Polaris RZR 570 (2012) - Workshop Manual - Wiring Diagram

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

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

CONTENTS:

2012 RANGER RZR 570 / INTL WORKSHOP MANUAL

- Foreword 
- Understanding manual safety labels and directions 
- Trademarks

CHAPTER 1 - GENERAL INFORMATION

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

CHAPTER 2 - MAINTENANCE

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

CHAPTER 3 - ENGINE / COOLING SYSTEM

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

CHAPTER 4 - ELECTRONIC FUEL INJECTION

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

CHAPTER 5 - BODY / STEERING / SUSPENSION

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

CHAPTER 6 - CLUTCHING

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

CHAPTER 7 - FINAL DRIVE

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

CHAPTER 8 - TRANSMISSION

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

CHAPTER 9 - BRAKES

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

CHAPTER 10 - ELECTRICAL

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

INDEX

WIRING DIAGRAMS

OWNERS MANUAL (ENGLISH)

OWNERS MANUAL (ITALIAN)