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2014 Sportsman 570 EF
Polaris 2014 Sportsman 570 EF Service Manual
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10
10.25
9924871
R03
-
2014
Polaris
Sportsman®
570
EFI
Service
Manual
©
Copyright
2013
Polaris
Sales
Inc.
EPS
T
roubleshooting
ELECTRICAL
404
406
Table of Contents
General Information Chapter 1 General Information
5
Table of Contents
5
Chapter 1
6
Model Number Designation
6
Vehicle Identification
6
Vehicle Identification Number (Vin) Designation
6
Vehicle and Engine Serial Numbers
7
Transmission I.D. Location
8
Vehicle Information
9
Publication Part Numbers
9
Replacement Keys
9
Special Tools
9
Vehicle Specifications
10
2014 Sportsman 570 Efi / Eps
10
2014 Sportsman Forest 570 Efi / Eps
11
2014 Sportsman Touring 570 Efi
13
2014 Sportsman Touring 570 Efi (Intl.)
13
Clutching Specifications
14
Clutching Chart
14
Misc. Specifications and Charts
15
Conversion Table
15
Standard Bolt Torque Specification
16
Metric Bolt Torque Specification
16
Sae Tap / Drill Sizes
17
Metric Tap / Drill Sizes
18
Decimal Equivalents
19
Maintenance Chapter 2 Maintenance
21
Special Tools
23
Break-In Period
24
Chapter 2
24
Inspection / Maintenance Intervals
24
Pre-Ride / Daily Inspection
24
Periodic Maintenance Chart
26
Vehicle Storage
28
Storage Tips
28
Lubricants / Service Products
29
Polaris Lubricants, Maintenance and Service Products
29
Lubrication Components
30
Fuel System and Air Intake
31
Fuel System
31
Fuel Lines
31
Vent Lines
31
Throttle Inspection
32
Throttle Cable / Throttle Release System (Trs Switch) Adjustment
32
Air Filter/Pre-Filter Service
33
Air Box Sediment Drain
34
Crankcase Breather Valve / Hose
35
Engine
36
Engine Oil Level
36
Oil and Filter Change
36
Compression Test Specification
38
Engine Mounts
38
Valve Clearance Inspection
38
Exhaust Pipe
40
Transmission and Front Gearcase
41
Transmission Lubrication
41
Shift Link Rod Maintenance
42
Front Gearcase Lubrication
42
Cooling System
44
Liquid Cooling System Overview
44
Coolant Level Inspection
44
Radiator Coolant Level
44
Cooling System Hoses
45
Cooling System Pressure Test
45
Coolant Strength / Type
46
Coolant Drain / Fill
46
Radiator/Grill Screen
47
Final Drive / Wheel and Tire
48
Wheels
48
Wheel, Hub, and Spindle Torque Table
48
Tire Pressure
48
Wheel Removal Front or Rear
48
Wheel Installation
48
Tire Inspection
49
CV Shaft Boot Inspection
49
Frame, Nuts, Bolts, Fasteners
49
Brake System
50
Brake System Inspection
50
Brake Pad Inspection
50
Hose/Fitting Inspection
50
Auxiliary Brake Testing
51
Auxiliary Brake Adjustment (Hydraulic)
51
Electrical and Ignition System
52
Battery Maintenance
52
Battery Removal
52
Battery Installation
53
Spark Plug Service
54
Engine to Frame Ground
55
Steering
56
Tie Rod End/Steering Inspection
56
Front Suspension
57
Suspension Spring Preload Adjustment
57
Toe Alignment Adjustment
57
Camber and Caster
57
Wheel Alignment
57
Engine Chapter 3 Engine
59
Chapter 3
62
Engine Lubrication Specifications
62
General Information
62
Special Tools
62
Oil Pressure Test
63
Engine Oil Flow Chart
64
Engine Service Specifications
65
Engine Specifications
65
Engine Detail - Torque Values / Sequences / Assembly Notes
67
Main Engine Components - Torque Specification and Sequence
67
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
68
Cylinder / Oil Filter / Oil Pump / Breather
69
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
70
Spark Plugs / Starter / Throttle Body / Valve Cover
71
Piston / Crankshaft / Balance Shaft
72
Engine Cooling System
73
Cooling System Specifications
73
Cooling System Exploded View and Coolant Flow Diagram
74
Cooling System Pressure Test
75
Pressure Cap Test
75
Radiator
76
Coolant Drain / Radiator Removal
76
Thermostat Replacement
77
Cooling System Bleeding Procedure
78
Water Pump Service
80
Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
80
Water Pump Mechanical Seal / Oil Seal Replacement
80
Engine Service
88
Accessible Engine Components
88
Top-End Service (Engine in Chassis)
88
Engine Removal
89
Engine Installation
92
Engine Break-In Period
95
Engine Lubrication Specifications
95
Engine Mounting and Torque Values
96
Setting Tdc (Top-Dead-Center)
97
Engine Disassembly / Inspection - Top End
98
Valve Cover Removal
98
Camshaft / Carrier Removal
98
Camshaft Sprocket Inspection
100
Camshaft Inspection
100
Exhaust Camshaft Decompression Mechanism
101
Cam Chain and Guide Service
101
Cylinder Head Removal
101
Cylinder Head Disassembly
102
Cylinder Head Inspection
103
Cylinder Head Warp Inspection
103
Valve Inspection
104
Combustion Chamber Cleaning
105
Valve Seat Reconditioning
105
Cylinder Removal
107
Cylinder Inspection
107
Piston Removal
108
Piston-To-Cylinder Clearance
109
Piston / Rod Inspection
109
Piston Ring Installed Gap
110
Honing to Oversize
111
Cylinder Hone Selection / Honing Procedure
111
Cleaning the Cylinder after Honing
111
Engine Assembly - Top End
112
Piston Ring Installation
112
Piston / Connecting Rod Assembly
113
Cylinder Installation
113
Cylinder Head Installation
114
Valve Sealing Test
115
Valve Clearance Check / Adjustment
116
Intake Valve Lash - Tappet Selection Matrix
119
Exhaust Valve Lash - Tappet Selection Matrix
120
Camshaft Installation / Timing
121
Camshaft Timing - Quick Reference
124
Valve Cover Installation
125
Engine Disassembly / Inspection - Lower End
126
Crankcase Disassembly
126
Flywheel / Stator Housing Removal
126
Starter One-Way Clutch Inspection
126
Starter One-Way Clutch Installation
128
Flywheel Installation
128
Stator Removal
129
Stator / Stator Cover Installation
129
Oil Pump Removal
130
Oil Pump Assembly
132
Crankcase Breather Valve / Hose
133
Crankcase Separation
134
Balance Shaft Removal / Inspection
135
Crankshaft Removal
136
Crankshaft Inspection
136
Pto Side Crankcase Bearing Service
137
Mag Side Crankcase Bearing Service
139
Oil Pickup Assembly Inspection
139
Oil Pressure Regulator (Bypass) Valve Inspection
139
Crankcase Inspection
140
Engine Assembly - Lower End
141
Crankcase Assembly - Pto Side
141
Balance Shaft Installation / Timing
143
Final Crankcase Assembly
143
Troubleshooting
145
Engine
145
Cooling System
146
Fuel System - General Chapter 4 Fuel System - General
147
Chapter 4
149
General Information
149
Service Notes
149
Efi System Exploded View
150
Electrical Diagram
151
Efi System Component Locations
152
Special Tools
153
Electronic Fuel Injection
156
Principal Components
156
Efi Operation Overview
156
Initial Priming / Starting Procedure
156
Electronic Control Unit (Ecu)
157
Operation Overview
157
Ecu Service
157
Ecu Replacement
157
Fuel Pump / Sender / Tank / Lines
159
Operation Overview
159
Fuel Pump Test
160
Fuel Pump Replacement
161
Fuel Tank Exploded View
165
Fuel Sender Test
166
Fuel Tank Removal
166
Fuel Tank Installation
167
Fuel Lines - Quick Connect
167
Temp / Manifold Absolute Pressure Sensor (T-Map)
168
Operation Overview
168
T-Map Sensor Test
168
T-Map Sensor Replacement
168
Crankshaft Position Sensor (Cps)
169
Operation Overview
169
Cps Test
169
Cps Replacement
170
Fuel Injectors
171
Operation Overview
171
Fuel Injector Troubleshooting
171
Fuel Injector Test
172
Fuel Injector Replacement
172
Idle Air Control (Iac)
174
Operation Overview
174
Iac Test
174
Iac Replacement
174
Throttle Position Sensor (Tps)
175
Operation Overview
175
Tps Resistance Tests
175
Tps Tester / Regulator
175
Tps Replacement
175
Engine Coolant Temperature Sensor (Ect)
177
Operation Overview
177
Ect Sensor Test
177
Ect Sensor Replacement
178
Ignition Coil
179
Operation Overview
179
Ignition Coil / Wire Testing
179
Efi Diagnostics
180
Instrument Cluster Trouble Code Display
180
Efi Troubleshooting
183
Digital Wrench Operation
185
Digital Wrench Diagnostic Software Overview
185
Special Tools
185
Diagnostic Software Version
185
Ecu Replacement
185
Guided Diagnostic Available
185
Digital Wrench Communication Errors
186
Digital Wrench - Diagnostic Connector
186
Digital Wrench Serial Number Location
186
Digital Wrench Version and Update
187
Digital Wrench Updates
187
Digital Wrench Feature Map
189
Engine Controller Reprogramming (Reflash)
190
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
195
Chapter 5
196
General Information
196
Multi-Function Pliers
196
Torque Specifications
196
Body
197
Side Panel Removal
197
Front Storage Box Lid / Front Rack and Access Panel Removal / Installation
197
Footwell Removal / Installation
198
Front Bumper Removal / Installation
199
Front Fender Removal / Installation
200
Mud Guard Removal / Installation
201
Front Rack / Storage Box Lid Assembly
202
Front Bumper Assembly
203
Front Cab Assembly
204
Rear Rack Assembly
206
Rear Cab, Seat, and Footwell Assembly
210
Rear Storage Box Assembly
216
Winch and Front Bumper Mounting
217
Headlight Pod Exploded View
218
Steering
219
Handlebar Block Installation Procedure
220
Steering Post Removal
220
Steering Post Assembly
220
Eps Unit Removal (Eps Models)
221
Eps Unit Installation (Eps Models)
221
Steering Exploded View (Eps Models)
224
Steering Post and Lock (Intl.)
219
Steering Assembly Exploded View
219
Suspension
227
Steering / A-Arm Exploded View
227
A-Arm Replacement
228
Ball Joint Replacement
228
Torsion Bar Exploded View
230
Strut Assembly
231
Front Strut Cartridge Replacement
233
Decal Replacement
234
Clutching Chapter 6 Clutching
235
Chapter 6
237
Clutching Chart
237
General Information
237
Pvt System Fastener Torques
237
Special Tools
237
Pvt System Overview
238
General Operation
238
Drive Clutch Operation
238
Driven Clutch Operation
238
Maintenance / Inspection
239
Pvt Break-In (Drive Belt / Clutches)
239
Overheating / Diagnosis
240
Pvt Exploded Views
241
Drive Clutch Exploded Views (Ebs Vs. Non-Ebs)
241
Pvt Sealing and Ducting Components
242
Pvt System Service
244
Disassembly
244
Assembly
245
Drive Belt
246
Belt Removal
246
Belt Inspection
246
Belt Installation
246
Pvt Break-In (Drive Belt / Clutches)
246
Clutch Alignment
247
Clutch Alignment Tool Use
247
Belt Deflection (Tension) (Non Ebs Only)
248
Setting Center-To-Center Distance
248
Drive Clutch Service
249
Drive Clutch Exploded View (All Models)
249
Clutch Disassembly
250
Shift Weight Inspection
251
Spider Removal
252
Roller, Pin, and Thrust Washer Inspection
252
Button to Tower Clearance Inspection
253
Bearing Inspection
253
Clutch Inspection
253
Bushing Service
255
Clutch Assembly
257
Drive Clutch Bushing Service (Non Ebs and Ebs)
259
Bushing Service
259
Driven Clutch Service (Non Ebs)
262
Exploded View
262
Clutch Disassembly / Inspection
263
Bushing Service
264
Moveable Sheave - Bushing Installation
266
Clutch Assembly
267
Driven Clutch Service (Ebs)
269
Exploded View
269
Clutch Disassembly
270
Bushing Service
273
Clutch Assembly
275
Driven Clutch Bushing Service
278
Bushing Service (Non Ebs and Ebs)
278
Troubleshooting
280
Final Drive Chapter 7 Final Drive
283
Chapter 7
284
Gearcase Fluid / Capacity
284
General Information
284
Torque Table
284
Front Hub
285
Disassembly
285
Assembly
285
Front Gearcase Removal and Installiation
286
Gearcase Removal
286
Gearcase Installation
287
Front Gearcase (Non-Adc)
288
Exploded View
288
Operation
290
Disassembly / Inspection
290
Reassembly / Inspection
294
Troubleshooting, Front Gearcase (Non-Adc)
297
Setting Ring Gear Backlash Non Adc
298
Front Drive (CV) Shaft
299
Inspection
299
Assembly
304
Installation
304
Rear Drive (CV) Shaft
306
Inspection
306
Removal
306
Installation
306
CV Drive Shaft Service
308
Drive Shafts and Propshafts Components
308
Drive Shaft and CV Joint Handling Tips
309
Outer CV Joint / Boot Replacement
309
Inner Plunging Joint / Boot Replacement
312
Drive Shaft Exploded Views
315
Prop Shaft - Front or Rear
316
Removal and Installation
316
U-Joint Service
317
Disassembly
317
Assembly
318
Transmission Chapter 8 Transmission
319
Chapter 8
320
Lubrication
320
Transmission - General
320
Transmission Frame Mounts
321
Transmission Upper Frame Mount
322
Transmission Rear Stabilizer Mounts
323
Transmission Control Arm Bracket Mounts
324
Shift Linkage Inspection
325
Gear Selector Removal
326
Transmission Installation
326
Transmission Removal
326
Troubleshooting Checklist
327
Transmission Disassembly / Assembly
328
Transmission Disassembly
328
Snorkel / Output Gear Backlash Procedure
334
Transmission Assembly
336
Sportsman Transmission Exploded View
343
Brakes Chapter 9 Brakes
345
Chapter 9
347
Component Service Limits
347
General Information
347
Torque Table
347
Special Tools
348
Hydraulic Brake System
349
Operation Overview
349
Brake Controls Overview
350
Brake Noise Troubleshooting
350
Brake Bleeding / Fluid Change
351
Brake System Exploded Views
353
Brake Caliper Exploded Views
355
Front Master Cylinder (All Models)
358
Removal
358
Installation
358
Front Brakes
359
Pad Removal
359
Assembly
360
Brake Burnishing Procedure
361
Front Brake Disc
362
Inspection
362
Removal / Replacement
363
Front Caliper
364
Removal
364
Inspection
365
Reassembly
365
Installation
366
Rear Brake Pad
367
Touring Pad Removal
367
Touring Pad Installation
368
Sportsman Rear Pad Removal
369
Sportsman Rear Pad Installation
370
Brake Burnishing Procedure
371
Sportsman Rear Caliper
372
Removal and Inspection
372
Assembly
373
Sportsman Touring Rear Caliper
375
Removal
375
Inspection
376
Reassembly
376
Rear Brake Disc
377
Inspection
377
Rear Master Cylinder
378
Electrical Chapter 10 Electrical
381
General Information
383
Chapter 10
384
Ignition System / Basic Electrical Components
384
Efi Component Testing
385
Electrical Service Notes
385
Troubleshooting
385
Instrument Cluster
386
Overview
386
Rider Information Display
387
Information Display Area
388
Diagnostic Mode
393
Controller Area Network (Can)
395
Can Troubleshooting
395
Transmission (Gear Position) Switch
396
All Wheel Drive (Awd) Coil
397
Operation Overview
397
Diagnosing System Failures
397
Speed Sensor
399
Speed Sensor Location
399
Speed Sensor Testing
399
Testing
400
Replacement
400
Throttle Release Switch (Trs)
401
Cooling System Components
402
Fan Control Circuit Operation
402
Fan Control Bypass Test
402
Fan Motor Current Draw Test
402
Coolant Temperature Sensor
403
Electronic Power Steering (Eps)
404
Eps Operation
404
Proper Eps System Diagnosing
404
Eps Circuit
404
Eps Troubleshooting
405
Starter System
406
Troubleshooting
406
Voltage Drop Test
406
Starter Motor Removal
406
Starter Motor Installation
406
Starter Solenoid Bench Test
407
Starter Solenoid Operation
407
Starter System Testing Flow Chart
408
Charging System
409
Current Draw - Key off
409
Break Even Test
409
Alternator Output Test
410
Regulator / Rectifier
411
Charging System Testing Flow Chart
412
Fuel Sender
413
Testing
413
Lighting
414
High Beam Headlight Bulb Replacement
414
Headlight Housing Replacement
414
High Beam Headlight Adjustment
415
Lower Headlamp Removal / Installation
416
Low Beam Headlight Adjustment (Non Intl)
417
Lower Headlight Adjustment (Forest)
417
Headlamp Switch Test
418
Brake Light Replacement
418
Brake Light Switch
419
Battery
420
Battery Identification
420
Battery Conductance Analyzer
420
Battery Activation (Conventional)
421
Battery Terminals/Bolts
421
Conventional Battery Inspection / Removal
421
Conventional Battery Installation
422
Conventional Battery Testing
422
Conventional Battery Ocv - Open Circuit Voltage Test
422
Conventional Battery Specific Gravity Test
423
Battery Load Test
423
Off Season Storage
423
Charging Procedure
424
Low Maintenance Battery
424
Low Maintenance Battery Charging
425
Low Maintenance Battery Inspection / Removal
425
Low Maintenance Battery Installation
426
Low Maintenance Battery - Ocv- Open Circuit Voltage Test
426
Low Maintenance Battery Load Test
426
Low Maintenance Battery Charging Procedure
427
Low Maintenance Battery Off-Season Storage
427
Sportsman 570 Efi Forest Electrical
428
Head Lamps / Tail Lamps - Exploded View
428
Hazard / Flasher Module
429
Rear Tail Lamp / Turn Signal Lamp Replacement
429
Front Turn Signal Lamp Replacement
430
Pod Indicator Lamp / Switch Replacement
430
Speed Control
430
Troubleshooting Diagrams
431
4
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Polaris 2014 Sportsman 570 EF Specifications
General
Brand
Polaris
Model
2014 Sportsman 570 EF
Category
Offroad Vehicle
Language
English
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