Polaris RZR 570 (2012) - Service Manual - Wiring Diagram - Owners Manual

POLARIS RZR 570 (2012) - REPAIR, SERVICE, WORKSHOP MANUAL - OWNERS

- English Service Manual, Wiring Diagram and Owners Manual to Polaris RZR 570.



CONTENTS:


2012 RANGER RZR 570 / INTL SERVICE MANUAL

- Foreword
- Understanding manual safety labels and directions
- Trademarks

CHAPTER 1 - GENERAL INFORMATION

- MODEL INFORMATION
- Model Identification
- Engine Designation Number
- VIN Identification
- Vehicle and Engine Serial Number Location
- VEHICLE INFORMATION
- Publication Numbers
- Replacement Keys
- SPECIAL TOOLS
- GENERAL SPECIFICATIONS
- MODEL: 2012 RANGER RZR 570
- MODEL: 2012 RANGER RZR 570
- MODEL: 2012 RANGER RZR 570 INTL
- MODEL: 2012 RANGER RZR 570 INTL
- MISC. SPECIFICATIONS AND CHARTS
- Conversion Table
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

CHAPTER 2 - MAINTENANCE

- SPECIAL TOOLS
- PERIODIC MAINTENANCE CHART
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 50 - 500 Hour Maintenance Interval
- Maintenance Quick Reference
- Maintenance Quick Reference
- Grease Lubrication Points
- LUBRICANTS / SERVICE PRODUCTS
- Polaris Lubricants, Maintenance and Service Products
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, and Fasteners
- Shift Cable Inspection / Adjustment
- FUEL SYSTEM AND AIR INTAKE
- Fuel System
- Fuel Line
- Fuel Pump / Fuel Filters
- Vent Lines
- Throttle Pedal Inspection
- Throttle Freeplay Adjustment
- Engine and PVT Intake Pre-Filter Service
- Air Filter Service
- ENGINE
- Engine Oil Level
- Engine Oil and Filter Service
- Engine Breather Hose Inspection
- Engine and Transmission Mounts
- Compression Test Specification
- Valve Clearance Inspection
- Exhaust - Spark Arrestor
- TRANSMISSION AND FRONT GEARCASE
- Specification Chart
- Transmission Lubrication
- Front Gearcase Lubrication
- COOLING SYSTEM
- Cooling System Exploded View
- Cooling System Overview
- Coolant Level Inspection
- Cooling System Pressure Test
- Coolant Strength / Type
- Cooling System
- Coolant Drain / Fill
- FINAL DRIVE / WHEEL AND TIRE
- Wheel and Hub Torque Table
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
- Drive Shaft Boot Inspection
- ELECTRICAL AND IGNITION SYSTEM
- Battery Maintenance
- Battery Removal
- Battery Installation
- Battery Off Season Storage
- Spark Plug Service
- Engine To Frame Ground
- STEERING
- Steering Inspection
- Steering Wheel Freeplay
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
- SUSPENSION
- Spring Preload Adjustment
- BRAKE SYSTEM
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose and Fitting Inspection
- Parking Brake Cable Adjustment (INTL)
- Parking Brake Pad Inspection (INTL)

CHAPTER 3 - ENGINE / COOLING SYSTEM

- GENERAL INFORMATION
- Special Tools
- Engine Lubrication Specifications
- Oil Pressure Test
- Engine Oil Flow Chart
- ENGINE SERVICE SPECIFICATIONS
- Engine Specifications - 1204286 RZR570HO-11
- ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES
- Main Engine Components - Torque Specification and Sequence
- Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
- Cylinder / Oil Filter / Oil Pump / Breather
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
- Spark Plugs / Starter / Throttle Body / Valve Cover
- Piston / Crankshaft / Balance Shaft
- ENGINE COOLING SYSTEM
- Cooling System Exploded View and Coolant Flow Diagram
- Cooling System Specifications
- Cooling System Pressure Test
- Pressure Cap Test
- Radiator
- Coolant Drain / Radiator Removal
- Thermostat Replacement
- Cooling System Bleeding Procedure
- Water Pump Service
- Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
- Water Pump Mechanical Seal / Oil Seal Replacement
- ENGINE SERVICE
- Accessible Engine Components
- Top-End Service (Engine in Chassis)
- Engine Removal
- Engine Installation
- Engine Break-In Period
- Engine Mounting and Torque Values
- Engine Lubrication Specifications
- SETTING TDC (TOP-DEAD-CENTER)
- ENGINE DISASSEMBLY / INSPECTION - top end
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection
- Exhaust Camshaft Decompression Mechanism
- Cam Chain and Guide Service
- Cylinder Head Removal
- Cylinder Head Disassembly
- Cylinder Head Inspection
- Cylinder Head Warp Inspection
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Seat Reconditioning
- Cylinder Removal
- Cylinder Inspection
- Piston Removal
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Ring Installed Gap
- Honing to Oversize
- Cylinder Hone Selection / Honing Procedure
- Cleaning the Cylinder After Honing
- ENGINE ASSEMBLY - TOP END
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Cylinder Installation
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Valve Clearance Check / Adjustment
- Intake Valve Lash - Shim Selection Matrix
- Exhaust Valve Lash - Shim Selection Matrix
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Cover Installation
- ENGINE DISASSEMBLY / INSPECTION - LOWER END
- Crankcase Disassembly
- Flywheel / Stator Housing Removal
- Starter One-Way Clutch Inspection
- Starter One-Way Clutch Installation
- Flywheel Installation
- Stator Removal
- Stator / Stator Cover Installation
- Oil Pump Removal
- Oil Pump Assembly
- Crankcase Breather Service
- Crankcase Separation
- Balance Shaft Removal / Inspection
- Crankshaft Removal
- Crankshaft Inspection
- PTO Side Crankcase Bearing Service
- MAG Side Crankcase Bearing Service
- Oil Pickup Assembly Inspection
- Oil Pressure Regulator (Bypass) Valve Inspection
- Crankcase Inspection
- ENGINE ASSEMBLY - LOWER END
- Crankcase Assembly - PTO Side
- Balance Shaft Installation / Timing
- Final Crankcase Assembly
- TROUBLESHOOTING
- Engine
- Cooling System

CHAPTER 4 - ELECTRONIC FUEL INJECTION

- GENERAL INFORMATION
- Special Tools
- Service Notes
- EFI System Exploded View
- EFI System Component Locations
- FUEL TANK
- Exploded View
- Fuel Lines - Quick Connect
- ELECTRONIC FUEL INJECTION
- Principal Components
- EFI Operation Overview
- Initial Priming / Starting Procedure
- ELECTRONIC CONTROL UNIT (ECU)
- Operation Overview
- ECU Service
- ECU Replacement
- ECU Replacement
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-mAP)
- Operation Overview
- T-MAP Sensor Test
- T-MAP Sensor Replacement
- CRANKSHAFT POSITION SENSOR (CPS)
- Operation Overview
- CPS Test
- CPS Replacement
- FUEL INJECTORS
- Operation Overview
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement
- FUEL PUMP
- Operation Overview
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump Replacement
- Fuel Tank Removal
- Fuel Tank Installation
- IDLE AIR CONTROL (IAC)
- Operation Overview
- IAC Test
- IAC Replacement
- THROTTLE POSITION SENSOR (TPS)
- Operation Overview
- TPS Resistance Tests
- TPS Tester / Regulator
- TPS Replacement
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- Operation Overview
- ECT Sensor Test
- ECT Sensor Replacement
- IGNITION COIL
- Operation Overview
- Ignition Coil Tests
- Ignition Coil and HT Lead Replacement
- EFI DIAGNOSTICS
- Instrument Cluster Trouble Code Display
- EFI Troubleshooting
- DIGITAL WRENCH™ OPERATION
- Digital Wrench™ Diagnostic Software Overview
- Special Tools (also refer to page 4.2)
- Diagnostic Software Version
- ECU Replacement
- Guided Diagnostic Available
- Digital Wrench™ Communication Errors
- Digital Wrench™ - Diagnostic Connector
- Digital Wrench™ Serial Number Location
- Digital Wrench™ Version and Update ID
- Digital Wrench™ Updates
- Digital Wrench™ Feature Map
- Engine Controller Reprogramming (Reflash)
- EFI SYSTEM ELECTRICAL Diagram

CHAPTER 5 - BODY / STEERING / SUSPENSION

- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- SPECIAL TOOLS
- Multi-Function Pliers
- CAB FRAME
- Assembly / Removal
- BODY EXPLODED VIEWS
- Side Safety Nets
- Dash Instruments / Controls / Glovebox
- Hood / Front Body Work
- Front Bumper
- Rear Bumper
- Seat Assembly
- Seat Belts / Mounting
- Floor / Rocker Panels
- Rear Cargo Box / Fenders
- Chassis / Main Frame
- BODY COMPONENT REMOVAL
- Seats
- Rear Service Panel
- Front Bumper
- Rear Bumper
- Hood and Front Body Work
- Rear Fender Flair Removal
- Cargo Box Assembly Removal
- Rocker Panels, Console and Floor
- STEERING ASSEMBLY
- Exploded View
- Steering Wheel Removal
- Steering Shaft Bearing Replacement
- FRONT A-ARMS
- Removal / Replacement
- Exploded View
- BALL JOINT SERVICE
- Removal
- Installation
- FRONT STABILIZER BAR
- Stabilizer Bar Linkage Removal
- Stabilizer Bar Removal
- Exploded View
- REAR A-ARMS
- Removal
- Installation
- Exploded View
- REAR STABILIZER BAR
- Removal / Installation
- SHOCKS / SPRINGS / FASTENERS
- Exploded View
- Shock Removal / Installation
- Shock Replacement
- DECAL REPLACEMENT

CHAPTER 6 - CLUTCHING

- SPECIAL TOOLS AND SUPPLIES
- TORQUE SPECIFICATIONS
- PVT System Fastener Torques
- PVT SYSTEM OVERVIEW
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In (Drive Belt / Clutches)
- Maintenance / Inspection
- Overheating / Diagnosis
- PVT SYSTEM SERVICE
- PVT Covers and Ducting Components
- PVT Disassembly
- PVT Assembly
- DRIVE BELT
- Belt Removal
- Belt Inspection
- Belt Installation
- PVT Break-In (Drive Belt / Clutches)
- CLUTCH CENTER DISTANCE
- Inspection
- Adjustment
- DRIVE CLUTCH SERVICE
- Drive Clutch Exploded View
- Clutch Disassembly
- Drive Clutch Spring Inspection
- Shift Weight Inspection
- Spider Removal
- Roller, Pin, and Thrust Washer Inspection
- Button To Tower Clearance Inspection
- Bearing Inspection
- Clutch Inspection
- Bushing Service
- Clutch Assembly
- DRIVEN CLUTCH SERVICE
- Exploded View
- Clutch Disassembly / Inspection
- Clutch Assembly
- TROUBLESHOOTING

CHAPTER 7 - FINAL DRIVE

- SPECIAL TOOLS
- TORQUE SPECIFICATIONS
- Wheel and Hub Torque Table
- FRONT BEARING CARRIER
- Bearing Carrier Inspection / Removal
- Bearing Replacement
- Bearing Carrier Installation
- FRONT DRIVE SHAFT
- Drive Shaft Removal
- Drive Shaft / CV Joint Handling Tips
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Installation
- PROPSHAFT SERVICE
- Removal / Installation
- PROPSHAFT U-JOINT SERVICE
- Disassembly
- Assembly
- FRONT GEARCASE / CENTRALIZED HILLIARD
- Centralized Hilliard Exploded View
- All Wheel Drive Operation
- AWD Diagnosis
- Gearcase Removal
- Gearcase Disassembly / Inspection
- Gearcase Assembly
- Gearcase Installation
- REAR BEARING CARRIER
- Bearing Carrier Inspection / Removal
- Bearing Replacement
- Bearing Carrier Bushing Replacement
- Bearing Carrier Installation
- REAR DRIVE SHAFT
- Drive Shaft Removal
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Exploded View
- Drive Shaft Installation
- WHEEL HUBS
- Front Hub Exploded View
- Rear Hub Exploded View

CHAPTER 8 - TRANSMISSION

- SPECIAL TOOLS
- SPECIFICATIONS
- Torque Specifications
- Special Tools
- Lubrication
- Transmission Mounting and Torque Values
- SHIFT LEVER
- Removal
- Installation
- SHIFT CABLE
- Inspection
- Adjustment
- TRANSMISSION SERVICE
- Transmission Removal
- Transmission Installation
- Transmission Disassembly
- Gear / Shaft / Bearing Inspection
- Snorkel Gear Backlash Procedure
- Transmission Assembly
- TRANSMISSION SERVICE (intl)
- Differential Operation
- Transmission Disassembly
- Planetary Differential Disassembly
- Planetary Differential Bushing Replacement
- Planetary Differential Assembly
- Gear / Shaft / Bearing Inspection
- Snorkel Gear Backlash Procedure
- Transmission Assembly
- TROUBLESHOOTING
- Troubleshooting Checklist
- TRANSMISSION EXPLODED VIEW
- TRANSMISSION EXPLODED VIEW (intl)

CHAPTER 9 - BRAKES

- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OPERATION
- BRAKE SYSTEM EXPLODED VIEW
- RZR 570
- MASTER CYLINDER
- Removal
- Installation
- BRAKE PEDAL LEVER
- Pedal Removal
- Pedal Installation
- BRAKE BLEEDING / FLUID CHANGE
- PARKING BRAKE (INTL MODEL)
- Exploded View
- Parking Brake Inspection
- Parking Brake Cable Adjustment
- PARKING BRAKE CALIPER SERVICE (INTL MODEL)
- Caliper Exploded View
- Caliper Removal
- Caliper Disassembly / Inspection
- New Brake Pad Installation
- Caliper Installation
- PARKING BRAKE DISC (INTL MODEL)
- Disc Inspection
- Disc Replacement
- FRONT BRAKE PADS
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure
- FRONT CALIPER SERVICE
- Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- FRONT BRAKE DISC
- Disc Runout
- Disc Inspection
- Disc Replacement
- REAR BRAKE PADS
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Brake Burnishing Procedure
- REAR CALIPER SERVICE
- Caliper Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- REAR BRAKE DISC
- Disc Inspection
- Disc Replacement
- TROUBLESHOOTING
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock

CHAPTER 10 - ELECTRICAL

- GENERAL INFORMATION
- Special Tools
- Electrical Service Notes
- Under-Dash Components
- SWITCHES / CONTROLS
- Ignition Key Switch / Headlamp Switch
- Ignition Key Switch (INTL)
- AWD / 2WD Switch
- AWD / 2WD / TURF Switch (INTL)
- Transmission (Gear Position) Switch
- Turn Signal Switch (INTL)
- Hazard Switch (INTL)
- Brake Light Switch
- Parking Brake Switch (INTL Model)
- REAR DIFF SOLENOID (INTL)
- Differential Solenoid Overview
- Differential Solenoid Circuit Operation
- VEHICLE SPEED SENSOR
- Speed Sensor Location
- Speed Sensor Testing
- Instrument Cluster
- Overview
- Rider Information Display
- Information Display Area
- Diagnostic Mode
- Instrument Cluster Pinouts
- Instrument Cluster Removal
- Instrument Cluster Installation
- ALL WHEEL DRIVE COIL
- Operation Overview
- Diagnosing System Failures
- HEAD LIGHTS
- Headlight Adjustment
- Headlamp Bulb Replacement
- Headlamp Housing Removal
- Headlamp Housing Installation
- TAIL / BRAKE LIGHTS
- Bulb Replacement
- COOLING SYSTEM
- Cooling System Break-Out Diagram
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- Coolant Temperature Sensor
- EFI DIAGNOSTICS
- EFI Component Testing
- FUEL SENDER
- Testing
- CHARGING SYSTEM
- Current Draw - Key Off
- Charging System “Break Even” Test
- Charging System Stator (Alternator) Tests
- Stator (Alternator) Replacement
- Regulator / Rectifier
- Charging System Testing Flow Chart
- BATTERY SERVICE
- Battery Specifications
- General Battery Information
- Battery Activation
- Battery Removal / Installation
- Battery Off Season Storage
- Battery Testing
- Battery Conductance Analyzer
- OCV - Open Circuit Voltage Test
- Load Test
- Specific Gravity Test
- Charging Procedure
- STARTING SYSTEM
- Troubleshooting
- Voltage Drop Test
- Starter Motor Removal
- Starter Motor Installation
- Starter Solenoid Bench Test
- Starter Solenoid Operation
- STARTING SYSTEM TESTING FLOW CHART
- Condition: Starter fails to turn over the engine.
- ELECTRICAL SYSTEM BREAKOUTS
- AWD
- Vehicle Speed Sensor
- Cooling Fan
- Charging System
- Chassis Power
- Lights

INDEX

WIRING DIAGRAMS

OWNERS MANUAL (ENGLISH)

OWNERS MANUAL (ITALIAN)