Polaris RANGER 500 2018 Manuals

Polaris RANGER 500 2018 Manuals

Manuals and User Guides for Polaris RANGER 500 2018. We have 2 Polaris RANGER 500 2018 manuals available for free PDF download: Service Manual

Polaris RANGER 500 2018 Service Manual

Polaris RANGER 500 2018 Service Manual (591 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 34.72 MB

Table of Contents

Chapter 1 1 General Information

5
- Table of Contents
  5
- Vehicle Information
  6
- Model Number Designation (2015 +)
  6
- Vehicle Identification Number (Vin) Designation (2015+)
  6
- Vin / Engine Number Location
  7
- Reference Information
  8
- Replacement Keys
  8
- Publication Numbers
  9
- Special Tools
  10
- Master Special Tools Table
  11
- Master Torque Table
  19
- Clutching Chart
  21
- General Specifications
  22
- 2017 Ranger 570 4X4 (Intl.)
  28
- Misc. Specifications and Charts
  34
- Conversion Table
  34
- Sae Tap / Drill Sizes
  36
- Metric Tap / Drill Sizes
  37
- Decimal Equivalents
  38
Chapter 2 Maintenance

41
- Cold Weather Operation
  43
- Periodic Maintenance Chart
  43
- Pre-Ride / Daily Inspection
  43
- Brake System Break-In
  44
- Break-In Period
  44
- Engine and Drivetrain Break-In
  44
- Pvt Break-In (Clutches / Belt)
  44
- Vehicle Break-In Period
  44
- Periodic Maintenance Chart
  45
- Periodic Maintenance Chart Key
  45
- Grease Lubrication Points
  48
- Component Quick Reference
  49
- Storage Tips
  50
- Lubricants / Service Products
  51
- Polaris Lubricants, Maintenance and Service Products
  51
- Compression and Leakdown Test
  52
- Engine
  52
- Engine Oil Level
  52
- Oil and Filter Change
  52
- Breather Hose
  53
- Breather Valve Inspection
  53
- 500 Sohc
  54
- 570 Dohc
  54
- Valve Clearance - Dohc
  54
- Valve Clearance - Sohc
  54
- Coolant Level Inspection
  56
- Cooling System
  56
- Cooling System Overview
  56
- 50/50 Extended-Life Engine Antifreeze
  58
- Coolant Strength / Type
  59
- Cooling System Hoses
  59
- Coolant Drain / Radiator Removal
  60
- Radiator Inspection / Cleaning
  60
- Air Filter Service
  62
- Fuel Lines
  62
- Fuel Pump / Filter
  62
- Fuel System
  62
- Fuel System and Air Intake
  62
- Throttle Pedal Inspection
  62
- Vent Lines
  62
- Engine Air Intake Inspection
  63
- Pvt Air Intake Inspection
  63
- Shift Cable Adjustment
  64
- Shift Cable Inspection
  64
- Transmission and Gearcase
  64
- Transmission Lubrication
  64
- Front Gearcase Lubrication
  65
- CV Shaft Boot Inspection
  67
- Final Drive / Wheel / Tire
  67
- Wheel and Hub Torque Table
  67
- Wheel Removal
  67
- Tire Inspection
  68
- Tire Pressure
  68
- Wheel Installation
  68
- Steering
  69
- Steering Inspection Note
  69
- Tie Rod End / Steering Inspection
  69
- Toe Adjustment
  70
- Wheel Toe Alignment Inspection
  70
- Camber and Caster
  71
- Spring Pre-Load Adjustment
  72
- Stabilizer Bar Pivot Lubrication
  72
- Suspension
  72
- Suspension Inspection
  72
- Suspension Pivot Point Lubrication
  72
- Brake Fluid Inspection
  73
- Brake Hose and Fitting Inspection
  73
- Brake Pad Inspection
  73
- Brake System
  73
- Brake Disc Inspection
  74
- Battery Fluid Level (Conventional Battery)
  75
- Battery Maintenance
  75
- Battery Removal
  75
- Electrical and Ignition System
  75
- 500 Sohc
  76
- Battery Charging
  76
- Battery Installation
  76
- Battery Storage
  76
- Spark Plug Service - 500
  76
- 570 Dohc
  77
- Spark Plug Service - 570
  77
- Main Frame/Engine Ground
  78
Chapter 3 Engine / Cooling System

79
- General Engine Information
  84
- General Information
  84
- Special Tools
  84
- Engine Lubrication Specifications
  85
- Oil Pressure Test
  86
- Engine Oil Flow Chart
  87
- Engine Specifications
  88
- Accessible Engine Components
  90
- Engine Removal
  90
- Engine Service
  90
- Top-End Service (Engine in Chassis)
  90
- Engine Installation
  93
- Engine Break-In Period
  96
- Engine Lubrication Specifications
  96
- Engine Mounting and Torque Values
  97
- Setting Tdc (Top-Dead-Center)
  98
- Cooling System
  100
- Cooling System Assembly View and Coolant Flow Diagram
  100
- Cooling System Pressure Test
  101
- Cooling System Specifications
  101
- Pressure Cap Test
  102
- Radiator
  102
- Coolant Drain / Radiator Removal
  103
- Cooling System Bleeding Procedure
  104
- Thermostat Replacement
  104
- Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
  105
- Water Pump Mechanical Seal / Oil Seal Replacement
  106
- Engine
  112
- Troubleshooting
  112
- Cooling System
  113
- 500Cc Sohc Engine
  114
- Engine Detail, Torques / Sequences
  114
- Engine Specifications
  114
- Engine Torque Sequences
  116
- Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
  122
- Crankcase Sealant Path
  122
- Cylinder / Oil Filter / Oil Pump / Breather
  125
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
  129
- Spark Plugs / Starter / Throttle Body / Valve Cover
  133
- Piston / Crankshaft / Balance Shaft
  137
- Camshaft / Carrier Removal
  143
- Engine / Cooling System
  143
- Engine Disassembly / Inspection - Top End
  143
- Valve Cover Removal
  143
- Camshaft / Camshaft Bore Inspection
  144
- Camshaft Sprocket Inspection
  144
- Cam Chain and Guide Service
  145
- Exhaust Camshaft Decompression Mechanism
  145
- Cylinder Head Disassembly
  146
- Cylinder Head Removal
  146
- Cylinder Head Inspection
  147
- Cylinder Head Warp Inspection
  147
- Valve Inspection
  147
- Combustion Chamber Cleaning
  149
- Valve Seat Reconditioning
  149
- Cylinder Inspection
  151
- Cylinder Removal
  151
- Piston Removal
  152
- Piston / Rod Inspection
  153
- Piston-To-Cylinder Clearance
  153
- Honing to Oversize
  154
- Piston Ring Installed Gap
  154
- Cleaning the Cylinder after Honing
  155
- Cylinder Hone Selection / Honing Procedure
  155
- Engine Assembly - Top End
  156
- Piston Ring Installation
  156
- Cylinder Installation
  157
- Piston / Connecting Rod Assembly
  157
- Cylinder Head Installation
  158
- Valve Clearance Check / Adjustment
  159
- Valve Sealing Test
  159
- Exhaust Valve Lash - Tappet Selection Matrix
  161
- Intake Valve Lash - Tappet Selection Matrix
  161
- Camshaft Installation / Timing
  162
- Camshaft Timing - Quick Reference
  164
- Valve Cover Installation
  165
- Crankcase Disassembly
  166
- Engine Disassembly / Inspection - Lower End
  166
- Flywheel / Stator Housing Removal
  166
- Starter One-Way Clutch Inspection
  166
- Flywheel Installation
  168
- Starter One-Way Clutch Installation
  168
- Stator / Stator Cover Installation
  169
- Stator Removal
  169
- Oil Pump Removal
  170
- Oil Pump Assembly
  172
- Crankcase Breather Valve / Hose
  173
- Crankcase Separation
  174
- Balance Shaft Removal / Inspection
  175
- Crankshaft Removal
  175
- Crankshaft Inspection
  176
- Crankcase Assembly - Pto Side
  178
- Engine Assembly - Lower End
  178
- Balance Shaft Installation / Timing
  179
- Final Crankcase Assembly
  180
- Crankcase Disassembly
  182
- Engine Disassembly / Inspection - Lower End
  182
- Starter One-Way Clutch Inspection
  182
- Stator Cover Removal
  182
- Stator Removal
  184
- Oil Pump Removal
  185
- Crankcase Breather Service
  187
- Oil Pump Assembly
  187
- Crankcase Separation
  188
- Balance Shaft Removal / Inspection
  189
- Crankshaft Inspection
  190
- Crankshaft Removal
  190
- Pto Side Crankcase Bearing Service
  191
- Mag Side Crankcase Bearing Service
  192
- Crankcase Inspection
  193
- Oil Pickup Assembly Inspection
  193
- Oil Pressure Regulator (Bypass) Valve Inspection
  193
- Crankcase Assembly - Pto Side
  194
- Engine Assembly - Lower End
  194
- Balance Shaft Installation / Timing
  196
- Final Crankcase Assembly
  196
- Flywheel Installation
  198
- Starter One-Way Clutch Installation
  198
- Stator / Stator Cover Installation
  200
- 570Cc Dohc Engine
  201
- Engine Detail, Torques / Sequences
  201
- Torque Specifications, Engine
  201
- Torque Sequence
  203
- Crankcase Sealant Path
  206
- Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
  207
- Cylinder / Oil Filter / Oil Pump / Breather
  209
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover - Black Cylinder Head Bolts
  211
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover - Silver Head Bolts
  213
- Spark Plugs / Starter / Throttle Body / Valve Cover
  215
- Piston / Crankshaft / Balance Shaft
  217
- Engine Detail, Torques / Sequences
  221
- Engine Fastener Torque Specifications
  221
- Torque Sequence
  223
- Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
  224
- Cylinder / Oil Filter / Oil Pump / Breather
  225
- Camshafts / Cylinder Head / Flywheel / Stator Cover - Black Head Bolts
  226
- Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts
  227
- Spark Plug / Starter / Throttle Body / Valve Cover
  228
- Piston / Crankshaft / Balance Shaft
  230
- Camshaft / Carrier Removal
  231
- Engine Disassembly / Inspection - Top End
  231
- Valve Cover Removal
  231
- Camshaft Sprocket Inspection
  232
- Camshaft Inspection
  233
- Exhaust Camshaft Decompression Mechanism
  233
- Cam Chain and Guide Service
  234
- Cylinder Head Removal
  234
- Cylinder Head Disassembly
  235
- Cylinder Head Inspection
  236
- Cylinder Head Warp Inspection
  236
- Valve Inspection
  236
- Combustion Chamber Cleaning
  237
- Valve Seat Reconditioning
  238
- Cylinder Inspection
  240
- Cylinder Removal
  240
- Piston Removal
  241
- Piston-To-Cylinder Clearance
  241
- Piston / Rod Inspection
  242
- Honing to Oversize
  243
- Piston Ring Installed Gap
  243
- Cleaning the Cylinder after Honing
  244
- Cylinder Hone Selection / Honing Procedure
  244
- Engine Assembly - Top End
  245
- Piston Ring Installation
  245
- Piston / Connecting Rod Assembly
  246
- Cylinder Head Identification
  247
- Cylinder Installation
  247
- Crankcase Identification
  248
- Cylinder Head Installation - Black Bolts
  249
- Cylinder Head Installation - Silver Bolts
  250
- Valve Clearance Check / Adjustment
  252
- Valve Sealing Test
  252
- Valve Lash - Tappet Selection
  255
- Exhaust Valve Lash - Tappet Selection Matrix
  256
- Camshaft Installation / Timing
  257
- Camshaft Timing - Quick Reference
  260
- Valve Cover Installation
  261
- Crankcase Disassembly
  262
- Engine Disassembly / Inspection - Lower End
  262
- Flywheel / Stator Housing Removal
  262
- Starter One-Way Clutch Inspection
  263
- Flywheel Installation
  264
- Starter One-Way Clutch Installation
  264
- Stator Removal
  265
- Oil Pump Removal
  266
- Stator / Stator Cover Installation
  266
- Oil Pump Assembly
  268
- Crankcase Breather Valve / Hose
  269
- Crankcase Separation
  270
- Balance Shaft Removal / Inspection
  271
- Crankshaft Inspection
  272
- Crankshaft Removal
  272
- Pto Side Crankcase Bearing Service
  273
- Mag Side Crankcase Bearing Service
  275
- Oil Pickup Assembly Inspection
  275
- Crankcase Inspection
  276
- Oil Pressure Regulator (Bypass) Valve Inspection
  276
- Crankcase Assembly - Pto Side
  277
- Engine Assembly - Lower End
  277
- Balance Shaft Installation / Timing
  279
- Final Crankcase Assembly
  279
- Crankcase Disassembly
  281
- Engine Disassembly / Inspection - Lower End
  281
- Starter One-Way Clutch Inspection
  281
- Stator Cover Removal
  281
- Stator Removal
  283
- Oil Pump Removal
  284
- Crankcase Breather Service
  286
- Oil Pump Assembly
  286
- Crankcase Separation
  287
- Balance Shaft Removal / Inspection
  288
- Crankshaft Inspection
  289
- Crankshaft Removal
  289
- Pto Side Crankcase Bearing Service
  290
- Mag Side Crankcase Bearing Service
  291
- Crankcase Inspection
  292
- Oil Pickup Assembly Inspection
  292
- Oil Pressure Regulator (Bypass) Valve Inspection
  292
- Crankcase Assembly - Pto Side
  293
- Engine Assembly - Lower End
  293
- Balance Shaft Installation / Timing
  295
- Final Crankcase Assembly
  295
- Flywheel Installation
  297
- Starter One-Way Clutch Installation
  297
- Stator / Stator Cover Installation
  299
Chapter 4 Fuel System

301
- Efi Operation Overview
  303
- General Information
  303
- Initial Priming / Starting Procedure
  303
- Principal Components
  303
- Special Tools
  304
- Digital Wrench® - Diagnostic Connector
  305
- Fuel Pressure Gauge Adapter - Pa-48838
  305
- Fuel Pressure Gauge Kit - Pu-43506-A
  305
- Digital Wrench® - Download Website
  306
- Digital Wrench® Diagnostic Softwarepu-47063-B
  306
- Digital Wrench® Smartlink Module Kitpu-47471
  306
- Efi Component Locations
  307
- Efi Component Locations - Left View
  307
- Efi Component Locations - Right View
  308
- Fuel Line Routing
  309
- Line / Hose Routing
  309
- Vent Line Termination Fitting
  309
- Air Box / Air Filter Assembly View
  310
- Air Box / Intake System
  310
- Air Box Removal / Installation
  312
- Ecu Overview
  313
- Ecu Service
  313
- Electronic Control Unit (Ecu)
  313
- Rpm Limit
  313
- Ecu Replacement
  314
- Electronic Throttle Body (Etc)
  315
- Etc Learn Procedure
  315
- Etc Overview
  315
- Etc Replacement
  315
- Etc Test
  315
- Operation Overview
  316
- Pedal Position Sensor (Pps)
  316
- Pps Replacement
  316
- Pps Test
  316
- Fuel Tank / Pump / Sendor
  317
- Fuel Tank Assembly View
  317
- Fuel Tank Removal
  317
- Fuel Sender Test
  318
- Fuel Tank Installation
  318
- Fuel Pump Test
  319
- Fuel Pump Replacement
  321
- T-Map Overview
  324
- T-Map Sensor Replacement
  324
- T-Map Sensor Test
  324
- Temperature / Manifold Absolute Pressure (T-Map)
  324
- Cps Overview
  325
- Cps Test
  325
- Crankshaft Position Sensor
  325
- Resistance Test
  325
- Air Gap Test
  326
- Encoder Flywheel / Keyway Inspection
  326
- Cps Replacement
  327
- Coil Pack Connections
  328
- Ignition Coil / Wire Overview
  328
- Ignition Coil / Wire Test
  328
- Ignition Coil Overview
  328
- Spark Plug Wire Connections
  328
- Fuel Injector
  329
- Fuel Injector Overview
  329
- Fuel Injector Replacement
  329
- Fuel Injector Test
  329
- Fuel Injector Troubleshooting
  331
- Ect Overview
  332
- Ect Sensor Test
  332
- Engine Coolant Temperature Sensor (Etc)
  332
- Resistance Vs. Temperature Test
  332
- System Operation Test
  332
- Ect Sensor Replacement
  333
- Efi Diagnosis
  334
- Service Notes - Fuel System
  334
- Trouble Code Display (Dtc)
  335
- Digital Wrench® - Diagnostic Connector
  342
- Digital Wrench® Diagnostic Software Overview
  342
- Digital Wrench® Operation
  342
- Digital Wrench® Version and Update
  343
- Polaris Mobile Digital Wrench (Pmdw)
  343
- Digital Wrench® Updates
  344
- Digital Wrench® Communication Errors
  347
- Guided Diagnostics
  347
- Digital Wrench® Feature Map
  348
- Digital Wrench® Serial Number Location
  348
- Ecu Replacement
  349
- Ecu Reprogramming (Reflash)
  349
- Etc Learn Procedure
  355
- Fuel Starvation / Lean Mixture
  356
- Fuel System Troubleshooting
  356
- Poor Idle
  356
- Rich Mixture
  356
Chapter 5 Pvt System

357
- General Information
  358
- Pvt System Fastener Torques
  358
- Special Tools
  358
- Clutching Chart
  359
- General Operation
  359
- Pvt System Overview
  359
- Drive Clutch Operation
  360
- Driven Clutch Operation
  360
- Maintenance / Inspection
  360
- Pvt Break-In (Drive Belt / Clutches)
  360
- Operating in Low Gear
  361
- Overheating / Diagnosis
  361
- Pvt Sealing, Guard, and Duct Components
  363
- Pvt System Service
  363
- Pvt Disassembly
  364
- Pvt Assembly
  365
- Belt Inspection
  366
- Belt Removal
  366
- Drive Belt
  366
- Belt Installation
  367
- Pvt Break-In (Drive Belt / Clutches)
  367
- Clutch Alignment / Offset / Center Distance
  368
- Inspection
  368
- Adjustment
  369
- Drive Clutch Assembly View
  370
- Drive Clutch Service
  370
- Clutch Disassembly
  371
- Shift Weight Inspection
  372
- Spider Removal
  373
- Bearing Inspection
  374
- Button to Tower Clearance Inspection
  374
- Clutch Inspection
  374
- Bushing Service
  376
- Clutch Assembly
  378
- Assembly View
  380
- Driven Clutch Service
  380
- Clutch Disassembly / Inspection
  381
- Clutch Assembly
  382
- Pvt System Troubleshooting
  383
- Troubleshooting
  383

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Polaris RANGER 500 2018 Service Manual

Polaris RANGER 500 2018 Service Manual (574 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 26.7 MB

Table of Contents

Chapter 1 1 General Information

9
- Table of Contents
  9
- Model Number Designation (2015 +)
  12
- Vehicle Identification Number (Vin) Designation (2015+)
  12
- Vehicle Information
  12
- Vin / Engine Number Location
  12
- Reference Information
  13
  - Replacement Keys
    13
  - Publication Part Numbers
    14
  - Special Tools
    16
  - Master Special Tools Table
    17
  - Master Torque Table
    25
  - Clutching Chart
    27
- General Specifications
  28
  - 2017-2018 Ranger
    28
  - 2017-2018 Ranger 570 4X4 (Intl.)
    32
- Misc. Specifications and Charts
  60
  - Conversion Table
    60
  - Sae Tap / Drill Sizes
    61
  - Metric Tap / Drill Sizes
    62
  - Decimal Equivalents
    63
- General Diagnostics
  65
  - General Diagnostics Information Overview
    65
  - Guided Symptom Diagnostic
    65
  - Guided Symptom References
    66
  - Engine and Drivability Diagnostic Procedures
    67
    
    Engine Cranks but Does Not Start
    70
    
    No Crank no Start or Slow Crank
    72
    
    Over Heating
    73
  - Warning Lights
    74
  - Engine Troubleshooting
    75
  - Cooling Troubleshooting
    77
- Digital Wrench
  78
- Polaris Mobile Digital Wrench® (Pmdw)
  82
- Engine Electrical Diagnostics
  83
- Fluid Inspection
  96
- Fluid Leaks
  96
- Fuel System Diagnostics
  97
  - Fuel System Troubleshooting
    97
- Pvt System Diagnostics
  99
  - Pvt System Troubleshooting
    99
  - Pvt System Overheating / Diagnosis
    101
- Transmission Diagnostics
  102
  - Hard Shifting
    102
  - Transmission Isolation
    102
- Final Drive Diagnostics
  103
  - All Wheel Drive (Awd) Concerns
    103
  - Driveshaft (Half Shaft) Diagnostics
    103
- Brake System Diagnostics
  104
  - Brake Noise Troubleshooting
    104
  - Brake Vibration
    104
  - Caliper Overheats (Brakes Drag)
    105
  - Poor Brake Performance
    105
  - Brakes Lock
    105
- Steering / Suspension Diagnostics
  106
- Electrical Diagnostics
  110
  - Electrical Service Notes
    110
  - Digital Multi-Meter (DMM) Notes
    110
  - Static and Dynamic Testing
    110
- Testing for a Short to Ground
  112
- Testing for a Short to Voltage
  113
- Testing Current Flow (Amperage)
  114
- Testing for Intermittent Conditions
  114
- Current Draw - Key off
  115
- Testing Voltage Drop
  115
Maintenance Chapter 2 Maintenance 2

117
- Maintenance
  119
- Periodic Maintenance Chart
  119
  - Pre-Ride / Daily Inspection
    119
  - Cold Weather Operation
    119
  - Break-In Period
    120
- Brake System Break-In
  120
- Chapter 2
  120
- Engine and Drivetrain Break-In Period
  120
- Pvt Break-In (Clutches / Belt)
  120
- Vehicle Break-In Period
  120
- Periodic Maintenance Chart
  121
- Periodic Maintenance Chart Key
  121
- Grease Lubrication Points
  124
- Component Quick Reference
  125
- Storage Tips
  126
- Lubricants / Service Products
  127
  - Polaris Lubricants, Maintenance and Service Products
    127
- Engine
  128
  - Compression and Leakdown Test
    128
  - Engine Oil Level
    128
  - Oil and Filter Change
    128
  - Breather Hose
    129
  - Breather Valve Inspection
    129
  - 500 Sohc
    130
    
    Valve Clearance - Sohc
    130
  - 570 Dohc
    130
    
    Valve Clearance - Dohc
    130
- Cooling System
  132
  - Cooling System Overview
    132
  - Coolant Level Inspection
    132
  - 50/50 Extended-Life Engine Antifreeze
    134
  - Coolant Strength / Type
    135
  - Cooling System Hoses
    135
  - Radiator Inspection / Cleaning
    136
  - Coolant Drain / Radiator Removal
    136
- Fuel System and Air Intake
  138
  - Fuel System
    138
  - Fuel Lines
    138
  - Fuel Pump / Filter
    138
  - Vent Lines
    138
  - Throttle Pedal Inspection
    138
  - Air Filter Service
    138
  - Engine Air Intake Inspection
    139
- Maintenance
  139
  - Pvt Air Intake Inspection
    139
- Transmission and Gearcase
  140
  - Shift Cable Inspection
    140
  - Shift Cable Adjustment
    140
  - Transmission Lubrication
    140
  - Front Gearcase Lubrication
    141
- Final Drive / Wheel / Tire
  143
  - Wheel and Hub Torque Table
    143
  - CV Shaft Boot Inspection
    143
  - Wheel Removal
    143
  - Wheel Installation
    144
  - Tire Inspection
    144
  - Tire Pressure
    144
- Steering
  145
  - Steering Inspection Note
    145
  - Tie Rod End / Steering Inspection
    145
  - Wheel Toe Alignment Inspection
    146
  - Toe Adjustment
    146
  - Camber and Caster
    147
- Suspension
  148
  - Suspension Inspection
    148
  - Spring Pre-Load Adjustment
    148
  - Stabilizer Bar Pivot Lubrication
    148
  - Suspension Pivot Point Lubrication
    149
  - Shock Analysis
    150
- Brake System
  151
  - Brake Fluid Inspection
    151
  - Brake Hose and Fitting Inspection
    151
  - Brake Pad Inspection
    151
  - Brake Disc Inspection
    152
- Electrical and Ignition System
  153
  - Battery Maintenance
    153
  - Battery Fluid Level (Conventional Battery)
    153
  - Battery Removal
    153
  - Battery Installation
    154
  - Battery Storage
    154
  - Battery Charging
    154
  - 500 Sohc
    154
    
    Spark Plug Service - 500
    154
  - 570 Dohc
    155
    
    Spark Plug Service - 570
    155
  - Main Frame/Engine Ground
    156
Chapter 3 Engine / Cooling System

157
- Engine Lubrication Specifications
  161
- General Engine Information
  161
- Special Tools
  161
- Oil Pressure Test
  162
- Engine Oil Flow Chart
  163
- Engine Specifications
  164
- Engine Service
  166
  - Accessible Engine Components
    166
  - Top-End Service (Engine in Chassis)
    166
  - Engine Removal
    166
  - Engine Installation
    169
  - Engine Break-In Period
    172
  - Engine Lubrication Specifications
    172
  - Engine Mounting and Torque Values
    173
  - Setting Tdc (Top-Dead-Center)
    174
- Cooling System
  176
- Troubleshooting
  187
  - Engine
    187
  - Cooling System
    188
- 500Cc Sohc Engine
  189
  - Engine Detail, Torques / Sequences
    189
    
    Engine Specifications
    189
    
    Engine Torque Sequences
    191
    
    Crankcase Sealant Path
    193
    
    Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
    194
    
    Cylinder / Oil Filter / Oil Pump / Breather
    195
    
    Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
    197
    
    Spark Plugs / Starter / Throttle Body / Valve Cover
    199
    
    Piston / Crankshaft / Balance Shaft
    201
  - Engine Disassembly / Inspection - Top End
    204
  - Valve Cover Removal
    204
  - Camshaft / Carrier Removal
    204
  - Camshaft Sprocket Inspection
    205
  - Exhaust Camshaft Decompression Mechanism
    206
  - Cam Chain and Guide Service
    206
  - Cylinder Head Removal
    207
  - Cylinder Head Disassembly
    207
  - Cylinder Head Inspection
    208
  - Cylinder Head Warp Inspection
    208
  - Valve Inspection
    208
  - Combustion Chamber Cleaning
    210
  - Valve Seat Reconditioning
    210
  - Cylinder Removal
    211
  - Cylinder Inspection
    212
  - Piston Removal
    212
  - Piston-To-Cylinder Clearance
    213
  - Piston / Rod Inspection
    213
  - Piston Ring Installed Gap
    214
- Engine Assembly - Top End
  215
  - Piston Ring Installation
    215
  - Piston / Connecting Rod Assembly
    216
  - Cylinder Installation
    216
  - Cylinder Head Installation
    217
  - Valve Sealing Test
    218
  - Valve Clearance Check / Adjustment
    218
  - Valve Lash - Tappet Selection Matrix
    220
  - Camshaft Installation / Timing
    221
  - Camshaft Timing - Quick Reference
    223
  - Valve Cover Installation
    224
- Engine Disassembly / Inspection - Lower End
  225
  - Crankcase Disassembly
    225
  - Stator Cover Removal
    225
  - Starter One-Way Clutch Inspection
    225
  - Stator Removal
    227
  - Oil Pump Removal
    228
  - Oil Pump Assembly
    230
  - Crankcase Breather Service
    231
  - Crankcase Separation
    231
  - Balance Shaft Removal / Inspection
    232
  - Crankshaft Removal
    233
  - Crankshaft Inspection
    233
  - Pto Side Crankcase Bearing Service
    234
  - Mag Side Crankcase Bearing Service
    235
  - Oil Pickup Assembly Inspection
    236
  - Oil Pressure Regulator (Bypass) Valve Inspection
    236
  - Crankcase Inspection
    236
- Engine Assembly - Lower End
  237
  - Crankcase Assembly - Pto Side
    237
  - Balance Shaft Installation / Timing
    239
  - Final Crankcase Assembly
    239
  - Starter One-Way Clutch Installation
    241
  - Flywheel Installation
    241
  - Stator / Stator Cover Installation
    243
- 570Cc Dohc Engine
  244
  - Engine Detail, Torques / Sequences
    244
    
    Engine Fastener Torque Specifications
    244
    
    Torque Sequence
    246
    
    Crankcase - Timing / Sealing Path
    248
  - Engine Disassembly / Inspection - Top End
    249
    
    Valve Cover Removal
    249
    
    Camshaft / Carrier Removal
    249
    
    Camshaft Sprocket Inspection
    250
    
    Camshaft Inspection
    251
    
    Exhaust Camshaft Decompression Mechanism
    251
    
    Cam Chain and Guide Service
    252
    
    Cylinder Head Removal
    252
    
    Cylinder Head Disassembly
    253
    
    Cylinder Head Inspection
    254
    
    Cylinder Head Warp Inspection
    254
    
    Valve Inspection
    254
    
    Combustion Chamber Cleaning
    255
    
    Valve Seat Reconditioning
    256
    
    Cylinder Removal
    258
    
    Cylinder Inspection
    258
    
    Piston Removal
    259
    
    Piston-To-Cylinder Clearance
    259
    
    Piston / Rod Inspection
    260
    
    Piston Ring Installed Gap
    261
  - Engine Assembly - Top End
    262
    
    Piston Ring Installation
    262
    
    Piston / Connecting Rod Assembly
    263
    
    Cylinder Installation
    264
    
    Cylinder Head Identification
    264
    
    Crankcase Identification
    265
    
    Cylinder Head Installation - Black Bolts
    266
    
    Cylinder Head Installation - Silver Bolts
    267
    
    Valve Sealing Test
    268
    
    Valve Clearance Check / Adjustment
    268
    
    Valve Lash - Tappet Selection
    271
    
    Camshaft Installation / Timing
    272
    
    Camshaft Timing - Quick Reference
    275
    
    Valve Cover Installation
    276
  - Engine Disassembly / Inspection - Lower End
    277
    
    Crankcase Disassembly
    277
    
    Stator Cover Removal
    277
  - Starter One-Way Clutch Inspection
    277
  - Stator Removal
    279
  - Oil Pump Removal
    280
  - Oil Pump Assembly
    282
  - Crankcase Breather Service
    283
  - Crankcase Separation
    283
  - Balance Shaft Removal / Inspection
    284
  - Crankshaft Removal
    285
  - Crankshaft Inspection
    285
  - Pto Side Crankcase Bearing Service
    286
  - Mag Side Crankcase Bearing Service
    287
  - Oil Pickup Assembly Inspection
    288
  - Oil Pressure Regulator (Bypass) Valve Inspection
    288
  - Crankcase Inspection
    288
- Engine Assembly - Lower End
  289
  - Crankcase Assembly - Pto Side
    289
  - Balance Shaft Installation / Timing
    291
  - Final Crankcase Assembly
    291
  - Starter One-Way Clutch Installation
    292
  - Flywheel Installation
    293
  - Stator / Stator Cover Installation
    294
Chapter 4 Engine Electrical

297
- Ecu Overview
  298
- Ecu Service
  298
- Electronic Control Unit (Ecu)
  298
- Rpm Limit
  298
- Ecu Replacement
  299
- Electronic Throttle Body (Etc)
  300
  - Etc Overview
    300
  - Etc Test
    300
  - Etc Replacement
    300
  - Etc Learn Procedure
    300
- Temperature / Manifold Absolute Pressure (T-Map)
  301
  - T-Map Overview
    301
  - T-Map Sensor Test
    301
  - T-Map Sensor Replacement
    301
- Pedal Position Sensor (Pps)
  302
  - Operation Overview
    302
  - Pps Test
    302
  - Pps Replacement
    302
- Crankshaft Position Sensor
  303
  - Cps Overview
    303
  - Cps Test
    303
  - Cps Replacement
    305
- Engine Coolant Temperature Sensor (Etc)
  306
  - Ect Overview
    306
  - Ect Sensor Test
    306
  - Ect Sensor Replacement
    307
Chapter 5 Fuel System

309
- Efi Operation Overview
  311
- Initial Priming / Starting Procedure
  312
- Principal Components
  312
- Special Tools
  313
- Digital Wrench® - Diagnostic Connector
  314
- Digital Wrench® - Download Website
  315
- Digital Wrench® Diagnostic Softwarepu-47063-B
  315
- Digital Wrench® Smartlink Module Kitpu-47471
  315
- Efi Component Locations
  316
  - Efi Component Locations - Left View
    316
  - Efi Component Locations - Right View
    317
- Line / Hose Routing
  318
  - Fuel Line Routing
    318
  - Vent Line Termination Fitting
    319
- Air Box / Intake System
  320
  - Air Box / Air Filter Assembly View
    320
  - Air Box Removal / Installation
    322
- Fuel Tank / Pump / Sending Unit
  323
  - Fuel Tank Assembly View
    323
  - Fuel Tank Removal
    323
  - Fuel Tank Installation
    324
  - Fuel Sender Test
    324
  - Fuel Pump Test
    325
  - Fuel Pump Replacement
    326
- Ignition Coil Overview
  330
  - Ignition Coil / Wire Overview
    330
  - Ignition Coil / Wire Test
    330
- Fuel Injector
  331
  - Fuel Injector Overview
    331
  - Fuel Injector Test
    331
  - Fuel Injector Replacement
    332
  - Fuel Injector Troubleshooting
    333
- Efi Diagnosis
  334
  - Service Notes - Fuel System
    334
  - Trouble Code Display (Dtc)
    335
- Fuel System Troubleshooting
  342
  - Fuel Starvation / Lean Mixture
    342
  - Rich Mixture
    342
Chapter 6 Pvt System

343
- Pvt System Fastener Torques
  344
- Special Tools
  344
- Pvt System Overview
  345
  - Clutching Chart
    345
  - General Operation
    345
  - Drive Clutch Operation
    346
  - Driven Clutch Operation
    346
  - Pvt Break-In (Drive Belt / Clutches)
    346
  - Maintenance / Inspection
    346
  - Overheating / Diagnosis
    347
- Pvt System Service
  348
  - Pvt Sealing, Guard, and Duct Components
    348
  - Pvt Disassembly
    349
  - Pvt Assembly
    350
- Drive Belt
  351
  - Belt Removal
    351
  - Belt Inspection
    351
  - Belt Installation
    352
  - Pvt Break-In (Drive Belt / Clutches)
    352
- Clutch Alignment / Offset / Center Distance
  353
  - Inspection
    353
  - Adjustment
    354
- Drive Clutch Service
  355
  - Drive Clutch Assembly View
    355
  - Clutch Disassembly
    356
  - Shift Weight Inspection
    357
  - Spider Removal
    358
  - Roller, Pin, and Thrust Washer Inspection
    358
  - Button to Tower Clearance Inspection
    359
  - Bearing Inspection
    359
  - Clutch Inspection
    359
  - Bushing Service
    361
  - Clutch Assembly
    364
- Driven Clutch Service
  365
  - Assembly View
    365
  - Clutch Disassembly / Inspection
    366
  - Clutch Assembly
    367
  - Secondary Clutch Adjustment
    367
- Pvt System Troubleshooting
  368
  - Troubleshooting
    368

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