Polaris 2014 Sportsman 570 EF Service Manual
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Polaris 2014 Sportsman 570 EF Service Manual

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Table of Contents

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2014 Polaris Sportsman® 570 EFI
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 August 2013 (PN 9924871 R03)
© Copyright 2013 Polaris Sales 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 2014 Sportsman 570 EF

  • Page 1 Publication Printed August 2013 (PN 9924871 R03) © Copyright 2013 Polaris Sales 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 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.
  • Page 3 GENERAL INFORMATION MAINTENANCE ENGINE FUEL SYSTEM - GENERAL BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 5: Table Of Contents

    ............... . .1.15 DECIMAL EQUIVALENTS 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 6: Vehicle Identification

    WORLD MFG. ID INDIVIDUAL SERIAL NO. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 7: Vehicle And Engine Serial Numbers

    This information can be found on the sticker applied to the top side of the crankcase (1). The vehicle serial number is stamped on the frame on all models (2). 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 8: Transmission I.d. Location

    Transmission I.D. Location The Transmission I. D. number is located on the RH side of the transmission case; visible from the RH side of the vehicle. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 9: Vehicle Information

    Bosch Automotive Service Solutions, by phone at 1-800-328-6657 or on-line at http://polaris. service-solutions.com /. Series # Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 10: Vehicle Specifications

    11 in. (28 cm) Ground Clearance Minimum Turning Radius 65 in. (165 cm) unloaded Dual overhead cam, 4 valve 4 Engine stroke single cylinder Displacement 567 cc 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 11: 2014 Sportsman Forest 570 Efi / Eps

    11 in. (28 cm) Ground Clearance Minimum Turning Radius 65 in. (165 cm) unloaded Dual overhead cam, 4 valve 4 Engine stroke single cylinder Displacement 567 cc 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 12 Dual overhead cam, 4 valve 4 Engine stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 13: 2014 Sportsman Touring 570 Efi

    / 48 in. (122 cm) Instrument Cluster 56 in. (142.2 cm) Wheelbase * Based on EU Directive 76/432/EC 11 in. (28 cm) Ground Clearance 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 14: Clutching Specifications

    Non-EBS: Black (6000–12000) PN 5632408 PN 7043594 PN 7041782 PN 3234356 EBS: Red Non-EBS PN 3234451 PN 5132344 *EBS models require no helix/spring adjustment 1.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 15: Misc. Specifications And Charts

    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 1.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 16: Standard Bolt Torque Specification

    151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 17: Sae Tap / Drill Sizes

    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 1.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 18: Metric Tap / Drill Sizes

    0.3437 11/32 10 x 1.50 0.339 11/32 11 x 1.50 0.375 12 x 1.50 13/32 0.406 13/32 12 x 1.75 13/32 0.406 13/32 1.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 19: Decimal Equivalents

    35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 1.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 20 23 mm = 0.9055″ 57/64 0.9063″ 29/32 59/64 0.9219″ 15/16 0.9375″ 24 mm = 0.9449″ 61/64 0.9531″ 31/32 0.9688″ 25 mm = 0.9843″ 63/64 0.9844″ 1.000″ 1.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 21 ...........2.28 WHEEL, HUB, AND SPINDLE TORQUE TABLE 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 22 ................. .2.37 WHEEL ALIGNMENT 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 23: Special Tools

    MAINTENANCE SPECIAL TOOLS Bosch Automotive Service Solutions- 1-800-328-6657 or http://polaris.service-solutions.com 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 24: Inspection / Maintenance Intervals

    • Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist. • Change both the engine oil and filter after 25 hours or one month. • See “Owner’s Manual” for additional break-in information. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 25 Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked with a ■...

  • Page 26: Periodic Maintenance Chart

    ▶ Engine oil change 1000 (1600) Change the oil and filter 100 H ▶ Oil lines and fasteners 1000 (1600) Inspect for leaks and loose 100 H 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 27 ▶ = Perform these procedures more often for vehicles subjected to severe use. E= Emission Control System Service (California) D = Have an authorized POLARIS dealer perform these services. *Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.

  • Page 28: Vehicle Storage

    Cover the vehicle with a genuine 5. If POLARIS fuel system additive is not used, the fuel POLARIS cover. Do not use plastic or coated materials. tank, fuel lines, and injectors should be completely They do not allow enough ventilation to prevent drained of gasoline.

  • Page 29: Lubricants / Service Products

    POLARIS Battery Tender™ Charger 2859044 NOTE: Each item can be purchased separately at your local Polaris dealer. NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

  • Page 30: Lubrication Components

    25hrs of operation in extreme use conditions (i.e. continuous operation on hilly or mountainous terrain or if ADC ‘on’ is primary mode of AWD operation). (C) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special.

  • Page 31: Fuel System And Air Intake

    • Never drain the system when the engine is hot. Severe burns may result. 2.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 32: Throttle Inspection

    If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure 2.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 33: Air Filter/Pre-Filter Service

    9. Reinstall pre-filter element over main filter. Be sure the element covers entire surface of main filter without folds, creases, or gaps. 4. Loosen clamp (1) and remove air filter assembly. 2.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 34: Air Box Sediment Drain

    NOTE: The sediment drain will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods. 2.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 35: Crankcase Breather Valve / Hose

    Operation of your vehicle without a breather valve can cause engine damage. Always reinstall the breather valve after removing it for service. 6. Install the left side panel 2.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 36: Engine

    NOTE: Rising oil level between checks in cool weather driving, can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil. 2.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 37 1/2 of a turn. 15. Remove dipstick (see “Engine Oils Level”). 16. Add two quarts (1.9 l) of of Polaris Premium 4 Synthetic Oil. 17. Place the transmission in PARK (P).

  • Page 38: Compression Test Specification

    5. Remove the valve cover from the engine. 6. Remove the outer PVT cover and drive belt as shown in chapter 6. 2.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 39 14. Connect the negative (-) battery cable to the battery. 15. Start the engine to ensure proper operation. 16. Reinstall the air box cover, PVT ducting and seats (see Chapter 5). 2.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 40: Exhaust Pipe

    6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved. 7. Stop the engine and allow the arrestor to cool. 8. Reinstall the clean out plugs. 2.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 41: Transmission And Front Gearcase

    Capacity: 33.8 oz. (1000 ml) To Change Lubricant: 6. Check for leaks. 7. Install fill plug. Torque to specification. Transmission Check/Fill Plug: 14 ft-lbs (19 Nm) 2.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 42: Shift Link Rod Maintenance

    The gearcase must be drained and re- filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures. 2.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 43 2. Clean and reinstall drain plug (A) using a new sealing washer (B). Torque to specification. 3. Remove fill plug. Inspect the O-ring. 2.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 44: Cooling System

    1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. 2. Fill reservoir to upper mark with Polaris Premium 60/ 40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

  • Page 45: Cooling System Hoses

    Using a funnel, add coolant until the fluid level is to the top of the filler neck. 6. Reinstall the pressure cap and install the front access cover. 2.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 46: Coolant Strength / Type

    4. Drain the coolant from the radiator by removing the lower coolant hose (1) from the radiator as shown. Properly dispose of the coolant. 5. Allow coolant to completely drain. 2.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 47: Radiator/Grill Screen

    MAX level. 10. Refer to Chapter 3 for the “Cooling System Bleeding Procedure”. Polaris Premium Antifreeze 2871534 - Quart 2871323 - Gallon 2.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 48: Final Drive / Wheel And Tire

    Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. Tire Pressure (Cold) Front Rear 5 (34.5 Kpa) 5 (34.5Kpa) 2.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 49: Tire Inspection

    Check that mm) or less. all cotter pins are in place. Refer to specific fastener torques listed in each chapter. 2.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 50: Brake System

    • Check brake for excessive travel or spongy feel. • Check brake system for fluid leaks. • Check friction pads wear, damage looseness. • Check surface condition of the disc. 2.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 51: Auxiliary Brake Testing

    Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Brake Chapter 9. 2.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 52: Electrical And Ignition System

    1/10 of the battery’s rated amp/ hour capacity (i.e. 12amp hr x .10 = 1.2 amp charging). Do not use the alternator to charge a new battery. 2.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 53: Battery Installation

    5. Lift the battery out of the vehicle. 3. Coat the terminals with dielectric grease or petroleum jelly. 4. Connect and tighten the red positive cable(s) first. 2.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 54: Spark Plug Service

    5. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes. 6. Clean with electrical contact cleaner only. 2.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 55: Engine To Frame Ground

    7 ft-lbs (10 Nm) Apply Anti-seize 11. Install spark plug wire into spark plug / engine. 12. Reinstall the (-) negative battery cable and driver’s seat. 2.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 56: Steering

    • Refer to the Body/Steering Chapter 5 or Final Drive Chapter 7 for service procedures. 2.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 57: Front Suspension

    The center section should always point straight back from the steering post. 2.37 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 58 1/8" to 1/4" (.3 to .6 cm) wider than the measurement at the rear (B) Wheel Toe-Out: (A) - (B) = 1/8” to 1/4" (3 to 6 mm) 2.38 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 59 ............. . .3.43 CAM CHAIN AND GUIDE SERVICE 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 60 ................3.82 CRANKCASE INSPECTION 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 61 ..................3.88 COOLING SYSTEM 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 62: General Information

    Synthetic Engine Oil Oil Pressure Minimum Specification: (using Polaris PS-4 at operating temperature) 10 PSI @ 1200 RPM (Minimum) 40 PSI @ 7000 RPM (Minimum) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 63: Oil Pressure Test

    4. Remove the plug (1) and insert the oil pressure adapter. Oil Gallery Plug: 11 ft-lbs (15 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 64: Engine Oil Flow Chart

    ENGINE Engine Oil Flow Chart 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 65: Engine Service Specifications

    Cylinder - Surface Warp Limit 0.00098" (mating with cylinder head) (0.025 mm) Cylinder 3.8976" ± 0.0003" Cylinder Bore - Standard (99.0 mm ± 0.008 mm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 66 Crankshaft Runout Limit See Service Procedure (PTO and MAG) Listed In This Chapter Bearing Journal O.D. 1.1798” - 1.1802" Balance Shaft (Standard) (29.969 - 29.979 mm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 67: Engine Detail - Torque Values / Sequences / Assembly Notes

    ENGINE ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES Main Engine Components - Torque Specification and Sequence 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 68: Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve

    ENGINE Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve 3.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 69: Cylinder / Oil Filter / Oil Pump / Breather

    ENGINE Cylinder / Oil Filter / Oil Pump / Breather 3.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 70: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover 3.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 71: Spark Plugs / Starter / Throttle Body / Valve Cover

    ENGINE Spark Plugs / Starter / Throttle Body / Valve Cover 3.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 72: Piston / Crankshaft / Balance Shaft

    ENGINE Piston / Crankshaft / Balance Shaft 3.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 73: Engine Cooling System

    Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use. 3.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 74: Cooling System Exploded View And Coolant Flow Diagram

    HOSE, RADIATOR, UPPER SCREW 36 in-lbs ± 10% HOSE, RADIATOR, LOWER SCREW 6 ft-lbs ± 10% CONDUIT, FLEX SCREW CLAMP, SPRINGBAND, GREEN CLAMP, HOSE 3.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 75: Cooling System Pressure Test

    If pressure loss is evident within five minutes, check the filler neck, radiator, hoses, clamps and water pump weep hole for leakage. 3.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 76: Radiator

    Radiator Removal 1. Remove the front bumper. 2. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 3.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 77: Thermostat Replacement

    8. Reverse this procedure for installation. Replace thermostat seal if worn or damaged. Torque thermostat cover bolts to specification. Thermostat Cover Bolts: 7.5 ft-lbs (10 Nm) 3.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 78: Cooling System Bleeding Procedure

    9. Start the engine and allow it to idle until the coolant fan has cycled. 10. Allow engine and cooling system to completely cool down (see CAUTION). 3.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 79 14. Fill the recovery bottle to the MAX line. 15. Reinstall the Left side panel, required PVT ducting and Center panel under the front rack. 3.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 80: Water Pump Service

    11. Inspect the water pump cover and impeller for 5. Remove the center cover under the front rack. damage. Replace as necessary. 3.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 81 Be sure engine coolant does not contaminate the the engine. engine oil during stator cover service. 17. Bring the stator cover assembly to a clean work bench. 3.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 82 19. Extract the mechanical seal (E) and the oil seal (F) from the stator cover. 3.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 83 Be sure bearing is fully seated in cover or severe engine damage may result. 3. Clean and de-grease the water pump drive shaft (H). 3.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 84 (J) until it is fully seated in the cover. 6. Lubricate the new water pump oil seal with clean engine oil. 9. Install a new stator cover gasket onto the engine. 3.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 85 11. Align the water pump drive shaft blade as shown below. 12. Apply a small amount of crankcase sealant to the area indicated below (1). 3.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 86 17. Install the water pump impeller (4). NOTE: The water pump impeller (4) uses reverse (LH) threads. Finger tighten only. 18. Install a new water pump cover gasket. 3.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 87 27. Fill cooling system with recommend coolant and bleed the system of air as outlined in this chapter. 28. Check for leaks. 3.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 88: Engine Service

    • Oil Pump Pickup Assembly Top-End Service (Engine in Chassis) ALL of the top-end engine components can be serviced while the engine is mounted in the chassis. 3.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 89: Engine Removal

    NOTE: Removal of the front cab is not required for touring models. Remove the right passenger footwell on touring models when performing engine removal. 3.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 90 17. Disconnect the ignition coil harness connector and bolt and remove the starter motor from the remove the spark plug wire from the engine. engine. 3.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 91 28. With the help of an assistant rotate the top of the engine forward until the top of the cylinder head is facing the front of the vehicle. 3.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 92: Engine Installation

    Front engine mount: 37 ft-lbs ± 10% (50 Nm ± 10%) Flanged nut: 23 ft-lbs ± 10% (50 Nm ± 10%) 3.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 93 19. Instal the starter motor onto the engine. 20. Install the starter motor and battery cables as outlined in Chapter 10. Starter Motor Fastener: 7 ft-lbs (10 Nm) 3.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 94 Chapter 6. (See CLUTCH ALIGNMENT, page 6.13) 29. Install the PVT inlet/exhaust ducts and the airbox top. 3.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 95: Engine Break-In Period

    5. Perform regular checks on fluid levels, controls and all important bolt torques. 6. Change oil and oil filter after break-in period at 25 hours. 3.37 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 96: Engine Mounting And Torque Values

    SCREW NUT, FLANGE, LOCK 23 ft-lbs ± 10% (50 Nm ± 10%) NUT, FLANGE, LOCK 37 ft-lbs ± 10% (50 Nm ± 10%) 3.38 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 97: Setting Tdc (Top-Dead-Center)

    Camshaft Timing Plate (PU-50563) can be installed into the slots of the camshafts as shown below. This will set TDC of the compression stroke. 3.39 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 98: Engine Disassembly / Inspection - Top End

    6. Remove the spark plug (D). Stuff spark plug hole with a shop towel to prevent anything from falling into combustion chamber further engine disassembly is required). 3.40 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 99 5. Attach a hook or other tool to the camshaft chain to prevent it from dropping down into the engine. 6. Mark the intake (I) and exhaust (J) camshafts to ensure proper assembly. 3.41 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 100: Camshaft Sprocket Inspection

    1. Visually inspect each cam lobe for wear or damage. 3.42 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 101: Exhaust Camshaft Decompression Mechanism

    3. Remove the fastener (3) that secure the lower cam chain guide (4) to the crankcase. 4. Inspect the cam chain guides and replace if excessive wear is evident. 3.43 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 102: Cylinder Head Disassembly

    1. Remove the valve tappet (Item 1) from the cylinder head. 2. Compress the valve spring by hand using valve spring compressor adapter (PV-43513-A). 3.44 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 103: Cylinder Head Inspection

    Cylinder Head Warp Limit: 7. Repeat the previous steps to remove the remaining .0024" (0.06 mm) valves. 8. Clean the combustion chamber and head gasket surface. 3.45 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 104: Valve Inspection

    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. 3.46 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 105: Combustion Chamber Cleaning

    2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to the areas around spark plug and valve seats. 3.47 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 106 * If the seat is too narrow, widen using the 45° cutter and re-check contact point on the valve face and seat width after each cut. 3.48 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 107: Cylinder Removal

    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. 3.49 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 108: Piston Removal

    5. Repeat procedure for second ring. 6. Remove oil control ring top rail first, then bottom rail. 7. Remove oil control ring expander. 3.50 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 109: Piston-To-Cylinder Clearance

    Std.: 0.8665 - 0.8670″ (22.010 - 22.023 mm) Piston Pin Bore: Std.: 0.8662 - 0.8665″ (22.004 - 22.010 mm) Service Limit: 0.8651″ (21.975 mm) 3.51 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 110: Piston Ring Installed Gap

    Std: 0.0098” - 0.0401" (0.25 - 1.02 mm) Limit: 0.0480" (1.22 mm) NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. 3.52 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 111: Honing To Oversize

    NOTE: Do not allow cylinder to heat up during honing. 3.53 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 112: Engine Assembly - Top End

    2. Install lower rail with end gap positioned as shown in illustration 1. 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. 3.54 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 113: Piston / Connecting Rod Assembly

    Warm piston crown with a heat gun if pin cannot be installed by hand, or use a piston pin installation tool. 3.55 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 114: Cylinder Head Installation

    2. Guide cam chain (D) through a new head gasket (E) and install the gasket on the cylinder, locating it on the alignment pins. 3.56 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 115: Valve Sealing Test

    The valve seats should hold fluid with no seepage. 3. Repeat for exhaust valves by pouring fluid into each exhaust port (C). 3.57 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 116: Valve Clearance Check / Adjustment

    4. Carefully install the camshafts into the cylinder head. The camshaft lobes should face out. Camshaft Carrier Bolts: 8 ft-lb (11 Nm) 5. Carefully install the camshaft carrier onto the camshafts. 3.58 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 117 18. Measure and confirm that valve clearance is now within specification for each valve. 19. If valve clearance is not within specification, repeat this procedure. 3.59 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 118 ENGINE 20. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 3.60 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 119: 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 3.61 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 120: 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 3.62 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 121: Camshaft Installation / Timing

    7. Carefully install the camshaft carrier onto the camshafts. 5. Wrap the cam chain around the exhaust cam sprocket and hold the exhaust cam in its current position. 3.63 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 122 12. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 13. If needed, install the camshaft carrier and bolts. 3.64 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 123 8 ft-lb (11 Nm) 17. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 15. Insure the new sealing washer (G) is in place. 3.65 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 124: Camshaft Timing - Quick Reference

    ENGINE Camshaft Timing - Quick Reference 3.66 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 125: Valve Cover Installation

    4. Install a new valve cover seal (B). 5. Install the (3) valve cover shoulder bolts (C) and isolators (D) using a T40 driver. 3.67 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 126: Engine Disassembly / Inspection - Lower End

    Discard the flywheel nut and replace for assembly. NOTE: The flywheel nut has standard rotation (right hand) threads. 3.68 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 127 7. Remove the (3) one-way clutch retaining bolts. 3.69 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 128: Starter One-Way Clutch Installation

    4. Rotate crankshaft so the flywheel key (2) is facing upward. One Way Clutch Retaining Bolts: 9 ft-lbs (12 Nm) Apply Loctite® 272™ 3.70 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 129: Stator Removal

    11. Install starter idler gear and shaft (4). 1. Clean and degrease screws and threads in stator housing. 2. Clean mounting surfaces of stator and housing. 3.71 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 130: Oil Pump Removal

    DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 3.72 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 131 NOTE: The larger oil pump sprocket mounts to that must be installed inward upon assembly the balance shaft extension, the smaller oil pump sprocket mounts to the oil pump shaft. 3.73 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 132: Oil Pump Assembly

    10. Install the oil pump sprockets, chain, washer and new bolts. Oil pump sprockets must be installed in the correct position, with the word “OUT” facing out. 3.74 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 133: Crankcase Breather Valve / Hose

    15. Tighten all bolts evenly until snug. 1. Remove the left side panel 2. Remove the hose clamps from the valve and pull the valve out of the hoses. 3.75 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 134: Crankcase Separation

    2. Remove the oil pan at this time if it has not already been removed. 6. Separate crankcase by tapping with a soft faced hammer in reinforced areas and lift MAG crankcase off PTO case. 3.76 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 135: Balance Shaft Removal / Inspection

    (radial) movement. 3. Inspect drive gear for broken or damaged teeth. 3.77 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 136: Crankshaft Removal

    “C” until the crankcase is Service Limit: 0.08682” (22.053 mm) completely separated from the crankshaft. 6. Remove all special tools from the crankcase. 3.78 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 137: Pto Side Crankcase Bearing Service

    The crankshaft is reusable if it meets specifications and MAG side bearing surface is not groved, pitted, damaged or excessively worn. 3.79 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 138 3. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 4. Install the retaining ring (2) for the crankshaft bearings. 3.80 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 139: Mag Side Crankcase Bearing Service

    3. Lubricate all bearing bores with clean engine oil. 4. Fully seat the new balance shaft bearing until bottomed in the bearing bore. 3.81 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 140: Crankcase Inspection

    2. Be sure alignment pins are in place where used. 3. Be sure oil passages are clean and free of any cleaning solvent. 3.82 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 141: Engine Assembly - Lower End

    “B”. 6. With the help of an assistant, slowly tighten the nut until the crankshaft is completely seated into the crankcase bearings. 3.83 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 142 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. 3.84 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 143: Balance Shaft Installation / Timing

    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. 3.85 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 144 • Sleeve adapter for a 2.375” bore engine stand: • (PW-47054) 10. Place engine onto the engine stand (PU- 50624– A) for top end engine assembly as outlined in this chapter. 3.86 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 145: Troubleshooting

    Engine Idles But Will Not Accelerate Excessive Smoke and Carbon Buildup • Spark plug fouled/weak spark • Excessive piston-to-cylinder clearance • Broken throttle cable 3.87 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 146: Cooling System

    • Lean mixture (vents, fuel pump or fuel valve) • Fuel pump output weak 3.88 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 147 ............... . .4.29 OPERATION OVERVIEW 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 148 ..........4.44 ENGINE CONTROLLER REPROGRAMMING (REFLASH) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 149: General Information

    • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 150: Efi System Exploded View

    FUEL SYSTEM - GENERAL EFI System Exploded View 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 151: Electrical Diagram

    FUEL SYSTEM - GENERAL Electrical Diagram Fuel Injection- 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 152: Efi System Component Locations

    3. Crankshaft Position Sensor (CPS)- Located in the magneto cover on the right-hand side of the Engine. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 153: Special Tools

    Digital Wrench PU-47469 Vehicle Interface Cable Digital Wrench PU-47468 SmartLink Module Bosch Automotive Service Solutions: 1-800-328-6657 or http://polaris.service-solutions.com /. Fuel Pressure Gauge Kit - PU-43506-A 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 154 The Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure once you have completed the fuel pressure test. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 155 SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This 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 http://polaris.spx.com...

  • Page 156: Electronic Fuel Injection

    4-stroke cycle. The total amount of fuel needed for one firing of a cylinder is injected during each 4.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 157: Electronic Control Unit (Ecu)

    TPS to the throttle body is altered, the TPS must be adjusted. For the purpose of troubleshooting, a known-good ECU from another Polaris product of the same model may be used without system or engine component damage. ECU Replacement...
  • Page 158 5. To install, reverse the procedure and tighten any fasteners to specification. NOTE: Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. 4.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 159: Fuel Pump / Sender / Tank / Lines

    In these situations, the “check engine” light will go on, but will turn off after 4 cranking revolutions if system function is OK. Once the engine is running, the fuel pump remains 4.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 160: Fuel Pump Test

    NOTE: If there was no continuity between the pump terminals, replace the fuel pump assembly. 4.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 161: Fuel Pump Replacement

    Excessive debris in fuel tank may cause premature wear of fuel pump and/or clogging of internal fuel filters. 4.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 162 Use care not to bend float arm during un-packaging. Do not lift or carry fuel pump assembly by the float arm. 4.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 163 15. Gently push down on fuel pump flange ensuring flange is centered. 4.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 164 24. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 4.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 165: Fuel Tank Exploded View

    FUEL SYSTEM - GENERAL Fuel Tank Exploded View 4.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 166: Fuel Sender Test

    2. Disconnect the negative battery cable. 3. Disconnect the fuel pump electrical harness(1). Fuel Sender Resistance Specifications: Full: 6 ± 1 Ω Empty: 90 ± 4.5 Ω 4.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 167: Fuel Tank Installation

    Verify the 6. Reinstall the PVT exhaust duct, air box top, front cab, connector tabs snap back into place. side panels and seat. 4.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 168: Temp / Manifold Absolute Pressure Sensor (T-Map)

    4. Remove the retaining bolt and remove the sensor from the intake boot. 5. Use a light coating of soapy water on the grommet to aid installation of the new sensor. 4.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 169: Crankshaft Position Sensor (Cps)

    Follow the “CPS Replacement” procedure to inspect CPS and flywheel encoder ring for damage. 5. If the resistance is incorrect, follow the “CPS Replacement” procedure. 4.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 170: Cps Replacement

    4. Torque the CPS and heat shield retaining bolts (if equipped) to specification. CPS Retaining Bolt: 9 ft-lbs (12 Nm) 5. Re-install the right side footwell and side panel. 4.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 171: 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. 4.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 172: Fuel Injector Test

    O-rings to aid installation. 6. Hold a shop towel over the fuel line fittings and remove the fuel supply line from the fuel rail. 4.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 173 18. Start the engine briefly and inspect the fuel rail and injector for fuel leaks. 19. Reinstall the seat, air box, PVT ducting, right and left side panels. 4.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 174: Idle Air Control (Iac)

    5. Reconnect the vehicle harness to the IAC motor. 6. Reinstall the right side panel, connect the negative (-) battery cable and install the drivers seat. 4.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 175: Throttle Position Sensor (Tps)

    2. Remove the seat, air box and PVT ducting, andright stop screw is repositioned or adjusted, the throttle side panel. body assembly must be replaced. 4.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 176 10. Verify voltage reading did not change. If voltage reading is now out of specification, repeat steps 3 - 11. Reinstall items that were removed to access TPS sensor. 4.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 177: Engine Coolant Temperature Sensor (Ect)

    Refer to Chapter 10 for additional ECT sensor information. Polaris dealers can test the sensor by using the Digital Wrench Diagnostic Software (dealer only). 4.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 178: Ect Sensor Replacement

    6. Torque the sensor to specification. ECT: 17 ft-lbs (23 Nm) 7. Add the required amount of coolant and properly bleed the cooling system. 4.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 179: Ignition Coil

    Terminal and spark plug. Spark Boot Terminal Coil Pack Connections Spark Plug Wire Connections 4.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 180: Efi Diagnostics

    5. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded. 4.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 181 M17; IAC Stepper Pin 1 Driver Circuit Grounded P1508 Idle Air Control Valve (IAC) Driver Circuit Open / Grounded 520268 P1515 M17; IAC Stepper Pin 3 4.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 182 Driver Circuit Open / Grounded P1535 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520270 P1539 M17; IAC Stepper Pin 6 Driver Circuit Grounded P1538 4.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 183: Efi Troubleshooting

    • Air Leaks, dirty injector • TPS damaged or adjusted • Tight valves • Ignition timing incorrect • Belt dragging • Dirty air cleaner 4.37 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 184 FUEL SYSTEM - GENERAL • Engine worn • Spark Plug fouled • Throttle stop screw set incorrectly (out of sync with ECU) 4.38 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 185: Digital Wrench Operation

    ECU is transferred to the replacement ECU. Refer to procedure and carefully follow all instructions provided in Digital Wrench. 4.39 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 186: Digital Wrench Communication Errors

    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. 4.40 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 187: Digital Wrench Version And Update

    2. Locate the “Service and Warranty” drop-down menu. 3. Click on “Digital Wrench Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 4. The Digital Wrench portal website should appear in a new web browser.
  • Page 188 Select "save" and download them to your PC before running the install. NOTE: Versions and updates are subject to change. 4.42 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 189: Digital Wrench Feature Map

    FUEL SYSTEM - GENERAL Digital Wrench Feature Map 4.43 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 190: Engine Controller Reprogramming (Reflash)

    Check all connections, and be sure battery voltage is as specified. 4.44 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 191 The process only takes a few minutes, and is best left alone until complete. 4.45 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 192 4. Select the model year, product line and vehicle 5. Select the “Special Tests” icon. description by selecting the “Change Vehicle Type” icon. 6. Select “Engine Controller Reprogramming”. 4.46 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 193 10. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop- down menu. 11. Enter or paste (CTRL+V) the Request Code into the box. 4.47 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 194 Digital Wrench screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete the reprogramming procedure. 4.48 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 195 ................5.40 DECAL REPLACEMENT 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 196: General Information

    Compression Tool 2871572 Strut Rod Wrench LH Strut Spring Compressor 2871573 RH Strut Spring Compressor 2871574 Bosch Automotive Service Solutions: 1-800-328-6657 or online at http://polaris.service-solutions.com 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 197: Body

    / front rack. 5. Remove the (2) T-27 screws that attach the front storage box lid / front rack to the front bumper. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 198: Footwell Removal / Installation

    4. Reverse the removal procedures to install the foot well. Be sure to properly align the fender ends into the foot wells upon reassembly. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 199: Front Bumper Removal / Installation

    7. Remove the front bumper by gently the pulling the lower portion of the bumper away from the vehicle frame and sliding it down. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 200: Front Fender Removal / Installation

    9. Reverse the removal steps for installation. Torque (6) front fender-to-frame screws to specification. Fender to Frame Screws 24 in-lbs (2.7 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 201: Mud Guard Removal / Installation

    6. Torque the T27 fasteners to specification. 3. Remove the (1) T27 bolt and the (3) plastic rivets per side. T27 Fasteners: 4-6 ft-lbs (6-8 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 202: Front Rack / Storage Box Lid Assembly

    BODY / STEERING / SUSPENSION Front Rack / Storage Box Lid Assembly 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 203: Front Bumper Assembly

    BODY / STEERING / SUSPENSION Front Bumper Assembly 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 204: Front Cab Assembly

    BODY / STEERING / SUSPENSION Front Cab Assembly 5.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 205 GUARD, SPLASH, RH SCREW GUARD, SPLASH, LH RIVET WASHER, FLAT SEAL, BULB PLUG, COMPARTMENT SCREW WASHER, FLAT BRACKET, PLUG MOUNT BOLT, CARRIAGE NUT, FLANGED, NYLOK 5.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 206: Rear Rack Assembly

    BODY / STEERING / SUSPENSION Rear Rack Assembly 5.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 207 BODY / STEERING / SUSPENSION PART DESCRIPTION NOTES ASM., RACK, REAR TUBE, SUPPORT, FRONT TUBE, SUPPORT, REAR CLIP, U SPEED NUT SCREW NUT, FLANGE, NYLOK 5.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 208 BODY / STEERING / SUSPENSION Touring Rear Rack and Hand Grips 5.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 209 CLIP, U SPEED NUT SCREW Torque fastener until fully seated. NUT, FLANGE, NYLOK ASM., HAND GRIP, PASSENGER, LH ASM., HAND GRIP, PASSENGER, RH 5.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 210: Rear Cab, Seat, And Footwell Assembly

    BODY / STEERING / SUSPENSION Rear Cab, Seat, And Footwell Assembly 5.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 211 RIVET FOOTWELL, BLACK, LH FOOTWELL, BLACK, RH SCREW NUT, NYLOK BUMPER, RUBBER ASM., CAB, REAR BUMPER, SEAT GROMMET, SEAT LATCH SCREW NUT, U-TYPE 5.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 212 BODY / STEERING / SUSPENSION Touring Seat 5.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 213 SUPPORT, SEAT BACK, BLACK ASM., PASSENGER SEAT BACK ASM., PASSENGER SEAT BACK COVER PLATE, SEAT BACK, SUPPORT BUMPER, RUBBER SCREW SCREW NUT, FLANGED, NYLOK 5.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 214 BODY / STEERING / SUSPENSION Touring Rear Cab and Footwells 5.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 215 SCREW Torque until full seated. NUT, NYLOK Torque until full seated. RIVET FOOTWELL, PASSENGER, LH FOOTWELL, PASSENGER, RH BUSHING SCREW SCREW NUT, U-TYPE 5.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 216: Rear Storage Box Assembly

    BODY / STEERING / SUSPENSION Rear Storage Box Assembly 5.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 217: Winch And Front Bumper Mounting

    BODY / STEERING / SUSPENSION Winch and Front Bumper Mounting 5.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 218: Headlight Pod Exploded View

    • Remove headlight (F) with adjuster • To adjust headlight, refer to procedure outlined in • Remove two screws securing bottom half of pod Chapter 2 Assembly 5.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 219: Steering Post And Lock (Intl.)

    International units are equipped with a steering locking mechanism to prevent theft or unauthorized use. Refer to the standard torque specifications chart in Chapter 1 whenever servicing the steering lock components. STEERING 5.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 220: Handlebar Block Installation Procedure

    5. Remove the steering tie rod ends from the steering bracket. Note the orientation of the fasteners and bracket on the steering assembly. 5.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 221: Eps Unit Removal (Eps Models)

    6. Remove the fasteners retaining the upper steering post bushing bracket. 7. Lift the upper steering post up from the power steering unit. 5.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 222 5. Install the (4) mount plate fasteners by hand, but do EPS unit and cause not torque fasteners at this time. a Power Steering Fault. 5.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 223 (2) fasteners to specification. 15. Install the front cover and front rack or storage box. Steering Post to Bulkhead Bolts: 20 ft-lbs (27 Nm) 5.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 224: Steering Exploded View (Eps Models)

    BODY / STEERING / SUSPENSION Steering Exploded View (EPS Models) 5.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 225 BOOT, SEAL, ROD END BOOT, SEAL, ROD END ROD, END ROD, END NUT, LH, JAM SCREW BOLT PIN, COTTER NUT, NYLOK NUT, FLANGE, NYLOK WASHER, FLAT 5.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 226 BODY / STEERING / SUSPENSION 5.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 227: Suspension

    The steering post arm bolt (B) points up; the rod end bolts (A) point down. Verify inner rod ends are placed between the steering post arms. 5.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 228: A-Arm Replacement

    Serious injury or death could result if fasteners come Serious injury may result if machine tips or falls. Be loose during operation. sure machine is secure before beginning this service procedure. 5.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 229 11. Apply heat to ease removal. Castle Nut: 30 ft-lbs (41 Nm) 21. Reinstall cotter pin with open ends toward rear of machine. 5.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 230: Torsion Bar Exploded View

    BUSHING, STABILIZER TUBE, BLACK BAR, STABILIZER TUBE, BLACK ARM, STABILIZER BAR, BLACK SCREW 30 ft-lbs (40 Nm) SUPPORT, STABILIZER, BLACK BUSHING, STABILIZER ROD, LINKAGE, STABILIZER 5.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 231: Strut Assembly

    BODY / STEERING / SUSPENSION Strut Assembly 5.37 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 232 BODY / STEERING / SUSPENSION Sportsman Rear Suspension Assembly 5.38 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 233: Front Strut Cartridge Replacement

    10. Torque strut rod nut to specification. Do not over torque the nut. Strut Rod Nut: 15 ft-lbs (21 Nm) 5.39 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 234: Decal Replacement

    Do not hold the torch too close to the surface. Keep the torch moving to prevent damage. 2. Apply the decal. 5.40 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 235 ............6.29 CLUTCH DISASSEMBLY / INSPECTION 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 236 TROUBLESHOOTING ..................6.46 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual...

  • Page 237: General Information

    PA-49011–A 2871710 Center Distance Tool PART NUMBER SPECIAL SUPPLIES Loctite™ 648 8560054 RTV Silicone Sealer Bosch Automotive Service Solutions- 1-800-328-6657 or online at http://polaris.service-solutions.com/ 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 238: Pvt System Overview

    During the development of a toward the outer diameter of the drive clutch sheaves Polaris ATV, the PVT system is matched first to the and downward into the sheaves of the driven clutch. This engine power curve; then to average riding conditions action, which increases the driven clutch speed, is called vehicle’s...

  • Page 239: Maintenance / Inspection

    Chapter 3 “Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break- in period. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 240: Overheating / Diagnosis

    PVT system. 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift transmission to Low during loading of the vehicle to prevent belt Clutch malfunction.

  • Page 241: Pvt Exploded Views

    CLUTCHING PVT EXPLODED VIEWS Drive Clutch Exploded Views (EBS vs. Non-EBS) NON EBS Clutch EBS Clutch 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 242: Pvt Sealing And Ducting Components

    CLUTCHING PVT Sealing And Ducting Components 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 243 Torque to 4 ft-lbs ± 10 % Inlet Duct Boot Replace if cracked or damaged. Clutch Cover Outlet Duct Lower Clutch Air Inlet Duct Upper Clutch Air Inlet Duct 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 244: Pvt System Service

    9. Remove inner cover retaining bolts and Panduit® strap. 10. Remove cover along with foam seal on back of cover or shaft. 6.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 245: Assembly

    Outer Cover Bolt: 4 ft-lbs (5.4 Nm) Driven Clutch Retaining Bolt: 13 ft-lbs (17 Nm) Drive Clutch Retaining Bolt: 47 ft-lbs (64 Nm) 6.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 246: Drive Belt

    Compare acceleration and high speed operation during the break- belt measurements with a new drive belt. Replace if in period. necessary. 6.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 247: Clutch Alignment

    .020” between the tool and stationary sheave of the drive clutch. 6.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 248: Belt Deflection (Tension) (Non Ebs Only)

    6.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 249: Drive Clutch Service

    CLUTCHING DRIVE CLUTCH SERVICE Drive Clutch Exploded View (All Models) 6.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 250: Clutch Disassembly

    Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 251: Shift Weight Inspection

    NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 6.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 252: Spider Removal

    Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 253: Button To Tower Clearance Inspection

    (when viewed from cover plate side) with only a slight amount of drag. When rotated counter-clockwise the one-way bearing should lock to the shaft without slipping. 6.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 254 Measure the thickness and compare to specification. Replace if worn or damaged. VESPEL® Washer Thickness Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 6.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 255: Bushing Service

    3. Remove nut from puller rod and set aside. Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 4. Install puller adapter (Item 10 from kit PN 2871226). 6.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 256 29. Remove nut from puller rod and set aside. 30. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 6.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 257: Clutch Assembly

    There should be one fiber washer on each side of the bearing. 6. Reinstall clutch spring. 7. Reinstall cover, aligning “X” mark with other marks. 6.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 258 CLUTCHING 8. Torque cover bolts evenly to specification. Cover Screw: 100 in-lbs (12 Nm) 6.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 259: Drive Clutch Bushing Service (Non Ebs And Ebs)

    3. Remove nut from puller rod and set aside. 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter Bosch Automotive Service Solutions: 1-800-328-6657 or http://polaris.service-solutions.com 6.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 260 11. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. 22. Remove installation tool. Drive Clutch Bushing Installation Cover Bushing Removal 6.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 261 29. Remove nut from puller rod and set aside. 30. Remove bushing and bushing removal tool from puller. Discard bushing. 6.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 262: Driven Clutch Service (Non Ebs)

    CLUTCHING DRIVEN CLUTCH SERVICE (NON EBS) Exploded View 6.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 263: Clutch Disassembly / Inspection

    5. Check alignment of tabs on spring. Replace the spring if tabs are misaligned or the spring coils are distorted. 6.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 264: Bushing Service

    1. Install Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386). 6.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 265 9. Remove nut from puller rod and set aside. 10. Remove adapters from puller. 11. Remove bushing and removal tool from adapters. Discard bushing. 6.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 266: Moveable Sheave - Bushing Installation

    9. Install new ramp buttons into the sheave. Apply thread locking agent to the fasteners. Install fasteners and tighten securely. 6.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 267: Clutch Assembly

    The least amount of tension will create a slower downshift and a harder upshift. 6.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 268 Compressor Tool PU-50518. Press down on the top of the spider assembly, pushing the spider onto the shaft. Install snap ring and slowly release the assembly. 6.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 269: Driven Clutch Service (Ebs)

    CLUTCHING DRIVEN CLUTCH SERVICE (EBS) Exploded View 6.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 270: Clutch Disassembly

    This will aid in assembly and maintains clutch balance. 3. Remove the four screws that secure the cam (helix) assembly using a T25 Torx driver. 6.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 271 8. Remove the E-clips (F), washers (G), and the clutch rollers (H). Inspect the rollers for wear; replace if worn. 9. Remove the clutch assembly from the holding tool. 6.37 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 272 14. Inspect the cam (helix) assembly bushing for wear. If the bushing is worn or the shaft does not fit snug into the bushing, replace the cam (helix) assembly. 6.38 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 273: Bushing Service

    Turn puller barrel for further tension if needed. 7. Turn clutch sheave counterclockwise until bushing is removed and sheave comes free. 6.39 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 274 Continue until bushing is seated. 18. Remove nut (C) from puller rod and set aside. 19. Remove installation tool and clutch sheave from puller. 6.40 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 275: Clutch Assembly

    NOTE: Press only on the outer race of the bearing during installation to prevent damaging the bearing. 4. Install the roller (A) onto the roller pin (B) on both sides. 6.41 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 276 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 6.42 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 277 Once the spider passes the retaining ring notch on the shaft, install the retaining ring. Helix Retaining Screws: 42-52 in. lbs. (4.75 - 5.88 Nm) 6.43 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 278: Driven Clutch Bushing Service

    Cover Bushing 5020631 Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter Bosch Automotive Service Solutions- 1-800-328-6657 or http://polaris.service-solutions.com 6.44 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 279 Continue until bushing is seated. 18. Remove nut (C) from puller rod and set aside. 19. Remove installation tool and clutch sheave from puller. 6.45 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 280: Troubleshooting

    -Dragging brake -Vehicle operated with park brake on. Inspect spots brake system. -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 6.46 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 281 -Replace belt. Refer to belt burnt troubleshooting Engagement -Thin spots on belt, worn belt and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.47 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 282 CLUTCHING NOTES 6.48 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 283 ..................7.36 ASSEMBLY 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 284: General Information

    Roller Pin Removal Tool CV Boot Clamp Pliers 8700226 or PU-48951 ADC Gearcase Piston PA-48542 Installation Tool Bosch Automotive Service Solutions: 1-800-328-6657 or polaris.service-solutions.com 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 285: Front Hub

    The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 286: Front Gearcase Removal And Installiation

    Replace the circlips on the CV shaft ends prior to reassembly. 5. Pull the hub and strut assembly out and pull the drive-shaft out of the gearcase. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 287: Gearcase Installation

    3. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 288: Front Gearcase (Non-Adc)

    FINAL DRIVE FRONT GEARCASE (NON-ADC) Exploded view 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 289 Bearing Spring Retainer (non serviceable, see parts book) Torsion Spring Thrust Button Asm. Fill Plug: Retaining Ring TORQUE 8-30 ft-lbs (11-40 Nm) Vent Tube 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 290: Operation

    The front drive will remain engaged until the 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 291 6. Remove the torsion spring retainer and torsion Replace component if found to be worn or damaged spring from the top of the ring gear. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 292 11. Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches. Inspect the H-springs, but do not remove them from the roll cage. 7.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 293 ASSEMBLY” procedure later in this chapter for details on backlash setting. 14. Remove the bolts retaining the input shaft cover and pinion gear assembly. 7.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 294: Reassembly / Inspection

    The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side. 7.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 295 Insert the rollers as the roll cage is installed. spring. 8. Install the ring gear and roll cage assembly into the gearcase housing. 7.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 296 Output Cover Bolts: 7-11 ft-lbs 15. Lay the gearcase on the side with the output cover facing up. 7.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 297: Troubleshooting, Front Gearcase (Non-Adc)

    Brown/White wires that feed the hub coil wires. There should be a minimum of 11.80-12.0 Volts present for proper operation. AWD Coil Applied Battery Voltage: 11.80-12.0 Vdc 7.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 298: Setting Ring Gear Backlash Non Adc

    4 times (1 revolution of ring gear). 6. The gearcase may be filled with the recommended amount of lubricant once gearlash procedure is complete. 7.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 299: Front Drive (Cv) Shaft

    Serious injury could occur if machine tips or falls. 6. Remove wheel. 9. Remove cotter pin and nut from lower A-arm ball joint. 7.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 300 11. Pull strut assembly out while pivoting the CV drive shaft away until it clears the strut assembly. 7.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 301 Brake Caliper Fastener: 18 ft-lbs (24 Nm) 6. Install wheel and tight wheel nuts to specification. Refer to the beginning of this chapter. 7.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 302 7. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire. 10. Remove upper control arm bolt as shown. 7.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 303 4. Inspect bearing housing for wear or damage. Replace housing if damaged. 7.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 304: Assembly

    1. Insert bearing carrier on drive shaft. 2. Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing corner housing. 7.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 305 Apply anti-seize to the splines. 6. Install cone washers with domed side facing outward. 7. Install retainer nut, wheel and wheel nuts. 7.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 306: Rear Drive (Cv) Shaft

    4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to specification. Upper Hub Carrier Bolt: 37 ft-lbs (50 Nm) 7.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 307 Aluminum Wheels 30 ft-lbs + 1/4 turn (41 Nm + 1/4 turn) 8. Grease all fittings thoroughly with Premium U-Joint Lubricant (PN 2871551). 7.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 308: Cv Drive Shaft Service

    FINAL DRIVE CV DRIVE SHAFT SERVICE Drive Shafts and Propshafts Components NOTE: Refer to your parts manual for the proper replacement parts. 7.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 309: Drive Shaft And Cv Joint Handling Tips

    4. Place the drive shaft in a soft-jawed vise. WAS CLEANED, add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit. 7.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 310 12. Install a NEW circlip on the end of the shaft. 7.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 311 17. Remove excess grease from the CV joint's external surfaces and place the excess grease in the boot. Axle Boot Clamp Tool 8700226 or PU-48951 7.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 312: Inner Plunging Joint / Boot Replacement

    6. Make sure the circlip is still on the shaft and not left in the joint. 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 7.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 313 17. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft. 7.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 314 7.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 315: Drive Shaft Exploded Views

    FINAL DRIVE Drive Shaft Exploded Views 7.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 316: Prop Shaft - Front Or Rear

    NOTE: If removing rear propshaft, loosening and/or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal. 7.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 317: U-Joint Service

    2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 7.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 318: Assembly

    If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 7.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 319 SPORTSMAN TRANSMISSION EXPLODED VIEW ...........8.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual...

  • Page 320: Transmission - General

    Bearing Seal Driver (50 mm) 2871282 Bosch Automotive Service Solutions: 1-800-328-6657 or http://polaris.service-solutions.com Lubrication Refer to Chapter 2 for transmission lubricant type and capacity. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 321: Transmission Frame Mounts

    2 - Side Fasteners: 37 ± 10 ft-lbs (50 ± 13 Nm) 3 - Frame Long Bolt: 20 ± 10 ft-lbs (27 ± 13 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 322: Transmission Upper Frame Mount

    1 - Upper Bracket-to-Frame Fasteners: 37 ± 10 ft-lbs (50 ± 13 Nm) 1 - Bracket-to-Transmission Bolt: 37 ± 10 ft-lbs (50 ± 13 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 323: Transmission Rear Stabilizer Mounts

    1 - Stabilizer-to-Frame Fasteners: 20 ft-lbs (27 Nm) 2 - Stabilizer-to-Transmission Bolt: 37 ft-lbs (50 Nm) 3 - Stabilizer-to-Transmission Fasteners: 37 ft-lbs (50 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 324: Transmission Control Arm Bracket Mounts

    TRANSMISSION Transmission Control Arm Bracket Mounts Bracket Fasteners: 37 ft-lbs (50 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 325: Shift Linkage Inspection

    SCREW KNOB, GEAR SELECTOR BUSHING, SNAP LINKAGE WASHER, THRUST ROD, SHIFTER HANDLE, SHIFT, BLACK NUT, NYLOK BOLT MOUNT, GEAR SELECTOR HOSE, SLIT CABLE TIE 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 326: Gear Selector Removal

    • Left/Right Foot Wells Transmission Installation 1. Apply Polaris Premium All Season Grease (PN 2871423) to splines of front output shaft ,install new O–ring in prop shaft. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 327: Troubleshooting Checklist

    Rear Wheel Nut: Refer to Chapter 2 14. With the ATV on level ground, add Polaris AGL Plus Gearcase Lubricant to the proper level. See Chapter proper fill procedures Torque Specifications. Polaris AGL Gearcase Lubricant (PN 2878068) (12 oz.)

  • Page 328: Transmission Disassembly / Assembly

    NOTE: Removal can be aided by using your thumbs to press down on the shafts while pulling up the cover with your fingers. 8.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 329 12. Note location of chain tensioner cam (N). If fully extended, chain is worn beyond service limit and should be replaced along with the chain tensioner shoe. 8.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 330 17. Remove the shift drum (V) from the gearcase by moving the drum up and to the right to clear the shift shaft. 8.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 331 (see Figure 8-2). 28. Remove the retaining ring, washer, 38T sprocket and needle bearing from the reverse shaft (see Figure 8- 8.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 332 Snorkel Shaft Removal / Disassembly 30. Using a T27 Torx driver, remove the snorkel tube locking screw located inside the gearcase. 8.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 333 35. Remove the snap ring and shim retaining the bearing in the snorkel tube. 38. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 8.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 334: Snorkel / Output Gear Backlash Procedure

    5. Install the output gear assembly. Be sure to properly mesh the snorkel shaft bevel gear with the output bevel gear. 8.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 335 8. Look down into the gearcase at the snorkel locking screw hole opening to reference your starting point. 8.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 336: Transmission Assembly

    8-12 ft-lbs (11-16 Nm) 13. With the snorkel shaft assembly properly installed, remove the (4) Torx screws and remove the output shaft assembly. 8.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 337 Replace the chain if the measurement is longer than the service limit. Silent Chain Service Limit (8 pitch): 3.090” (7.849 cm) 8.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 338 • The differential gear bearing may be lightly tapped into place. The output seal can be installed once the assembly is in place. Output Gear Retaining Screws: 8-12 ft-lbs (11-16 Nm) 8.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 339 Gearcase Cover Bolts: • Place the spring over the front pin and hook 25-30 ft-lbs (34-41 Nm) the spring leg under the cam. 8.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 340 Install the shift shaft assembly and sector gear (11T) into the bushing pocket on the left side. Align the timing marks on the gears as shown. 8.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 341 Install the sector cover and torque the bolts to specification. Sector Cover Bolts: 8-12 ft-lbs (11-16 Nm) 8.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 342 NOTE: Image is for reference only. 21. Install the transmission gear selector switch and secure the switch with the retaining ring. 8.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 343: Sportsman Transmission Exploded View

    TRANSMISSION SPORTSMAN TRANSMISSION EXPLODED VIEW 8.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 344 Shim Ball Bearing Needle Bearing Input Shaft Speed Sensor O-Ring Chain Output Shaft Shift Fork Compression Spring Lockout Disc Magnetic Plug Shift Rail 8.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 345 REAR MASTER CYLINDER................9.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual...
  • Page 346 ..................9.36 BRAKES LOCK 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 347: General Information

    .180-.195” / 4.57-4.95 mm .170” / 4.318 mm Brake Disc Thickness Variance – .002” / .051 mm Between Measurements – Brake Disc Runout .010” / .254 mm 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 348: Special Tools

    BRAKES Special Tools PN 2870975 Mity Vac® Bosch Automotive Service Solutions: 1-800-328-6657 or online at http://polaris.service-solutions.com 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 349: Hydraulic Brake System

    Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder piston assembly. The port is open when the 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 350: Brake Controls Overview

    Wrong pad for conditions harder pad (if available) drop, which can lead to brake fade and the possible loss of control. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 351: Brake Bleeding / Fluid Change

    9. Tighten bleeder screw securely and remove bleeder hose. Torque the bleeder screw to specification. Bleeder Screw: 25-30 in-lbs (2.80-3.40 Nm) 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 352 16. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found. 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 353: Brake System Exploded Views

    BRAKES BRAKE SYSTEM EXPLODED VIEWS Bake System Components 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 354 BRAKES Bake System Components (Forest and Intl. Models) 9.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 355: Brake Caliper Exploded Views

    BRAKES BRAKE CALIPER EXPLODED VIEWS Front Caliper Assembly (All Models) 9.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 356 BRAKES Rear Caliper Assembly (All Non Touring Models) 9.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 357 BRAKES Rear Caliper Assembly (non INTL.) 9.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 358: Front Master Cylinder (All Models)

    4. Follow proper bleeding procedures. Check all connections for leaks and repair if necessary. 9.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 359: Front Brakes

    Remove excess fluid from reservoir as required. 6. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 4. Remove caliper from mounting bracket. 9.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 360: Assembly

    If pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. Front Brake Pad Thickness Service Limit: .180” / 4.6 mm 9.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 361: Brake Burnishing Procedure

    NOTE: Front Wheel Nut Torque: Refer to Chapter 9.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 362: Front Brake Disc

    .010” / .254 mm Brake Disc Thickness: Service Limit: .140” / 3.556 mm Brake Disc Thickness Variance Service Limit: .002” (.051 mm) between measurements. 9.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 363: Removal / Replacement

    Rear - 27 ft-lbs (37 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 364: Front Caliper

    NOTE: Be sure to clean seal grooves in caliper body. 2. Push upper pad retainer pin inward and slip brake pads past edge. Loosen pad adjuster. 9.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 365: Inspection

    3. Inspect the brake disc and pads as outlined for brake pad replacement in this section. See “BRAKE PAD INSPECTION” earlier in this chapter. 9.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 366: Installation

    5. Install wheels and torque wheel nuts to specification. Refer to Chapter 2. Brake Caliper Mounting Bolt: 18 ft-lbs (24 Nm) 9.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 367: Rear Brake Pad

    NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 368: Touring Pad Installation

    Use only new clean pads. Rear Brake Pad Thickness Service Limit: .180” (4.6 mm) 9.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 369: Sportsman Rear Pad Removal

    6. Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap. 7. Install wheel(s) and torque wheel nut(s). 9.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 370: Sportsman Rear Pad Installation

    7. Clean the caliper with brake cleaner or alcohol. 2. Install and tighten the slide pin with a hex wrench. 9.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 371: Brake Burnishing Procedure

    Repeat this procedure 10 times. 4. Install the slide bolt snap ring. Torque the slide pin to specification. Caliper Slide Bolt: 30-35 ft-lbs (41-48Nm) 9.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 372: Sportsman Rear Caliper

    O-rings and replace if necessary. 4. Remove the slide bolt snap rings (A), the slide pins (B), the bracket pad (C), and the brake pads (D). 9.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 373: Assembly

    11. Inspect surface of caliper piston for nicks, scratches, Caliper Anvil Bolt: or damage and replace if necessary. 16-18 ft-lbs (22-24 Nm) 9.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 374 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation. 9.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 375: Sportsman Touring Rear Caliper

    6. Remove piston, dust seals and piston seals. 3. Remove the two caliper mounting bolts and the caliper. 4. Loosen the adjuster screw and remove the brake pads. 9.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 376: Inspection

    Piston should slide in and out of bore smoothly, with light resistance. Rear Caliper Piston Bore I.D. Service Limit: 1.193” (30.30 mm) 9.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 377: Rear Brake Disc

    3. Mount dial indicator and measure disc runout. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit: .010” / .254 mm 9.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 378: Rear Master Cylinder

    COMPONENTS TO SWELL. service. • Check and adjust master cylinder reservoir fluid level after pad service. Rear Master Cylinder Exploded View (All Models) 9.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 379 Banjo Bolt: 15 ft-lbs (21 Nm) Flare Stye Brake Line: 12-15 ft-lbs (16-20 Nm) 6. Perform brake bleeding procedures as outlined in this chapter. 9.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 380 • Parking brake left on • Residue build up under caliper seals • Operator riding brakes Brakes Lock • Alignment of caliper to disc 9.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 381 STARTER SYSTEM TESTING FLOW CHART ............10.28 10.1 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 382 TROUBLESHOOTING DIAGRAMS ............... . 10.51 10.2 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 383: General Information

    Harness Static Timing Light 2871745 Harness Battery Conductance Polaris MDX-610P Analyzer SPX PN: PU-50296 Bosch Automotive Service Solutions: 1-800-328-6657 or online at http://polaris.service-solutions.com 10.3 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 384: Ignition System / Basic Electrical Components

    Starter Solenoid Battery 12 volt Starter Fuse Box Terminal Block Diagnostic Connector Voltage Regulator Stator Coil Left Hand Controls key Switch Instrument Cluster 10.4 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 385: Electrical Service Notes

    • Faulty CPS • Low Battery EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4. 10.5 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 386: Instrument Cluster

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 10.6 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 387: Rider Information Display

    (International Models Only). 16. Active Descent Control Indicator - Illuminated when the RH control switch is in the ADC 4x4 position and ADC is active. 10.7 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 388: Information Display Area

    2. To reset to 0, push and hold the MODE button until the distance display changes to 0. 3. Perform this same procedure to reset Trip 2. Tachometer (RPM) Engine RPM can be displayed digitally. 10.8 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 389 3. Toggle the MODE button to increase the service interval hours in 5 hour increments to a maximum of 100 hours. 4. To turn off the service interval function, toggle the MODE button until “OFF” is displayed. 10.9 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 390 5. Repeat steps 3-4 twice to set the 10 minute and 1 minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode. 10.10 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 391 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings. 10.11 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 392 If battery voltage rises above 15 volts, a warning screen will display “OV” and provide the present battery voltage. If voltage rises above 16.5 volts, LCD backlighting and icons will turn off. 10.12 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 393: Diagnostic Mode

    5. If more than one code exists, press the MODE button to advance to the next trouble code. 6. To exit diagnostic mode, press and hold MODE button or turn ignition key OFF once the codes are recorded. 10.13 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 394 Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input Fuel Level Sensor International Models Only Turn Signal Input, LH Turn Signal Input, RH 10.14 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 395: Controller Area Network (Can)

    CAN High (YELLOW) and CAN Low (GREEN) wires on the diagnostic connector. If 120 ohms is measured at the connector, there is a break somewhere within the CAN circuit. 10.15 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 396: Transmission (Gear Position) Switch

    Resistance Value Gear Position when measured at switch terminals A and B HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 10.16 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 397: All Wheel Drive (Awd) Coil

    NOTE: Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before suspecting a component failure. A high percentage of electrical issues are caused by bad/ failed connections and grounds. 10.17 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 398 ELECTRICAL 10.18 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 399: Speed Sensor

    4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good. NOTE: Image For Reference Only. 10.19 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 400: Testing

    Speed Sensor Bolt: 8-12 ft-lbs (11-17 Nm) Speed Sensor Test Using Special Tools: Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 10.20 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 401: Throttle Release Switch (Trs)

    Normal Operation (throttle open or above idle) Pins 1 and 2: 6.76kΩ TRS is CLOSED Throttle Cable Stuck Pins 1 and 2: 2.15kΩ 10.21 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 402: Cooling System Components

    6. If the fan motor draws more than 10 Amps, replace the motor. Fan Motor Current Draw: Should Be Less Than 10 Amps NOTE: Fan motor current draw specification may vary. 10.22 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 403: Coolant Temperature Sensor

    Verify the cooling system is full and purged of air. Refer to Maintenance Chapter 2 for cooling system information. 10.23 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 404: Electronic Power Steering (Eps)

    EPS unit as the first step in diagnosing an EPS CAN CIRCUITS. problem. EPS Circuit NOTE: Refer to “Cooling Fan & EPS” breakout diagram near the end of this Chapter. 10.24 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 405: Eps Troubleshooting

    ELECTRICAL EPS Troubleshooting 10.25 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 406: Starter System

    .1 Vdc per connection the starter drive (bendix) with the flywheel. This helps prevent binding and starter damage. 10.26 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 407: Starter Solenoid Bench Test

    Orange wire. • The key switch must be turned to the “start” position to provide 12V power via the Green / White wire. 10.27 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 408: Starter System Testing Flow Chart

    A digital multitester must be used for this test. This flow chart assumes that the starter lockout system is functional. 10.28 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 409: Charging System

    9. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 10.29 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 410: Alternator Output Test

    Any measurement other than Infinity (open) will indicate a failed or shorted stator leg. TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM 10.30 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 411: Regulator / Rectifier

    If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. 10.31 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 412: 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. 10.32 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 413: Fuel Sender

    NOTE: **In the event of a failure, fuel tank assembly replacement is required on ALL models, as the sender assembly or pump assembly is not serviceable. 10.33 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 414: Lighting

    4. Turn the headlight lamp socket counter-clockwise and remove. 3. Unplug headlamp harness (C). 5. Carefully remove headlamp bulb from housing. 10.34 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 415: High Beam Headlight Adjustment

    Lower Headlight - Turn knob clockwise 6. Lift the adjusting knob up to remove from the locking tabs. 7. Carefully pull the assembly up and out of pod. 10.35 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 416: Lower Headlamp Removal / Installation

    8, (20.3 cm) in 25' from the center of the low beam lamp. 5. Adjust beam to desired position. 10.36 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 417: Low Beam Headlight Adjustment (Non Intl)

    / downward. adjustment screw. 4. Adjust the beam to the desired position by loosening or tightening the (3) T-25 adjustment / mounting screws. 10.37 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 418: Headlamp Switch Test

    1. To remove the brake light electrical connector (A) , press in on the tab on the connector to unlock the connector and pull the connector from the bulb assembly. 10.38 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 419: Brake Light Switch

    Replace switch if there is no continuity or greater than .5 ohms resistance when the brake is applied with slight pressure. 10.39 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 420: Battery

    ATV has, refer to the illustration below and batteries. follow the correct service and charging procedures that follow in the manual. Polaris MDX-610P SPX PN: PU-50296 10.40 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 421: Battery Activation (Conventional)

    30% of the battery's full potential. distilled water only to the upper level line. To remove the battery: 10.41 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 422: Conventional Battery Installation

    3. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. Coat terminals and bolt threads with Nyogel® Grease (PN 2871329). 10.42 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 423: Conventional Battery Specific Gravity Test

    40° F will freeze at higher temperatures as the battery discharges. The chart below indicates freezing points by specific gravity. 10.43 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 424: Charging Procedure

    Refer to the Battery Activation and Maintenance Video (PN 9917987) for proper instruction on servicing Low Maintenance batteries. 10.44 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 425: Low Maintenance Battery Charging

    CAUTION Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and reinstall the negative cable last! 3. Remove the battery. 10.45 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 426: Low Maintenance Battery Installation

    0% Charged less than 12.0V less than 11.9V * Measurement at 80° F NOTE: Subtract .01 from the specific gravity reading at 40° F. 10.46 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 427: Low Maintenance Battery Charging Procedure

    SPECIFIC GRAVITY OF FREEZING POINT ELECTROLYTE 1.265 -75° F 1.225 -35° F 1.200 -17° F 1.150 +5° F 1.100 +18° F 1.050 +27° F 10.47 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 428: Sportsman 570 Efi Forest Electrical

    Stop, Tail, Turn lamp Housing Asm 1/4 Turn Socket Head lamp Housing Asm Turn Bulb 35W Head Lamp Tail lamp Socket Position Lamp Tail / Stop Lamp 10.48 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 429: Hazard / Flasher Module

    1. To remove the turn lamp electrical connector (A), pull down on the connector lock and pull the connector from the bulb assembly. 10.49 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 430: Front Turn Signal Lamp Replacement

    Should the vehicle speed reach 67 Kph (42 Mph), the ‘check engine’ light will illuminate on the LCD gauge to indicate there is a problem with the system. 10.50 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

  • Page 431: Troubleshooting Diagrams

    ELECTRICAL TROUBLESHOOTING DIAGRAMS All Wheel Drive- 10.51 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 432 ELECTRICAL Fuel Pump- 10.52 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 433 ELECTRICAL Fuel Injection- 10.53 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 434 ELECTRICAL Fan Control- 10.54 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 435 ELECTRICAL Charging System- 10.55 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 436 ELECTRICAL NOTES 10.56 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 437 Bleeding Procedure..........3.20 Auxiliary Testing ..........2.31 Coolant Drain............. 3.18 Bleeding .............. 9.7 Coolant Level Inspection........2.24 Brake Caliper Removal, Rear ......9.28 IX.1 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 438 Controller Reprogramming........4.44 Break-In Period ..........3.37 Diagnostic Connector ......... 4.40 Cam Chain and Guide Service ......3.43 Cam Shaft Removal ........... 3.40 IX.2 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 439 Valve Cover Installation ........3.67 Ground Valve Cover Removal ......... 3.40 Engine............... 2.35 Valve Inspection ..........3.46 Guided Diagnostics..........4.39 Valve Sealing Test ..........3.57 IX.3 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 440 Service Products and Lubricants ......2.9 Maintenance ............6.5 Shift Linkage............2.22 Overheating / Diagnosis........6.6 Storage Tips ............2.8 Service .............. 6.10 Throttle.............. 2.12 IX.4 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 441 Engine Mounts ........... 3.38 Speedometer ............10.6 Transmission Standard Bolt Torque Specification ......1.12 Assembly............8.18 Starter Control Arm Bracket Mounts ......... 8.6 IX.5 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.
  • Page 442 VIN Number ............1.2 Voltage Drop Test ..........10.26 Water Pump Installation ............3.22 Mechanical Seal / Oil Seal ........3.22 Removal ............3.22 IX.6 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc.

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2014 sportsman 570 eps2014 sportsman 570 forest2014 sportsman touring 570 int’l2014 sportsman 570 eps forest2014 sportsman touring 570Sportsman 570 hd 2018

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