Description
2017-2018 Polaris Ranger 500 / 570 Service Manual 9928485 R01 PDF
The 2017-2018 Polaris Ranger 500 / 570 Service Manual 9928485 R01 PDF is a comprehensive workshop reference for RANGER 500 and RANGER 570 utility vehicles covered by this publication. Printed in September 2017 as publication 9928485 R01, the manual spans 586 PDF pages and combines model identification, scheduled maintenance, engine and cooling service, electronic fuel injection diagnosis, PVT clutch service, transmission work, final-drive procedures, steering and suspension repair, brake service, body and frame procedures, and electrical testing. The manual includes separate technical material for the 500CC SOHC engine and 570CC DOHC engine, plus model-specific specification sections for 2X4, 4X4, international, tractor, EPS and CREW configurations shown in the document.
File Details
- Manual type: Service Manual
- Brand / model: Polaris RANGER 500 / 570
- Coverage: 2017-2018
- Publication number: 9928485 R01
- Publication date: Printed September 2017
- Language: English
- Page count: 591 pages
- File format: PDF
Vehicle and Model Coverage
The manual identifies and illustrates the RANGER 500 / 570 family through dedicated general-specification pages and service procedures. Model coverage presented in the document includes 2018 RANGER 500, 2018 RANGER 570 2X4, 2018 RANGER 570 4X4, 2017 RANGER 570 4X4 (INTL.), 2018 RANGER 570 4X4 TRACTOR (INTL.), and 2018 RANGER 570 CREW. The manual also provides model-number and VIN designation information, locations for the VIN and engine number, publication references, a master special-tools table, a master torque table and clutching charts.
Engine information is separated where necessary. The 500 section identifies a 500cc single-cylinder, 4-stroke SOHC platform, while the 570 specification material identifies a 567cc single-cylinder, liquid-cooled, 4-stroke DOHC platform. Service data throughout the manual includes capacities, clearances, torque values, inspection limits, pressure figures, adjustment values and model-specific procedures rather than only general maintenance instructions.
Service Information and Diagnostic Depth
This 2017-2018 Polaris Ranger 500 / 570 service manual is built around workshop procedures. Maintenance coverage includes pre-ride inspection, break-in, periodic service intervals, lubrication points, oil and filter service, valve-clearance checks, coolant service, air-filter service, transmission and front-gearcase lubrication, wheel and tire inspection, steering alignment, suspension inspection, brake checks, battery care and spark-plug service. The engine chapters continue into compression and leakdown testing, oil-pressure testing, engine removal and installation, cooling-system pressure testing, thermostat and water-pump service, top-end and lower-end disassembly, cylinder-head work, valve-seat reconditioning, piston and cylinder measurements, camshaft timing, crankshaft and balance-shaft service, and detailed assembly sequences.
Fuel-system diagnosis covers EFI operation, component locations, fuel and vent routing, air intake, ECU service, electronic throttle control, pedal-position sensing, fuel-tank and pump procedures, T-MAP and temperature-related components, diagnostic trouble information and troubleshooting. The PVT section covers drive and driven clutch operation, belt inspection and replacement, clutch alignment and center distance, clutch disassembly and inspection, bushing work and troubleshooting. Transmission and final-drive material adds shift-cable adjustment, transmission removal and internal service, differential operation, front and rear drive shafts, front gearcase service, AWD diagnosis, bearing carriers and prop-shaft work. Electrical coverage includes switches and controls, AWD circuits, vehicle-speed sensing, instrument cluster diagnosis, lighting, cooling-fan control, ignition-coil tests, relays, fuses, charging-system tests, battery testing and starter-system troubleshooting.
Chapters Covered
- Chapter 1: General Information
- Vehicle identification, model-number and VIN designation, VIN / engine number location
- Publication references, special tools and master torque data
- Clutching chart and general model specifications
- 2018 RANGER 500, 2018 RANGER 570 2X4, 2018 RANGER 570 4X4, 2017 RANGER 570 4X4 (INTL.), 2018 RANGER 570 4X4 TRACTOR (INTL.) and 2018 RANGER 570 CREW
- Chapter 2: Maintenance
- Periodic maintenance chart, pre-ride inspection and break-in
- Engine oil, filter, valve-clearance, cooling-system and air-intake service
- Transmission / gearcase lubrication, wheels, tires, steering and suspension checks
- Brake, battery, ignition, spark-plug and storage procedures
- Chapter 3: Engine / Cooling System
- Engine lubrication, oil-pressure testing, engine specifications and engine removal / installation
- Cooling-system flow, pressure testing, thermostat, radiator, bleeding and water-pump service
- 500CC SOHC and 570CC DOHC engine detail, torque sequences and assembly views
- Top-end and lower-end disassembly, inspection, measurement and reassembly
- Engine and cooling-system troubleshooting
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “2017-2018 Polaris Ranger 500 / 570 Service Manual 9928485 R01 PDF” are as follows:
2017-2018 RANGER 500 / 570p. 1
Trademarksp. 3
Revision Indexp. 3
+CHAPTER 1: GENERAL INFORMATIONp. 5
+VEHICLE INFORMATIONp. 6
MODEL NUMBER DESIGNATION (2015 +)p. 6
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)p. 6
VIN / ENGINE NUMBER LOCATIONp. 7
+REFERENCE INFORMATIONp. 8
REPLACEMENT KEYSp. 8
PUBLICATION NUMBERSp. 9
SPECIAL TOOLSp. 10
MASTER SPECIAL TOOLS TABLEp. 11
MASTER TORQUE TABLEp. 19
CLUTCHING CHARTp. 21
+GENERAL SPECIFICATIONSp. 22
+2018p. 22
2018 RANGER 500p. 22
2018 RANGER 570 2X4p. 24
2018 RANGER 570 4X4p. 26
2017 RANGER 570 4X4 (INTL.)p. 28
2018 RANGER 570 4X4 TRACTOR (INTL.)p. 30
2018 RANGER 570 CREWp. 32
+MISC. SPECIFICATIONS AND CHARTSp. 34
CONVERSION TABLEp. 34
SAE TAP / DRILL SIZESp. 36
METRIC TAP / DRILL SIZESp. 37
DECIMAL EQUIVALENTSp. 38
+CHAPTER 2: MAINTENANCEp. 41
+PERIODIC MAINTENANCE CHARTp. 43
PRE-RIDE / DAILY INSPECTIONp. 43
COLD WEATHER OPERATIONp. 43
+BREAK-IN PERIODp. 44
VEHICLE BREAK-IN PERIODp. 44
ENGINE AND DRIVETRAIN BREAK-INp. 44
BRAKE SYSTEM BREAK-INp. 44
PVT BREAK-IN (CLUTCHES / BELT)p. 44
PERIODIC MAINTENANCE CHART KEYp. 45
PERIODIC MAINTENANCE CHARTp. 45
GREASE LUBRICATION POINTSp. 48
COMPONENT QUICK REFERENCEp. 49
STORAGE TIPSp. 50
+LUBRICANTS / SERVICE PRODUCTSp. 51
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTSp. 51
+ENGINEp. 52
COMPRESSION AND LEAKDOWN TESTp. 52
ENGINE OIL LEVELp. 52
OIL AND FILTER CHANGEp. 52
BREATHER HOSEp. 53
BREATHER VALVE INSPECTIONp. 53
+500 SOHCp. 54
VALVE CLEARANCE – SOHCp. 54
+570 DOHCp. 54
VALVE CLEARANCE – DOHCp. 54
+COOLING SYSTEMp. 56
COOLING SYSTEM OVERVIEWp. 56
COOLANT LEVEL INSPECTIONp. 56
50/50 EXTENDED-LIFE ENGINE ANTIFREEZEp. 58
COOLANT STRENGTH / TYPEp. 59
COOLING SYSTEM HOSESp. 59
RADIATOR INSPECTION / CLEANINGp. 60
COOLANT DRAIN / RADIATOR REMOVALp. 60
+FUEL SYSTEM AND AIR INTAKEp. 62
FUEL SYSTEMp. 62
FUEL LINESp. 62
FUEL PUMP / FILTERp. 62
VENT LINESp. 62
THROTTLE PEDAL INSPECTIONp. 62
AIR FILTER SERVICEp. 62
ENGINE AIR INTAKE INSPECTIONp. 63
PVT AIR INTAKE INSPECTIONp. 63
+TRANSMISSION AND GEARCASEp. 64
SHIFT CABLE INSPECTIONp. 64
SHIFT CABLE ADJUSTMENTp. 64
TRANSMISSION LUBRICATIONp. 64
FRONT GEARCASE LUBRICATIONp. 65
+FINAL DRIVE / WHEEL / TIREp. 67
WHEEL AND HUB TORQUE TABLEp. 67
CV SHAFT BOOT INSPECTIONp. 67
WHEEL REMOVALp. 67
WHEEL INSTALLATIONp. 68
TIRE INSPECTIONp. 68
TIRE PRESSUREp. 68
+STEERINGp. 69
STEERING INSPECTION NOTEp. 69
TIE ROD END / STEERING INSPECTIONp. 69
WHEEL TOE ALIGNMENT INSPECTIONp. 70
TOE ADJUSTMENTp. 70
CAMBER AND CASTERp. 71
+SUSPENSIONp. 72
SUSPENSION INSPECTIONp. 72
SPRING PRE-LOAD ADJUSTMENTp. 72
STABILIZER BAR PIVOT LUBRICATIONp. 72
SUSPENSION PIVOT POINT LUBRICATIONp. 72
+BRAKE SYSTEMp. 73
BRAKE FLUID INSPECTIONp. 73
BRAKE HOSE AND FITTING INSPECTIONp. 73
BRAKE PAD INSPECTIONp. 73
BRAKE DISC INSPECTIONp. 74
+ELECTRICAL AND IGNITION SYSTEMp. 75
BATTERY MAINTENANCEp. 75
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY)p. 75
BATTERY REMOVALp. 75
BATTERY INSTALLATIONp. 76
BATTERY STORAGEp. 76
BATTERY CHARGINGp. 76
+500 SOHCp. 76
SPARK PLUG SERVICE – 500p. 76
+570 DOHCp. 77
SPARK PLUG SERVICE – 570p. 77
MAIN FRAME/ENGINE GROUNDp. 78
+CHAPTER 3: ENGINE / COOLING SYSTEMp. 79
+GENERAL ENGINE INFORMATIONp. 84
+GENERAL INFORMATIONp. 84
SPECIAL TOOLSp. 84
ENGINE LUBRICATION SPECIFICATIONSp. 85
OIL PRESSURE TESTp. 86
ENGINE OIL FLOW CHARTp. 87
ENGINE SPECIFICATIONSp. 88
+ENGINE SERVICEp. 90
ACCESSIBLE ENGINE COMPONENTSp. 90
TOP-END SERVICE (ENGINE IN CHASSIS)p. 90
ENGINE REMOVALp. 90
ENGINE INSTALLATIONp. 93
ENGINE BREAK-IN PERIODp. 96
ENGINE LUBRICATION SPECIFICATIONSp. 96
ENGINE MOUNTING AND TORQUE VALUESp. 97
SETTING TDC (TOP-DEAD-CENTER)p. 98
+COOLING SYSTEMp. 100
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAMp. 100
COOLING SYSTEM SPECIFICATIONSp. 101
COOLING SYSTEM PRESSURE TESTp. 101
PRESSURE CAP TESTp. 102
RADIATORp. 102
COOLANT DRAIN / RADIATOR REMOVALp. 103
THERMOSTAT REPLACEMENTp. 104
COOLING SYSTEM BLEEDING PROCEDUREp. 104
WATER PUMP COVER AND IMPELLER SERVICE (STATOR COVER REMAINS ON ENGINE)p. 105
WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENTp. 106
+TROUBLESHOOTINGp. 112
ENGINEp. 112
COOLING SYSTEMp. 113
+500CC SOHC ENGINEp. 114
+ENGINE DETAIL, TORQUES / SEQUENCESp. 114
ENGINE SPECIFICATIONS, 500p. 114
ENGINE TORQUE SEQUENCESp. 116
CRANKCASE SEALANT PATHp. 122
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVEp. 122
CYLINDER / OIL FILTER / OIL PUMP / BREATHERp. 125
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVERp. 129
SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVERp. 133
PISTON / CRANKSHAFT / BALANCE SHAFTp. 137
+ENGINE DISASSEMBLY / INSPECTION – TOP ENDp. 143
VALVE COVER REMOVALp. 143
CAMSHAFT / CARRIER REMOVALp. 143
CAMSHAFT SPROCKET INSPECTIONp. 144
CAMSHAFT / CAMSHAFT BORE INSPECTIONp. 144
EXHAUST CAMSHAFT DECOMPRESSION MECHANISMp. 145
CAM CHAIN AND GUIDE SERVICEp. 145
CYLINDER HEAD REMOVALp. 146
CYLINDER HEAD DISASSEMBLYp. 146
CYLINDER HEAD INSPECTIONp. 147
CYLINDER HEAD WARP INSPECTIONp. 147
VALVE INSPECTIONp. 147
COMBUSTION CHAMBER CLEANINGp. 149
VALVE SEAT RECONDITIONINGp. 149
CYLINDER REMOVALp. 151
CYLINDER INSPECTIONp. 151
PISTON REMOVALp. 152
PISTON-TO-CYLINDER CLEARANCEp. 153
PISTON / ROD INSPECTIONp. 153
PISTON RING INSTALLED GAPp. 154
HONING TO OVERSIZEp. 154
CYLINDER HONE SELECTION / HONING PROCEDUREp. 155
CLEANING THE CYLINDER AFTER HONINGp. 155
+ENGINE ASSEMBLY – TOP ENDp. 156
PISTON RING INSTALLATIONp. 156
PISTON / CONNECTING ROD ASSEMBLYp. 157
CYLINDER INSTALLATIONp. 157
CYLINDER HEAD INSTALLATIONp. 158
VALVE SEALING TESTp. 159
VALVE CLEARANCE CHECK / ADJUSTMENTp. 159
INTAKE VALVE LASH – TAPPET SELECTION MATRIXp. 161
EXHAUST VALVE LASH – TAPPET SELECTION MATRIXp. 161
CAMSHAFT INSTALLATION / TIMINGp. 162
CAMSHAFT TIMING – QUICK REFERENCEp. 164
VALVE COVER INSTALLATIONp. 165
+ENGINE DISASSEMBLY / INSPECTION – LOWER ENDp. 166
CRANKCASE DISASSEMBLYp. 166
FLYWHEEL / STATOR HOUSING REMOVALp. 166
STARTER ONE-WAY CLUTCH INSPECTIONp. 166
STARTER ONE-WAY CLUTCH INSTALLATIONp. 168
FLYWHEEL INSTALLATIONp. 168
STATOR REMOVALp. 169
STATOR / STATOR COVER INSTALLATIONp. 169
OIL PUMP REMOVALp. 170
OIL PUMP ASSEMBLYp. 172
CRANKCASE BREATHER VALVE / HOSEp. 173
CRANKCASE SEPARATIONp. 174
BALANCE SHAFT REMOVAL / INSPECTIONp. 175
CRANKSHAFT REMOVALp. 175
CRANKSHAFT INSPECTIONp. 176
+ENGINE ASSEMBLY – LOWER ENDp. 178
CRANKCASE ASSEMBLY – PTO SIDEp. 178
BALANCE SHAFT INSTALLATION / TIMINGp. 179
FINAL CRANKCASE ASSEMBLYp. 180
+ENGINE DISASSEMBLY / INSPECTION – LOWER ENDp. 182
CRANKCASE DISASSEMBLYp. 182
STATOR COVER REMOVALp. 182
STARTER ONE-WAY CLUTCH INSPECTIONp. 182
STATOR REMOVALp. 184
OIL PUMP REMOVALp. 185
OIL PUMP ASSEMBLYp. 187
CRANKCASE BREATHER SERVICEp. 187
CRANKCASE SEPARATIONp. 188
BALANCE SHAFT REMOVAL / INSPECTIONp. 189
CRANKSHAFT REMOVALp. 190
CRANKSHAFT INSPECTIONp. 190
PTO SIDE CRANKCASE BEARING SERVICEp. 191
MAG SIDE CRANKCASE BEARING SERVICEp. 192
OIL PICKUP ASSEMBLY INSPECTIONp. 193
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTIONp. 193
CRANKCASE INSPECTIONp. 193
+ENGINE ASSEMBLY – LOWER ENDp. 194
CRANKCASE ASSEMBLY – PTO SIDEp. 194
BALANCE SHAFT INSTALLATION / TIMINGp. 196
FINAL CRANKCASE ASSEMBLYp. 196
STARTER ONE-WAY CLUTCH INSTALLATIONp. 198
FLYWHEEL INSTALLATIONp. 198
STATOR / STATOR COVER INSTALLATIONp. 200
+570CC DOHC ENGINEp. 201
+ENGINE DETAIL, TORQUES / SEQUENCESp. 201
TORQUE SPECIFICATIONS, ENGINE – 570p. 201
TORQUE SEQUENCEp. 203
CRANKCASE SEALANT PATHp. 206
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVEp. 207
CYLINDER / OIL FILTER / OIL PUMP / BREATHERp. 209
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER – BLACK CYLINDER HEAD BOLTSp. 211
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER – SILVER HEAD BOLTSp. 213
SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVERp. 215
PISTON / CRANKSHAFT / BALANCE SHAFTp. 217
+ENGINE DETAIL, TORQUES / SEQUENCESp. 221
ENGINE FASTENER TORQUE SPECIFICATIONSp. 221
TORQUE SEQUENCEp. 223
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVEp. 224
CYLINDER / OIL FILTER / OIL PUMP / BREATHERp. 225
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER – BLACK HEAD BOLTSp. 226
CAMS / CYL HEAD / FLYWHEEL / STATOR COVER – SILVER HEAD BOLTSp. 227
SPARK PLUG / STARTER / THROTTLE BODY / VALVE COVERp. 228
PISTON / CRANKSHAFT / BALANCE SHAFTp. 230
+ENGINE DISASSEMBLY / INSPECTION – TOP ENDp. 231
VALVE COVER REMOVALp. 231
CAMSHAFT / CARRIER REMOVALp. 231
CAMSHAFT SPROCKET INSPECTIONp. 232
CAMSHAFT INSPECTIONp. 233
EXHAUST CAMSHAFT DECOMPRESSION MECHANISMp. 233
CAM CHAIN AND GUIDE SERVICEp. 234
CYLINDER HEAD REMOVALp. 234
CYLINDER HEAD DISASSEMBLYp. 235
CYLINDER HEAD INSPECTIONp. 236
CYLINDER HEAD WARP INSPECTIONp. 236
VALVE INSPECTIONp. 236
COMBUSTION CHAMBER CLEANINGp. 237
VALVE SEAT RECONDITIONINGp. 238
CYLINDER REMOVALp. 240
CYLINDER INSPECTIONp. 240
PISTON REMOVALp. 241
PISTON-TO-CYLINDER CLEARANCEp. 241
PISTON / ROD INSPECTIONp. 242
PISTON RING INSTALLED GAPp. 243
HONING TO OVERSIZEp. 243
CYLINDER HONE SELECTION / HONING PROCEDUREp. 244
CLEANING THE CYLINDER AFTER HONINGp. 244
+ENGINE ASSEMBLY – TOP ENDp. 245
PISTON RING INSTALLATIONp. 245
PISTON / CONNECTING ROD ASSEMBLYp. 246
CYLINDER INSTALLATIONp. 247
CYLINDER HEAD IDENTIFICATIONp. 247
CRANKCASE IDENTIFICATIONp. 248
CYLINDER HEAD INSTALLATION – BLACK BOLTSp. 249
CYLINDER HEAD INSTALLATION – SILVER BOLTSp. 250
VALVE SEALING TESTp. 252
VALVE CLEARANCE CHECK / ADJUSTMENTp. 252
VALVE LASH – TAPPET SELECTIONp. 255
EXHAUST VALVE LASH – TAPPET SELECTION MATRIXp. 256
CAMSHAFT INSTALLATION / TIMINGp. 257
CAMSHAFT TIMING – QUICK REFERENCEp. 260
VALVE COVER INSTALLATIONp. 261
+ENGINE DISASSEMBLY / INSPECTION – LOWER ENDp. 262
CRANKCASE DISASSEMBLYp. 262
FLYWHEEL / STATOR HOUSING REMOVALp. 262
STARTER ONE-WAY CLUTCH INSPECTIONp. 263
STARTER ONE-WAY CLUTCH INSTALLATIONp. 264
FLYWHEEL INSTALLATIONp. 264
STATOR REMOVALp. 265
STATOR / STATOR COVER INSTALLATIONp. 266
OIL PUMP REMOVALp. 266
OIL PUMP ASSEMBLYp. 268
CRANKCASE BREATHER VALVE / HOSEp. 269
CRANKCASE SEPARATIONp. 270
BALANCE SHAFT REMOVAL / INSPECTIONp. 271
CRANKSHAFT REMOVALp. 272
CRANKSHAFT INSPECTIONp. 272
PTO SIDE CRANKCASE BEARING SERVICEp. 273
MAG SIDE CRANKCASE BEARING SERVICEp. 275
OIL PICKUP ASSEMBLY INSPECTIONp. 275
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTIONp. 276
CRANKCASE INSPECTIONp. 276
+ENGINE ASSEMBLY – LOWER ENDp. 277
CRANKCASE ASSEMBLY – PTO SIDEp. 277
BALANCE SHAFT INSTALLATION / TIMINGp. 279
FINAL CRANKCASE ASSEMBLYp. 279
+ENGINE DISASSEMBLY / INSPECTION – LOWER ENDp. 281
CRANKCASE DISASSEMBLYp. 281
STATOR COVER REMOVALp. 281
STARTER ONE-WAY CLUTCH INSPECTIONp. 281
STATOR REMOVALp. 283
OIL PUMP REMOVALp. 284
OIL PUMP ASSEMBLYp. 286
CRANKCASE BREATHER SERVICEp. 286
CRANKCASE SEPARATIONp. 287
BALANCE SHAFT REMOVAL / INSPECTIONp. 288
CRANKSHAFT REMOVALp. 289
CRANKSHAFT INSPECTIONp. 289
PTO SIDE CRANKCASE BEARING SERVICEp. 290
MAG SIDE CRANKCASE BEARING SERVICEp. 291
OIL PICKUP ASSEMBLY INSPECTIONp. 292
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTIONp. 292
CRANKCASE INSPECTIONp. 292
+ENGINE ASSEMBLY – LOWER ENDp. 293
CRANKCASE ASSEMBLY – PTO SIDEp. 293
BALANCE SHAFT INSTALLATION / TIMINGp. 295
FINAL CRANKCASE ASSEMBLYp. 295
STARTER ONE-WAY CLUTCH INSTALLATIONp. 297
FLYWHEEL INSTALLATIONp. 297
STATOR / STATOR COVER INSTALLATIONp. 299
+CHAPTER 4: FUEL SYSTEMp. 301
+GENERAL INFORMATIONp. 303
EFI OPERATION OVERVIEWp. 303
PRINCIPAL COMPONENTSp. 303
INITIAL PRIMING / STARTING PROCEDUREp. 303
SPECIAL TOOLSp. 304
FUEL PRESSURE GAUGE KIT – PU-43506-Ap. 305
FUEL PRESSURE GAUGE ADAPTER – PA-48838p. 305
DIGITAL WRENCH® – DIAGNOSTIC CONNECTORp. 305
DIGITAL WRENCH® DIAGNOSTIC SOFTWAREPU-47063-Bp. 306
DIGITAL WRENCH® SMARTLINK MODULE KITPU-47471p. 306
DIGITAL WRENCH® – DOWNLOAD WEBSITEp. 306
+EFI COMPONENT LOCATIONSp. 307
EFI COMPONENT LOCATIONS – LEFT VIEWp. 307
EFI COMPONENT LOCATIONS – RIGHT VIEWp. 308
+LINE / HOSE ROUTINGp. 309
FUEL LINE ROUTINGp. 309
VENT LINE TERMINATION FITTINGp. 309
+AIR BOX / INTAKE SYSTEMp. 310
AIR BOX / AIR FILTER ASSEMBLY VIEWp. 310
AIR BOX REMOVAL / INSTALLATIONp. 312
+ELECTRONIC CONTROL UNIT (ECU)p. 313
ECU OVERVIEWp. 313
RPM LIMITp. 313
ECU SERVICEp. 313
ECU REPLACEMENTp. 314
+ELECTRONIC THROTTLE BODY (ETC)p. 315
ETC OVERVIEWp. 315
ETC TESTp. 315
ETC REPLACEMENTp. 315
ETC LEARN PROCEDUREp. 315
+PEDAL POSITION SENSOR (PPS)p. 316
OPERATION OVERVIEWp. 316
PPS TESTp. 316
PPS REPLACEMENTp. 316
+FUEL TANK / PUMP / SENDORp. 317
FUEL TANK ASSEMBLY VIEWp. 317
FUEL TANK REMOVALp. 317
FUEL TANK INSTALLATIONp. 318
FUEL SENDER TESTp. 318
FUEL PUMP TESTp. 319
FUEL PUMP REPLACEMENTp. 321
+TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP)p. 324
T-MAP OVERVIEWp. 324
T-MAP SENSOR TESTp. 324
T-MAP SENSOR REPLACEMENTp. 324
+CRANKSHAFT POSITION SENSORp. 325
CPS OVERVIEWp. 325
CPS TESTp. 325
RESISTANCE TESTp. 325
AIR GAP TESTp. 326
ENCODER FLYWHEEL / KEYWAY INSPECTIONp. 326
CPS REPLACEMENTp. 327
+IGNITION COIL OVERVIEWp. 328
IGNITION COIL / WIRE OVERVIEWp. 328
IGNITION COIL / WIRE TESTp. 328
COIL PACK CONNECTIONSp. 328
SPARK PLUG WIRE CONNECTIONSp. 328
+FUEL INJECTORp. 329
FUEL INJECTOR OVERVIEWp. 329
FUEL INJECTOR TESTp. 329
FUEL INJECTOR REPLACEMENTp. 329
FUEL INJECTOR TROUBLESHOOTINGp. 331
+ENGINE COOLANT TEMPERATURE SENSOR (ETC)p. 332
ECT OVERVIEWp. 332
ECT SENSOR TESTp. 332
SYSTEM OPERATION TESTp. 332
RESISTANCE VS. TEMPERATURE TESTp. 332
ECT SENSOR REPLACEMENT – 570p. 333
+EFI DIAGNOSISp. 334
SERVICE NOTES – FUEL SYSTEMp. 334
TROUBLE CODE DISPLAY (DTC)p. 335
+DIGITAL WRENCH® OPERATIONp. 342
DIGITAL WRENCH® – DIAGNOSTIC CONNECTORp. 342
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEWp. 342
POLARIS MOBILE DIGITAL WRENCH (PMDW)p. 343
DIGITAL WRENCH® VERSION AND UPDATE IDp. 343
DIGITAL WRENCH® UPDATESp. 344
DIGITAL WRENCH® COMMUNICATION ERRORSp. 347
GUIDED DIAGNOSTICSp. 347
DIGITAL WRENCH® SERIAL NUMBER LOCATIONp. 348
DIGITAL WRENCH® FEATURE MAPp. 348
ECU REPLACEMENTp. 349
ECU REPROGRAMMING (REFLASH)p. 349
ETC LEARN PROCEDUREp. 355
+FUEL SYSTEM TROUBLESHOOTINGp. 356
FUEL STARVATION / LEAN MIXTUREp. 356
RICH MIXTUREp. 356
POOR IDLEp. 356
+CHAPTER 5: PVT SYSTEMp. 357
+GENERAL INFORMATIONp. 358
SPECIAL TOOLSp. 358
PVT SYSTEM FASTENER TORQUESp. 358
+PVT SYSTEM OVERVIEWp. 359
CLUTCHING CHARTp. 359
GENERAL OPERATIONp. 359
DRIVE CLUTCH OPERATIONp. 360
DRIVEN CLUTCH OPERATIONp. 360
PVT BREAK-IN (DRIVE BELT / CLUTCHES)p. 360
MAINTENANCE / INSPECTIONp. 360
OVERHEATING / DIAGNOSISp. 361
OPERATING IN LOW GEARp. 361
+PVT SYSTEM SERVICEp. 363
PVT SEALING, GUARD, AND DUCT COMPONENTSp. 363
PVT DISASSEMBLYp. 364
PVT ASSEMBLYp. 365
+DRIVE BELTp. 366
BELT REMOVALp. 366
BELT INSPECTIONp. 366
BELT INSTALLATIONp. 367
PVT BREAK-IN (DRIVE BELT / CLUTCHES)p. 367
+CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCEp. 368
INSPECTIONp. 368
ADJUSTMENTp. 369
+DRIVE CLUTCH SERVICEp. 370
DRIVE CLUTCH ASSEMBLY VIEWp. 370
CLUTCH DISASSEMBLYp. 371
SHIFT WEIGHT INSPECTIONp. 372
SPIDER REMOVALp. 373
ROLLER, PIN, AND THRUST WASHER INSPECTIONp. 373
BUTTON TO TOWER CLEARANCE INSPECTIONp. 374
BEARING INSPECTIONp. 374
CLUTCH INSPECTIONp. 374
BUSHING SERVICEp. 376
CLUTCH ASSEMBLYp. 378
+DRIVEN CLUTCH SERVICEp. 380
ASSEMBLY VIEWp. 380
CLUTCH DISASSEMBLY / INSPECTIONp. 381
CLUTCH ASSEMBLYp. 382
+PVT SYSTEM TROUBLESHOOTINGp. 383
+CHAPTER 6: TRANSMISSIONp. 385
+GENERAL INFORMATIONp. 386
TORQUE SPECIFICATIONSp. 386
SPECIAL TOOLS, TRANSMISSIONp. 386
SPECIAL TOOLSp. 387
TRANSMISSION GEARSp. 388
LUBRICATIONp. 388
TRANSMISSION MOUNTING AND TORQUE VALUESp. 388
+ASSEMBLY VIEWp. 389
TRANSMISSION ASSEMBLY VIEWp. 389
+SHIFT LEVERp. 391
REMOVALp. 391
INSTALLATIONp. 391
+SHIFT CABLEp. 392
INSPECTIONp. 392
ADJUSTMENTp. 392
+TRANSMISSION SERVICEp. 393
TRANSMISSION REMOVALp. 393
TRANSMISSION INSTALLATIONp. 394
+TRANSMISSION INTERNALS SERVICEp. 398
DIFFERENTIAL OPERATIONp. 398
TRANSMISSION DISASSEMBLYp. 399
PLANETARY DIFFERENTIAL DISASSEMBLYp. 404
PLANETARY DIFFERENTIAL BUSHING REPLACEMENTp. 404
PLANETARY DIFFERENTIAL ASSEMBLYp. 406
GEAR / SHAFT / BEARING INSPECTIONp. 407
SNORKEL GEAR BACKLASH PROCEDUREp. 408
+TROUBLESHOOTINGp. 415
TROUBLESHOOTING CHECKLISTp. 415
+CHAPTER 7: FINAL DRIVEp. 417
+GENERAL INFORMATIONp. 419
SPECIAL TOOLSp. 419
FINAL DRIVE TORQUE TABLEp. 419
+FRONT HUB / BEARINGp. 420
HUB REMOVAL / INSPECTIONp. 420
HUBSTRUT BEARING REPLACEMENTp. 420
HUB INSTALLATIONp. 421
FRONT HUB/WHEEL EXPLODED VIEWp. 423
+FRONT DRIVE SHAFTp. 424
FRONT DRIVE SHAFT REMOVALp. 424
FRONT DRIVE SHAFT INSTALLATIONp. 425
+FRONT GEARCASEp. 426
GEARCASE REMOVALp. 426
GEARCASE INSTALLATIONp. 426
+FRONT GEARCASE (NON-ADC)p. 428
FRONT GEARCASE ASSEMBLY VIEWp. 428
ALL WHEEL DRIVE OPERATIONp. 429
AWD DIAGNOSISp. 430
FRONT GEARCASE DISASSEMBLY / INSPECTIONp. 432
FRONT GEARCASE ASSEMBLYp. 435
+FRONT GEARCASE (ADC)p. 438
EXPLODED VIEW, FRONT GEARCASE (4WDC)p. 438
OPERATION, FRONT GEARCASE (4WDC)p. 440
DISASSEMBLY / INSPECTION, FRONT GEARCASE (ADC)p. 441
REASSEMBLY, FRONT GEARCASE (ADC)p. 444
TROUBLESHOOTING, FRONT GEARCASE (ADC)p. 447
+REAR BEARING CARRIERp. 450
INSPECTIONp. 450
REMOVALp. 450
DISASSEMBLYp. 451
ASSEMBLYp. 451
INSTALLATIONp. 452
+REAR DRIVE SHAFTp. 454
REAR DRIVE SHAFT REMOVALp. 454
REAR DRIVE SHAFT INSTALLATIONp. 454
+DRIVE SHAFT SERVICEp. 455
DRIVE SHAFT / CV JOINT HANDLING TIPSp. 455
OUTER CV JOINT / BOOT REPLACEMENTp. 455
INNER PLUNGING JOINT / BOOT REPLACEMENTp. 458
DRIVE SHAFT ASSEMBLY VIEWp. 460
+PROPSHAFT U-JOINT SERVICEp. 462
REMOVAL / INSTALLATIONp. 462
FRONT PROP SHAFT COMPONENTSp. 462
REMOVAL / INSTALLATION (CREW)p. 462
SUPPORT BEARING REPLACEMENT (CREW)p. 463
DISASSEMBLYp. 464
ASSEMBLYp. 465
+CHAPTER 8: STEERING / SUSPENSIONp. 467
+GENERAL INFORMATIONp. 468
TORQUE SPECIFICATIONSp. 468
SPECIAL TOOLSp. 469
+STEERING ASSEMBLYp. 470
STEERING ASSEMBLY VIEW (NON-EPS)p. 470
STEERING ASSEMBLY VIEW (EPS)p. 472
STEERING WHEEL REMOVAL (NON-EPS MODELS)p. 474
STEERING SHAFT BEARING REPLACEMENTp. 474
STEERING SHAFT / STEERING RACK REMOVAL (NON-EPS MODELS)p. 475
STEERING WHEEL / UPPER STEERING SHAFT REMOVAL (EPS)p. 476
POWER STEERING UNIT REMOVALp. 477
POWER STEERING UNIT INSTALLATIONp. 477
+FRONT STRUTp. 479
ASSEMBLY VIEWp. 479
FRONT STRUT CARTRIDGE REPLACEMENTp. 479
BALL JOINT REPLACEMENTp. 480
+REAR A-ARMSp. 482
REMOVAL / REPLACEMENTp. 482
INSTALLATIONp. 483
ASSEMBLY VIEWp. 484
+REAR STABALIZER BAR / LINKAGEp. 485
REMOVAL / INSTALLATIONp. 485
ASSEMBLY VIEWp. 485
+SHOCKS / SPRINGSp. 486
ASSEMBLY VIEWp. 486
SHOCK REMOVAL / INSTALLATIONp. 486
SHOCK REPLACEMENTp. 486
+CHAPTER 9: BRAKE SYSTEMp. 487
+GENERAL INFORMATIONp. 489
BRAKE SERVICE SPECIFICATIONSp. 489
TORQUE SPECIFICATIONSp. 489
SPECIAL TOOLSp. 489
+BRAKE SYSTEM NOTESp. 490
BRAKE SYSTEM SERVICE NOTESp. 490
BRAKE NOISE TROUBLESHOOTINGp. 490
HYDRAULIC BRAKE SYSTEM OPERATIONp. 491
+BRAKE SYSTEM ASSEMBLY VIEWSp. 492
RANGERp. 492
RANGER CREWp. 493
+MASTER CYLINDERp. 494
REMOVALp. 494
INSTALLATIONp. 494
BRAKE PRESSURE SWITCHp. 495
+BRAKE PEDALp. 496
PEDAL REMOVALp. 496
PEDAL INSTALLATIONp. 496
+BRAKE SERVICE PROCEDURESp. 497
BRAKE BLEEDING / FLUID CHANGEp. 497
BRAKE BURNISHING PROCEDUREp. 498
+FRONT BRAKE PADSp. 499
+2 SEATp. 499
PAD REMOVAL / DISASSEMBLYp. 499
BRAKE PAD INSPECTIONp. 499
PAD ASSEMBLY / INSTALLATION- RANGERp. 500
PAD ADJUSTMENT- RANGERp. 500
+CREWp. 500
PAD REMOVAL – CREWp. 500
PAD INSPECTIONp. 501
PAD ASSEMBLY / INSTALLATION- CREWp. 502
+FRONT CALIPERp. 503
+2 SEATp. 503
FRONT CALIPER ASSEMBLY VIEWp. 503
FRONT CALIPER REMOVAL- RANGERp. 504
FRONT CALIPER DISASSEMBLY – RANGERp. 504
FRONT CALIPER INSPECTION- RANGERp. 505
FRONT CALIPER ASSEMBLYp. 505
FRONT CALIPER INSTALLATIONp. 506
+CREWp. 507
FRONT CALIPER ASSEMBLY VIEWp. 507
FRONT CALIPER REMOVAL- CREWp. 508
FRONT CALIPER DISASSEMBLY – CREWp. 508
FRONT CALIPER INSPECTION – CREWp. 509
FRONT CALIPER ASSEMBLY – CREWp. 510
FRONT CALIPER INSTALLATION – CREWp. 510
+FRONT BRAKE DISCp. 512
DISC INSPECTIONp. 512
DISC REMOVAL / REPLACEMENTp. 513
+REAR BRAKE PADSp. 513
PAD REMOVALp. 513
BRAKE PAD INSPECTIONp. 514
REAR PAD INSTALLATIONp. 515
+REAR CALIPERSp. 516
CALIPER ASSEMBLY VIEWp. 516
CALIPER REMOVALp. 517
REAR CALIPER DISASSEMBLYp. 517
REAR CALIPER INSPECTIONp. 518
REAR CALIPER ASSEMBLYp. 518
REAR CALIPER INSTALLATIONp. 519
+REAR BRAKE DISCp. 520
DISC RUNOUTp. 520
BRAKE DISC INSPECTIONp. 520
DISC REMOVAL / REPLACEMENTp. 521
+TROUBLESHOOTINGp. 522
BRAKES SQUEAL / POOR BRAKE PERFORMANCEp. 522
PEDAL VIBRATIONp. 522
CALIPER OVERHEATS (BRAKES DRAG)p. 522
BRAKES LOCKp. 522
+CHAPTER 10: BODY / FRAMEp. 523
+GENERAL INFORMATIONp. 524
TORQUE SPECIFICATIONSp. 524
SPECIAL TOOLSp. 524
+CHASSIS / BODY ASSEMBLY VIEWSp. 525
FRAME ASSEMBLY VIEWp. 525
CREW FRAME ASSEMBLY VIEWp. 526
CAB FRAME ASSEMBLY VIEWp. 527
2017 CREW CAB FRAME ASSEMBLY VIEWp. 528
DASH INSTRUMENTS / CONTROLSp. 531
HOOD / DASH / FRONT FASCIAp. 532
FLOOR / REAR FENDERSp. 533
SEAT MOUNTING / SEAT BELTSp. 534
CREW FLOOR / REAR FENDERSp. 535
CREW SEAT MOUNTING / SEAT BELTSp. 536
+REAR CARGO BOXp. 537
CARGO BOX – TAILGATE / BOX SUPPORTp. 537
BOX REMOVALp. 539
BOX INSTALLATIONp. 539
+BODY COMPONENT REMOVALp. 540
LOWER SEAT BASEp. 540
FRONT BUMPERp. 540
FENDERS / FOOT PADSp. 540
HOOD / DASHp. 541
FLOORSp. 542
+DECALSp. 543
+CHAPTER 11: ELECTRICALp. 545
+GENERAL INFORMATIONp. 547
SPECIAL TOOLSp. 547
ELECTRICAL SERVICE NOTESp. 547
BATTERY CONDUCTANCE ANALYZERp. 547
COMPONENTS UNDER HOODp. 548
+SWITCHES / CONTROLSp. 549
IGNITION / HEADLIGHT SWITCHp. 549
AWD / 2WD / TURF SWITCHp. 549
DIFFERENTIAL SOLENOIDp. 550
REAR DIFFERENTIAL SOLENOID OPERATIONp. 550
BRAKE PRESSURE SWITCHp. 550
+ALL WHEEL DRIVE (AWD) COILp. 551
OPERATION OVERVIEWp. 551
DIAGNOSING SYSTEM FAILURESp. 551
+VEHICLE SPEED SENSORp. 552
SPEED SENSOR LOCATIONp. 552
SPEED SENSOR TESTINGp. 552
+INSTRUMENT CLUSTERp. 553
OVERVIEWp. 553
RIDER INFORMATION DISPLAYp. 554
INFORMATION DISPLAY AREAp. 555
DIAGNOSTIC MODEp. 557
INSTRUMENT CLUSTER PINOUTSp. 558
INSTRUMENT CLUSTER REMOVALp. 558
INSTRUMENT CLUSTER INSTALLATIONp. 558
+HEADLIGHTSp. 559
HEADLIGHT ADJUSTMENTp. 559
HEADLIGHT BULB REPLACEMENTp. 560
HEADLIGHT HOUSING REMOVALp. 560
HEADLIGHT HOUSING INSTALLATIONp. 560
+TAIL LIGHT / BRAKE LIGHTp. 561
LED LAMP REPLACEMENTp. 561
+COOLING SYSTEMp. 562
FAN CONTROL CIRCUIT OPERATIONp. 562
FAN CONTROL CIRCUIT BYPASS TESTp. 562
+IGNITION COILp. 563
OPERATION OVERVIEWp. 563
IGNITION COIL TESTSp. 563
PRIMARY TESTp. 563
SECONDARY TESTSp. 563
IGNITION COIL AND HT LEAD REPLACEMENTp. 564
+RELAYSp. 565
+FUSES / CIRCUIT BREAKERp. 567
OPERATIONp. 567
OPERATION (INTL.)p. 568
+CHARGING SYSTEMp. 569
CURRENT DRAW – KEY OFFp. 569
CHARGING SYSTEM “BREAK EVEN” TESTp. 569
CHARGING SYSTEM ALTERNATOR TESTSp. 569
CHARGING SYSTEM TESTING FLOW CHARTp. 571
+BATTERY SERVICEp. 572
BATTERY TERMINALS / BOLTSp. 572
BATTERY TERMINAL BLOCKp. 572
BATTERY ACTIVATIONp. 572
BATTERY INSPECTIONp. 573
BATTERY REMOVAL / INSTALLATIONp. 574
CONVENTIONAL BATTERY TESTINGp. 574
OCV – OPEN CIRCUIT VOLTAGE TESTp. 574
VOLTAGE DROP TESTp. 574
SPECIFIC GRAVITY TESTp. 575
LOAD TESTp. 575
CHARGING PROCEDUREp. 575
OFF SEASON STORAGEp. 576
+STARTER SYSTEMp. 577
TROUBLESHOOTINGp. 577
STARTER MOTOR DOES NOT RUNp. 577
STARTER MOTOR TURNS OVER SLOWLYp. 577
STARTER MOTOR TURNS – ENGINE DOES NOT ROTATEp. 577
STARTER DRIVEp. 577
STARTER SOLENOID BENCH TESTp. 578
STARTER SOLENOID OPERATIONp. 579
STARTING SYSTEM TESTING FLOW CHARTp. 580
- Chapter 4: Fuel System
- EFI operation, special tools and Digital Wrench diagnostic information
- EFI component locations, fuel-line / vent routing and air-box service
- ECU, electronic throttle body and pedal-position sensor testing
- Fuel tank, pump and sender service plus sensor diagnosis and fuel-system troubleshooting
- Chapter 5: PVT System
- PVT operation, clutching chart, drive and driven clutch operation and break-in
- PVT sealing, ducts, disassembly and assembly
- Drive-belt removal, inspection and installation
- Clutch alignment / offset / center distance, drive-clutch and driven-clutch service
- PVT troubleshooting for belt, clutch, heat, water-ingestion and engagement concerns
- Chapter 6: Transmission
- Torque specifications, transmission gears, lubrication and mounting
- Shift lever and shift-cable inspection / adjustment
- Transmission removal and installation
- Differential operation, internal disassembly, inspection and reassembly
- Shifting troubleshooting checklist
- Chapter 7: Final Drive
- Front hub / bearing and front drive-shaft service
- Front gearcase removal, installation, disassembly and assembly
- All Wheel Drive operation and diagnosis, including non-ADC and ADC gearcase material
- Rear bearing carrier, rear drive shaft and prop-shaft service
- Chapter 8: Steering / Suspension
- Steering assembly views for non-EPS and EPS models
- Steering wheel, shaft, rack and power-steering unit service
- Front strut and ball-joint replacement
- Rear A-arms, stabilizer bar / linkage, shocks and springs
- Chapter 9: Brake System
- Brake service specifications, hydraulic operation and brake-noise troubleshooting
- Master cylinder, brake-pressure switch and brake-pedal procedures
- Brake bleeding, fluid change and burnishing
- Front brake pad and caliper service for RANGER and CREW configurations
- Brake-system troubleshooting
- Chapter 10: Body / Frame
- Frame, CREW frame and cab-frame assembly views
- Dash instruments / controls, hood, dash, front fascia, floor and rear fenders
- Seat mounting, seat belts and CREW body components
- Rear cargo box, tailgate, body-component removal and decal replacement
- Chapter 11: Electrical
- Electrical service notes, special tools and under-hood components
- Ignition / headlight, AWD / 2WD / TURF and differential controls
- Vehicle-speed sensor and instrument-cluster diagnosis
- Headlights, tail / brake lights, cooling-fan control and ignition-coil testing
- Relays, fuses, circuit breakers, charging system, battery service and starter-system diagnosis
Across these chapters, the document uses assembly views, exploded component illustrations, service measurements, torque sequences and diagnostic check procedures to support both inspection and repair. That makes the 2017-2018 Polaris Ranger 500 / 570 Service Manual 9928485 R01 PDF useful for routine service as well as deeper work involving engine internals, clutching, gearbox components, drive systems, chassis components and electrical fault tracing.
Repair Procedures, Measurements and Workshop Reference
The manual is particularly detailed where repair accuracy depends on measured limits. It contains master torque data and component-specific torque specifications, valve clearances, cylinder and piston measurements, camshaft and valve data, fluid capacities, fuel pressure information, cooling-system temperatures and pressure specifications, wheel and hub torques, alignment data, brake wear limits and electrical test procedures. Dedicated special-tool sections identify tools used for engine, fuel, PVT, transmission, final-drive, steering / suspension, brake and electrical work. Safety warnings and procedure notes are integrated throughout the repair steps, including guidance for operations that require a properly equipped shop and suitable mechanical knowledge.
For owners and technicians working on the covered RANGER variants, this level of detail helps move beyond parts replacement by giving the inspection points and service criteria needed to decide whether a component can be reused, adjusted, serviced or replaced. The exploded views and installation sequences also help with component orientation and reassembly after larger jobs such as engine teardown, transmission service, gearcase repair, brake caliper work or body removal.
Get the Manual and Start the Repair
The 2017-2018 Polaris Ranger 500 / 570 Service Manual 9928485 R01 PDF gives you a single technical reference for scheduled maintenance, engine and cooling repairs, EFI diagnosis, PVT clutch and belt work, transmission and final-drive service, steering and suspension repairs, brake work, body disassembly and electrical testing on the RANGER 500 / 570 models covered by the publication. Following the specified procedures, measurements, service limits and torque values matters when diagnosing faults and putting components back together correctly. After payment, the manual is delivered as an instant PDF download with no physical shipping; you can open it on compatible phones, tablets and computers and print the pages you need for workshop use.
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