industries Inc.
  • Page 283 Planet Gear Bushing Replacement 5. Press the old bushing out of the planet gear. 6. Thoroughly clean the bore of the planet gear and check for any unwanted burs. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.39 © Copyright Polaris Industries Inc.

  • Page 284: Planetary Differential Assembly

    4. Apply Loctite ® 2760 ™ to cover screws. 13. Thoroughly clean the bore of the side gear and check for any unwanted burs. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.40 © Copyright Polaris Industries Inc.
  • Page 285 TRANSMISSION 5. Install screws hand tight. Place assembly in soft jaw vise and torque to specification. TORQUE Differential Cover Screws: 21 ft-lb (28 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.41 © Copyright Polaris Industries Inc.

  • Page 286: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.42 © Copyright Polaris Industries Inc.

  • Page 287: Snorkel Gear Backlash Procedure

    NOTE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.43 © Copyright Polaris Industries Inc.
  • Page 288 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.44 © Copyright Polaris Industries Inc.
  • Page 289 Inspect case half mating surfaces for damage. 18. Install shift fork (S) and torsion spring into transmission housing as an assembly. Load spring as shown in image below 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.45 © Copyright Polaris Industries Inc.
  • Page 290 Torque to assembly previously disassembled (see specification. illustrations). TORQUE Shift Fork Screws: 8 ft-lb (11 Nm) 20. Slide engagement dog (U) onto retaining pins of shift fork. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.46 © Copyright Polaris Industries Inc.
  • Page 291 Be sure the shift forks are engaged into the engagement dogs. NOTE Shift fork pins should be offset towards the input shaft as shown above. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.47 © Copyright Polaris Industries Inc.
  • Page 292 (.070" or 1.8 mm from outer face of bore). 28. Apply a continuous bead of Crankcase 3 Bond Sealant (PN 2871557) to the left hand transmission mating surface. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.48 © Copyright Polaris Industries Inc.
  • Page 293 35. Install the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.49 © Copyright Polaris Industries Inc.
  • Page 294 40. Install the sector cover and align the transmission case dowel with the alignment hole. Install and torque the bolts to specification. TORQUE Sector Cover Bolts: 11 ft-lb (15 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.50 © Copyright Polaris Industries Inc.

  • Page 295: Transmission Assembly View (Int

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW (INT’L) 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.51 © Copyright Polaris Industries Inc.
  • Page 296 105. Screw, M8 x 1.25 x 25 34. Bearing, Ball 68. Shift Dog, Park 106. Ring Gear, 53T 35. Bearing, Ball 108. Bearing, Plain 69. Gear, 44T 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.52 © Copyright Polaris Industries Inc.

  • Page 297: Troubleshooting

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.53 © Copyright Polaris Industries Inc.
  • Page 298 TRANSMISSION NOTES 9926813 R04 - 2013-2016 RZR 570 Service Manual 6.54 © Copyright Polaris Industries Inc.
  • Page 299 ............... .7.38 REAR HUB EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 300: General Information

    Rear Hub Castle Nut 43 ft-lb (58 Nm) Tie Rod End Fastener Steel Rims: 27 ft- lbs (37 Nm) Wheel Lug Nuts Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 301: Bearing Carrier

    12. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 302: Front Bearing Replacement

    3. Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 303: Front Bearing Carrier Installation

    Refer to the photos below to ensure proper placement of the tie rod end. TORQUE Ball Joint Pinch Bolts: 23 ft-lb (31 Nm) 4. Apply grease to drive shaft axle splines. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 304: Rear Bearing Carrier Inspection / Removal

    Aluminum Rims: 30 ft-lbs (41 Nm) + 90° bolts. 11. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 305 8. Remove the bolts, nuts and washers that attach the rear bearing carrier to the upper and lower A-arms. Discard nuts and replace with new. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 306: Rear Bearing Replacement

    6. Support the bottom of the bearing carrier housing. CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 307: Rear Bearing Carrier Bushing Replacement

    A-arms. Torque NEW nuts to specification. TORQUE Upper and Lower Rear Bearing Carrier Nuts: 40 ft-lb (54 Nm) 3. Apply grease to drive shaft axle splines. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 308 44 ft-lbs (60 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 309: Drive Shaft

    Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 310: Front Drive Shaft Installation

    4. Install the upper ball joint end into the front bearing FRONT DRIVE SHAFT INSTALLATION carrier. 1. Install new spring ring on drive shaft. Apply an anti- seize compound to splines. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.12 © Copyright Polaris Industries Inc.
  • Page 311 Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 11. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.13 © Copyright Polaris Industries Inc.

  • Page 312: Rear Drive Shaft Removal

    8. Slide the rear drive shaft out of the bearing carrier by brake line. pulling the bearing carrier assembly outward and tipping it down to remove the shaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.14 © Copyright Polaris Industries Inc.

  • Page 313: Rear Drive Shaft Installation

    3. Slide the rear drive shaft into the rear bearing carrier. REAR DRIVE SHAFT INSTALLATION 1. Install new spring ring on drive shaft. Apply anti- seize compound to splines. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.15 © Copyright Polaris Industries Inc.
  • Page 314 8. Torque wheel hub nut to specification and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TORQUE Rear Wheel Hub Castle Nut: 110 ft-lbs (149 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 315: Drive Shaft / Cv Joint Handling Tips

    Refer to text for grease capacity of CV joints and CV joint boots. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.17 © Copyright Polaris Industries Inc.

  • Page 316: Outer Cv Joint / Boot Replacement

    IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.18 © Copyright Polaris Industries Inc.
  • Page 317 CV Boot Clamp Pliers: 8700226 NOTE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 318: Inner Plunging Joint / Boot Replacement

    CV Boot Clamp Pliers: 8700226 INNER PLUNGING JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps IMPORTANT Tap on inner race only! 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 319 9. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.21 © Copyright Polaris Industries Inc.

  • Page 320: Prop Shaft Removal / Installation

    1. Remove both seats and the engine service panel as outlined in Chapter 5. 2. Disconnect the negative (-) battery cable. 7. Remove the gear selector cap and remove the retaining screw and handle. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 321 11. Slide prop shaft back far enough to remove it from the front gearcase input shaft splines. 12. Pull sharply forward to remove the propshaft from transmission shaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.23 © Copyright Polaris Industries Inc.

  • Page 322: Disassembly

    If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct re-positioning during installation. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.24 © Copyright Polaris Industries Inc.

  • Page 323: Assembly

    4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 5. Install outer yoke, aligning marks made disassembly and repeat Steps 1-3 to install bearing caps on outer yoke. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 324: Front Gearcase / Centralized Hilliard

    Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic Roll Cage Retaining Ring, External Hub / Race Assembly 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.26 © Copyright Polaris Industries Inc.

  • Page 325: All Wheel Drive Operation

    The front drive will remain engaged until the torque requirement goes away (i. e. rear wheels regain traction). 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.27 © Copyright Polaris Industries Inc.

  • Page 326: Awd Diagnosis

    Step 5. A wear band with an interrupted wear mark may indicate warped plate, which cause intermittent operation. See the following illustrations: 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.28 © Copyright Polaris Industries Inc.

  • Page 327: Gearcase Removal

    5. Remove the vent line from the front gearcase. 6. Remove the four bolts securing the front gearcase to frame. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.29 © Copyright Polaris Industries Inc.

  • Page 328: Gearcase Disassembly / Inspection

    Remove any metal particles from the drain plug magnet. 2. Remove the seven cover screws and remove the cover plate assembly. NOTE Nylon spacer is non-serviceable and should not be removed. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.30 © Copyright Polaris Industries Inc.
  • Page 329 7. Remove the RH output hub assembly from the 5. Remove the torsion spring retainer and torsion gearcase housing. spring from the top of the ring gear. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.31 © Copyright Polaris Industries Inc.
  • Page 330 (B) sliding surfaces and H-springs. NOTE Refer to the “Electronic Parts Catalog” for individual part availability. Most parts are to be replaced as an assembly or as a complete kit. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.32 © Copyright Polaris Industries Inc.

  • Page 331: Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.33 © Copyright Polaris Industries Inc.
  • Page 332 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 333 11. Install a new O-ring on the cover plate assembly. NOTE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.35 © Copyright Polaris Industries Inc.

  • Page 334: Gearcase Installation

    4. Install the vent line. Front Housin:g Capacity 6.75 fl. oz. (200 ml) TORQUE Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.36 © Copyright Polaris Industries Inc.

  • Page 335: Wheel Hubs

    FINAL DRIVE WHEEL HUBS FRONT HUB EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.37 © Copyright Polaris Industries Inc.

  • Page 336: Rear Hub Exploded View

    FINAL DRIVE REAR HUB EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 7.38 © Copyright Polaris Industries Inc.
  • Page 337 ................8.25 SHOCK REPLACEMENT 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 338: General Information

    TOOL PART NUMBERS Bosch Automotive Service Solutions – 1-800-328-6657 or http://polaris.service-solutions.com/ TOOL DESCRIPTION PART NUMBER Shock Spanner Wrench 2871095 Shock Spring Compressor Tool 2870623 Multi-Function Pliers 2876389 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 339: Steering System

    STEERING / SUSPENSION STEERING SYSTEM EXPLODED VIEW (NON-EPS MODELS) 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 340: Steering Wheel Removal (Non-Eps Models)

    Use care not to allow any of the Loctite ® to get in the bearing. NOTE Be sure the lower washers and spacers are still on the steering shaft. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 341 65 ft-lbs (88 Nm) 36 ft-lb (48 Nm) 15. Wipe the pivot tube clean of any excess Loctite. ® 16. Install steering wheel cap and field test steering operation. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 342: Exploded View (Eps Models)

    STEERING / SUSPENSION EXPLODED VIEW (EPS MODELS) 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 343: Upper Steering Shaft Removal (Eps Models)

    2. Remove the pinch bolt retaining the upper steering shaft to the power steering unit. 5. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 344: Steering Wheel Removal (Eps Models)

    3. Loosen the nut and back it half way off the steering shaft. 4. Place the assembly in a vise. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 345: Power Steering Unit Removal

    5. Carefully remove the power steering unit and mount bracket from the vehicle as an assembly. 3. Remove the pinch bolt retaining the lower steering shaft to the power steering unit. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 346: Lower Steering Shaft Removal (Eps Models)

    Mark the lower steering shaft, gear box stub shaft and gear box to aid installation. 3. Remove the power steering unit (see Chapter 5 – Power Steering Unit Removal, page 8.9 procedure). 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 347: Power Steering Unit Installation

    5. Position the lower steering shaft on the power steering unit stub shaft and install the pinch bolt. Torque to specification. TORQUE Lower Steering Shaft Pinch Bolt: 36 ft-lb (48 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 348: Upper Steering Shaft Installation (Eps Models)

    TORQUE Pivot Tube Fasteners: 23 ft-lb (31 Nm) 3. Install tilt shock and torque fastener to specification. TORQUE Upper Tilt Shock Fastener: 7 ft-lbs (10 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 349: Front Suspension

    TORQUE TORQUE Front Upper / Lower A-arm Bolts: Front Ball Joint Pinch Bolts: 39 ft-lb (53 Nm) 23 ft-lb (31 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.13 © Copyright Polaris Industries Inc.
  • Page 350 23. Install front wheel. Torque wheel nuts specification. TORQUE Wheel Nuts: Steel Rims: 27 ft-lbs (37 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 351: Exploded View

    STEERING / SUSPENSION EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 352: Service Preparation

    - If necessary, remove the lower front shock fastener from the A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint. 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 353: Ball Joint Installation

    4. Install the Press Asm. (C) onto the A-arm to engage the Installation Adapter and Spacer. 5. Tighten the Press Asm. screw and fully install the ball joint into the arm. 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 354: Stabilizer Bar Linkage Removal

    Steel Rims: 27 ft-lbs (37 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° STABILIZER BAR LINKAGE REMOVAL 1. Elevate and safely support the front of the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.18 © Copyright Polaris Industries Inc.

  • Page 355: Stabilizer Bar Removal

    8. Lift up on the stabilizer bar and remove it from the vehicle. 5. Allow radiator to sag down to allow access to recovery bottle retaining screws and filler neck retaining screws. 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 356: Exploded View

    9. Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed. 10. Reverse the procedure for installation. Torque the linkage fasteners to specification (see “Exploded View”). 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 357: Rear Suspension

    7. Insert new A-arm bushings and pivot tubes into new A-arm. Lower A-arm Removal 8. Disengage the rear brake line from the routing clip on the lower A-arm. 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 358: Rear A-Arm Installation

    Steel Rims: 27 ft-lbs (37 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 359: Stabilizer Bar Removal / Installation

    6. Inspect the rubber bushings on the linkage rod and replace if needed. 7. Reverse the procedure for installation. 8. Torque stabilizer mounting nuts specification. TORQUE Stabilizer Mounting Bolt: 18 ft-lb (24 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 360: Shocks / Springs

    Retainer gap should be RETAINER, SPRING 180° from spring end. SCREW SPRING, MATTE BLACK [AD] CAM, ADJUSTING, SPRING SHOCK, REAR BOLT SPRING, MATTE BLACK [AD] SPACER, SPRING 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 361: Shock Removal / Installation

    The spring retainer gap should be 180° from the end of the spring upon installation. 4. Reinstall the shock onto the vehicle and torque new fasteners to specification (refer to exploded views). 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.25 © Copyright Polaris Industries Inc.
  • Page 362 STEERING / SUSPENSION NOTES 9926813 R04 - 2013-2016 RZR 570 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 363 ................. . .9.25 DISC INSPECTION 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.
  • Page 364 ................... .9.37 BRAKES LOCK 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 365: General Specifications

    Parking Brake Disc Mounting Bolt 21 ft-lbs (28 Nm) Parking Brake Lever Mount Bolts 16 ft-lbs (22 Nm) Parking Brake Mount Bracket to Transmission 37 ft-lbs (50 Nm) Bolts 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 366: Special Tools

    MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.

  • Page 367: Brake Bleeding / Fluid Change

    Mity Vac™: 2870975 3. Add brake fluid to the indicated MAX level of reservoir. Polaris DOT 4 Brake Fluid: 2872189 4. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container.

  • Page 368: Brake System Exploded View

    BRAKE SYSTEM BRAKE SYSTEM EXPLODED VIEW RZR 570 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 369: Master Cylinder

    1. Reverse Steps 1-5 for master cylinder installation. Refer to the torque specifications in the illustration. 2. After installing the foot brake check pedal freeplay. Pedal freeplay should not exceed .090” (2.286 mm). 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 370: Brake Pedal Lever

    (B) and clip (A). Brake Pedal Freeplay: 2. Remove the E-ring (E) from the pedal mount and .090” (2.28 mm) remove the brake pedal lever (L) from the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 371: Parking Brake (Intl Model)

    BRAKE SYSTEM PARKING BRAKE (INTL MODEL) EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual © Copyright Polaris Industries Inc.

  • Page 372: Parking Brake Inspection

    5. Place the vehicle in neutral on a flat level surface. 6. Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.10 © Copyright Polaris Industries Inc.
  • Page 373 9. Repeat Step 3 and Step 4 until the proper adjustment is obtained for the parking brake. NOTE See Chapter 10 for more information on the parking brake switch. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 374: Parking Brake Caliper Service (Intl Model)

    BRAKE SYSTEM PARKING BRAKE CALIPER SERVICE (INTL MODEL) CALIPER EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.12 © Copyright Polaris Industries Inc.

  • Page 375: Caliper Removal

    5. Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed. 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.13 © Copyright Polaris Industries Inc.

  • Page 376: New Brake Pad Installation

    Parking Brake Caliper Assembly Bolts: 37 ft-lbs (50 Nm) 5. Ensure the parking brake assembly functions properly by actuating the lever. Install the mounting sleeves (D) before installation. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 377: Caliper Installation

    TORQUE Parking Brake Caliper Mount Bracket Bolts: 37 ft-lbs (50 Nm) 3. Install the cable, pin and clip pin. Test the park brake for proper function. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 378: Parking Brake Disc (Intl Model)

    4. Install the new brake disc. Install the mounting bolt and flat washer. Torque the mounting bolt to specification. TORQUE Parking Brake Disc Mounting Bolt: 21 ft-lbs (28 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.16 © Copyright Polaris Industries Inc.

  • Page 379: Front Brake Pads

    When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 7. Remove the inner pad from the bracket and caliper. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 380: Pad Inspection

    4. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 381: Brake Burnishing Procedure

    7. Install wheel and torque wheel nuts to specification. TORQUE Wheel Nuts: Steel Rims: 27 ft-lbs (37 Nm) Aluminum Rims: 30 ft-lbs (41 Nm) + 90° 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 382: Front Caliper Service

    BRAKE SYSTEM FRONT CALIPER SERVICE CALIPER EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 383: Caliper Removal

    The piston sealing surfaces will become 6. Remove and discard the two caliper mounting bolts damaged if a standard pliers is used. and remove the caliper assembly from the front hub. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 384: Caliper Inspection

    MEASUREMENT Front Caliper Piston O.D.: Std: 1.002″ (25.45 mm) Service Limit: 1.000″ (25.4 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 385: Caliper Assembly

    30 ft-lbs (41 Nm) 3. Torque the banjo bolt to the proper torque specification. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
  • Page 386 Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. NOTE If new pads are installed, refer to “FRONT BRAKE PADS - Brake Burnishing Procedure”. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.24 © Copyright Polaris Industries Inc.

  • Page 387: Front Brake Disc

    New .188″ (4.78 mm) Service Limit .170″ (4.32 mm) Brake Disc Thickness Variance Service Limit: .002″ (.051 mm) Brake Disc Runout difference between measurements Service Limit .010” (.254 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.25 © Copyright Polaris Industries Inc.

  • Page 388: Disc Replacement

    Rotor bolts: 30 ft-lbs (41 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 389: Rear Brake Pads

    NOTE When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.27 © Copyright Polaris Industries Inc.

  • Page 390: Pad Inspection

    2. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Rear Brake Pad Thickness: New .298 ± .007″ (7.57 mm ± .178 mm) Service Limit .180″ (4.6 mm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.28 © Copyright Polaris Industries Inc.

  • Page 391: Pad Assembly / Installation

    Use only new clean pads. 3. Install caliper and torque the new mounting bolts to specification. TORQUE Rear Caliper Mount Bolt: 44 ft-lbs (60 Nm) 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 392: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.30 © Copyright Polaris Industries Inc.

  • Page 393: Rear Caliper Service

    BRAKE SYSTEM REAR CALIPER SERVICE CALIPER EXPLODED VIEW 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.31 © Copyright Polaris Industries Inc.

  • Page 394: Caliper Removal

    5. Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 6. Remove and discard the two caliper mounting bolts and remove the caliper. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.32 © Copyright Polaris Industries Inc.

  • Page 395: Caliper Inspection

    MEASUREMENT Rear Caliper Piston O.D.: Standard: 1.1875″ (30.16 mm) Service Limit: 1.186″ (30.12 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.33 © Copyright Polaris Industries Inc.

  • Page 396: Caliper Assembly

    Be sure groove is clean and free of residue or brakes Torque mounting bolts to specification. may drag upon assembly. 2. Coat piston with clean Polaris DOT 4 Brake Fluid TORQUE (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in Rear Caliper Mount Bolt Torque: and out of bore smoothly with light resistance.

  • Page 397: Rear Brake Disc

    Disc Bolts: 30 ft-lbs (41 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.35 © Copyright Polaris Industries Inc.
  • Page 398 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.36 © Copyright Polaris Industries Inc.

  • Page 399: Troubleshooting

    • Compensating port plugged • Pad clearance set incorrectly • Brake pedal binding or unable to return fully • Residue build up under caliper seals • Operator riding brakes 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.37 © Copyright Polaris Industries Inc.
  • Page 400 BRAKE SYSTEM NOTES 9926813 R04 - 2013-2016 RZR 570 Service Manual 9.38 © Copyright Polaris Industries Inc.
  • Page 401 ................10.19 DECAL REPLACEMENT 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.1 © Copyright Polaris Industries Inc.

  • Page 402: General Information

    28 ft-lb (38 Nm) Cab Frame Bolts Hip Bolster Bolts 8 ft-lb (11 Nm) 40 ft-lbs (54 Nm) Seat Belt to Seat Base 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 403: Cab Frame

    (steps 1-5). Tighten screws to specification. 3. Place the straps from the safety net over the front coupler posts. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 404: Body Assembly Views

    BODY / FRAME BODY ASSEMBLY VIEWS SIDE SAFETY NETS 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 405: Dash Instruments / Controls / Glovebox

    BODY / FRAME DASH INSTRUMENTS / CONTROLS / GLOVEBOX 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 406: Hood / Front Body Work

    BODY / FRAME HOOD / FRONT BODY WORK 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.6 © Copyright Polaris Industries Inc.

  • Page 407: Front Bumper

    BODY / FRAME FRONT BUMPER 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 408: Rear Bumper

    BODY / FRAME REAR BUMPER 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.8 © Copyright Polaris Industries Inc.

  • Page 409: Seat Assembly

    BODY / FRAME SEAT ASSEMBLY 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.9 © Copyright Polaris Industries Inc.

  • Page 410: Seat Belts / Mounting

    BODY / FRAME SEAT BELTS / MOUNTING 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 411: Floor / Rocker Panels

    BODY / FRAME FLOOR / ROCKER PANELS 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.11 © Copyright Polaris Industries Inc.

  • Page 412: Rear Cargo Box / Fenders

    BODY / FRAME REAR CARGO BOX / FENDERS 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.12 © Copyright Polaris Industries Inc.

  • Page 413: Chassis / Main Frame

    BODY / FRAME CHASSIS / MAIN FRAME 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.13 © Copyright Polaris Industries Inc.

  • Page 414: Body Component Removal

    2. Remove the six Torx screws retaining the upper, middle and lower portion of the bumper. 3. Disconnect the front head lamp connectors and remove the front bumper from the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 415: Rear Bumper

    2. Tilt the hood back to disengage the front tabs and remove the hood from the vehicle. Front Body / Dash Removal 3. Remove the hood as previously described. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.15 © Copyright Polaris Industries Inc.

  • Page 416: Rear Fender Flair Removal

    12. Remove the six push rivets and remove fender flairs from the dash assembly. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 417: Cargo Box Assembly Removal

    9. Remove the two push pins (D) from both sides of the cargo box / rocker panels. 10. Remove intake grill and foam filters from the LH side of the rear storage box. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 418: Rocker Panels, Console And Floor

    5. Remove the Torx screws retaining the upper floor to the lower floor. 6. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 419: Decals

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.19 © Copyright Polaris Industries Inc.
  • Page 420 BODY / FRAME NOTES 9926813 R04 - 2013-2016 RZR 570 Service Manual 10.20 © Copyright Polaris Industries Inc.
  • Page 421 ............11.27 BATTERY CONDUCTANCE ANALYZER 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.1 © Copyright Polaris Industries Inc.
  • Page 422 ................. 11.47 CAN SYSTEM TESTING 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.2 © Copyright Polaris Industries Inc.

  • Page 423: General Information

    (K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.3 © Copyright Polaris Industries Inc.

  • Page 424: Instrument Cluster

    Certain products, including insect repellents and chemicals, will damage the instrument cluster lens. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.4 © Copyright Polaris Industries Inc.
  • Page 425 Helmet / Seat Belt Indicator - LED icon illuminates for several seconds when the key is turned to the ON position. The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating the vehicle. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 426: Information Display Area

    To reset the trip meter: 1. Toggle the MODE button to TRIP 1. Engine hours are logged anytime the engine is running. Total hours can not be reset. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.6 © Copyright Polaris Industries Inc.
  • Page 427 Refer to “Units of Measurement” to change the format (Standard 12-hour / Metric-24 hour). To set the clock, follow these steps: 7. Toggle the MODE button until the odometer is displayed. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.7 © Copyright Polaris Industries Inc.
  • Page 428 When the park brake is fully engaged, “BRAKE” appears in the rider information display. Engine speed is limited to 1500 RPM in all gears, except 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.8 © Copyright Polaris Industries Inc.

  • Page 429: Diagnostic Mode

    MIL will illuminate and blink in place of the check engine MIL. 2. Press and hold the MODE button to enter the diagnostics code menu. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 430: Instrument Cluster Removal

    Do not remove the rubber mount from the dash panel. Only remove the rubber mount if necessary. The bezel is a snap-on assembly and is a serviceable part. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.10 © Copyright Polaris Industries Inc.

  • Page 431: Instrument Cluster Installation

    Apply pressure on the bezel while pressing down on the instrument cluster. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 432: Switches / Controls

    A and B; C and D; E and F. • Turn the ignition key to START. There should be con- tinuity between switch pins A and B; C and D; E and F. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.12 © Copyright Polaris Industries Inc.

  • Page 433: Awd / 2Wd Switch

    • Move the switch to 2WD. There should be no continuity between any pins. • Move the switch to TURF. There should be continuity between switch pins 1 and 2; 4 and 5. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 434: Transmission (Gear Position) Switch

    TURN SIGNAL SWITCH (INTL) 1. Disconnect the Turn Signal switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.14 © Copyright Polaris Industries Inc.

  • Page 435: Hazard Switch (Intl)

    2 and 3. • Move switch to NONE / OFF. There should be no con- tinuity between switch pins. HI BEAM BEAM L - TURN TURN HORN 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 436: Brake Light Switch

    This feature has been added to prevent drive-away with the parking brake applied. Testing The Parking Brake Switch 1. Disconnect the harness connector at the parking brake switch (Orange/Red and Red/Blue wires). 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.16 © Copyright Polaris Industries Inc.

  • Page 437: Speed Sensor Location

    1500 RPM in all gears, except neutral. If throttle is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 438: Speed Sensor Testing

    • Remove solenoid from rear differential and ensure the solenoid plunger is actuating. CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.18 © Copyright Polaris Industries Inc.

  • Page 439: All Wheel Drive Coil

    Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before suspecting a component failure. 80% of all electrical issues are caused by bad/failed connections and grounds. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 440: Charging System

    7. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 441: Charging System Stator (Alternator) Tests

    TEST 2: Resistance Value of Each Stator Leg to Ground 2. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.21 © Copyright Polaris Industries Inc.

  • Page 442: Stator (Alternator) Replacement

    Be sure to thoroughly drain the engine coolant and clean the area around the stator cover prior to removal. See chapter 3. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.22 © Copyright Polaris Industries Inc.
  • Page 443 The unit will turn on again after it has cooled down. If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.23 © Copyright Polaris Industries Inc.

  • Page 444: Charging System Testing Flow Chart

    Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.24 © Copyright Polaris Industries Inc.

  • Page 445: Battery

    12.8 V or higher. 2. If the voltage is below 12.6 V, the battery will need to recharged (see Chapter – Charging Procedure, page 11.31). 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 446: Battery Activation

    5. Add electrolyte to bring the level back to the upper level mark on the battery case. 6. Charge battery for 10 - 17 hours at 1 to 1.5 AMPS. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.26 © Copyright Polaris Industries Inc.

  • Page 447: Battery Testing

    OPEN CIRCUIT VOLTAGE load testing. STATE OF CHARGE MAINTENANCE FREE Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris 12.7 V and up 100% batteries. 75% Charged 12.5 V 50% Charged 12.2 V...

  • Page 448: Load Test

    At 14 seconds into the test, check battery voltage. A good 12V battery will have at least 10.5 volts. If the reading is low, charge the battery and retest. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.28 © Copyright Polaris Industries Inc.

  • Page 449: Specific Gravity Test

    Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.29 © Copyright Polaris Industries Inc.
  • Page 450 If the battery is stored or used in a partially charged condition, or with low electrolyte levels, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.30 © Copyright Polaris Industries Inc.

  • Page 451: Charging Procedure

    If electrolyte contacts the vehicle frame, corrosion will occur. 7. Route cables so they are tucked away in front and behind battery. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.31 © Copyright Polaris Industries Inc.

  • Page 452: Lighting System

    Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.32 © Copyright Polaris Industries Inc.

  • Page 453: Headlamp Bulb Replacement

    3. Insert new bulb. Reinstall the wire harness onto the headlamp assembly. NOTE Make sure the tabs on the bulb locate properly in the housing. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.33 © Copyright Polaris Industries Inc.

  • Page 454: Headlamp Housing Installation

    1. Disconnect the wire harness. 2. Remove bulb by turning the rubber base 1/4 turn and pulling the bulb out. Replace it with recommended bulb. Apply Dielectric Grease (PN 2871329). 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.34 © Copyright Polaris Industries Inc.

  • Page 455: Cooling System

    ELECTRICAL COOLING SYSTEM COOLING SYSTEM BREAK-OUT DIAGRAM 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.35 © Copyright Polaris Industries Inc.

  • Page 456: Fan Control Circuit Operation / Testing

    If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.36 © Copyright Polaris Industries Inc.

  • Page 457: Starting System

    Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.37 © Copyright Polaris Industries Inc.

  • Page 458: Starter Motor Removal

    10. Connect the (-) negative battery cable and install the using the upper starter mounting bolt. driver’s side seat. 5. Remove the starter from the engine. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.38 © Copyright Polaris Industries Inc.

  • Page 459: Starter Solenoid Bench Test

    12V power via the Green / White wire. • Once the pull-in coil is energized, the solenoid pro- vides a current path for 12V power to reach the starter motor. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.39 © Copyright Polaris Industries Inc.

  • Page 460: Electrical Testing

    ELECTRICAL ELECTRICAL TESTING Condition: Starter fails to turn over the engine. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.40 © Copyright Polaris Industries Inc.

  • Page 461: Electronic Power Steering

    The 4. Click on Set SAS Zero. system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the vehicle’s diagnostic port.

  • Page 462: Eps Troubleshooting (Power Steering Non-Functional With Mil On)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.42 © Copyright Polaris Industries Inc.

  • Page 463: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.43 © Copyright Polaris Industries Inc.

  • Page 464: Eps Troubleshooting (Using Digital Wrench)

    ELECTRICAL EPS TROUBLESHOOTING (USING DIGITAL WRENCH) 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.44 © Copyright Polaris Industries Inc.

  • Page 465: Fuses / Relays

    FUSE BOX DECAL On EPS units, the headlights are controlled through the headlight switch so no relay is required. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.45 © Copyright Polaris Industries Inc.

  • Page 466: Relays

    WIRE COLOR FUSE BOX FUNCTION High side power to Red / Blue fuel pump Red / Dark Blue Coil power from ECM B+ splice / key switch 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.46 © Copyright Polaris Industries Inc.

  • Page 467: Can System

    60 Ω. A reading of 120 Ω is bad. CAN SYSTEM TESTING A component not displaying information correctly could be the cause of damaged CAN wiring or a faulty component. 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.47 © Copyright Polaris Industries Inc.
  • Page 468 ELECTRICAL NOTES 9926813 R04 - 2013-2016 RZR 570 Service Manual 11.48 © Copyright Polaris Industries Inc.
  • Page 469 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams Click Here for wiring diagrams...
  • Page 471 CV Joint / Boot Brake System, Operation ..........9.4 Replacement (Outer) ..........7.18 Brakes Cylinder Head Front Pad Assembly..........9.18 Combustion Chamber Cleaning.........3.45 General Specifications ..........9.3 Disassembly ............3.42 9926813 R04 - 2013-2016 RZR 570 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 472 Cam Chain and Guide Service ........3.41 Floor (RZR / RZR S) ..........10.11 Cam Shaft Removal..........3.39 Flywheel Installation ..........3.84 Camshaft Bore Inspection ........3.41 Flywheel, Removal ............3.68 9926813 R04 - 2013-2016 RZR 570 Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 473 Replacement............1.4 Parking Brake, Inspection (INT’L) .........9.10 Plunging Joint / Boot Replacement (Inner) ..........7.20 Polaris Mobile Digital Wrench (PMDW) ......4.46 Power Steering Unit, Installation ........8.11 Leakdown Test ............2.13 Power Steering Unit, Removal ........8.9 Lower Steering Shaft, Installation (EPS) ......8.10 Pre-Ride / Daily Inspection ..........2.10...
  • Page 474 Toe Adjustment ............2.29 Steering/Suspension..........8.2 Torque Special Tools, Electrical ..........11.3 Sequence .............. 3.8 Special Tools, Transmission ......... 6.2 Torque Offset Procedure Specification Chart EPS) ..............11.41 9926813 R04 - 2013-2016 RZR 570 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 475 Vehicle Identification Number........1.3 Vent Lines ...............2.20 VIN ................. 1.3 VIN Number .............. 1.2 Voltage Drop Test ............ 11.37 Water Pump Mechanical Seal / Oil Seal........3.22 9926813 R04 - 2013-2016 RZR 570 Service Manual IX.5 © Copyright Polaris Industries Inc.

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