Polaris RANGER 500 2021

3
9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual
© Copyright Polaris Inc.
3.3
CRANKCASE ASSEMBLY – PTO SIDE . .. . ............. . . . . . ............. . . . . . .. ........... .. . . ......3.81
BALANCE SHAFT INSTALLATION / TIMING ......... . . . . . ............. .............. ... ........... .. .3.83
FINAL CRANKCASE ASSEMBLY . . .. ............. . . . . . .. ........... . . . . . .............. . . . . . ..........3.83
STARTER ONE-WAY CLUTCH INSTALLATION .......... .. .............. . . . . . ............. . . . . . ......3.85
FLYWHEEL INSTALLATION .. . .. ............ . . . . . . ............ . . . . . ............. .. .. ............. . . . .3.85
STATOR / STATOR COVER INSTALLATION ......... . . . . . ............. .. .. ............. . . . . . .........3.87
570CC DOHC ENGINE ....... . . . . . .............. . . . . . ............. . . . . . ............. .. . ............. . . . . . ...3.88
ENGINE DETAIL, TORQUES / SEQUENCES ... .............. .............. .............. .. . . .............3.88
ENGINE FASTENER TORQUE SPECIFICATIONS ....... .............. .............. .. . . ............ .3.88
TORQUE SEQUENCE.. .. ........... ... ............. . . . . . ............. .. ............ .. . . .............3.90
CRANKCASE - TIMING / SEALING PATH ............ . . . . . ............. .............. ... ........... .. .3.92
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . ............ .. .. ............. . . . . . ............. . . .3.93
VALVE COVER REMOVAL.............. . . . . . .............. . . . . . ............. . . . . . ............. .. .. ...3.93
CAMSHAFT / CARRIER REMOVAL ........... . . . . . ............ .. .. ............. . . . . . ............. . . .3.93
CAMSHAFT SPROCKET INSPECTION . . . . . ............. .............. .. .............. . . . . . ..........3.94
CAMSHAFT INSPECTION. ............. ... ........... ... ........... .. . . ............ . . . . . .............3.95
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM ...... .. ............ .. . . ............. . . . . . ..3.95
CAM CHAIN AND GUIDE SERVICE .. .. ............. . . . . . ............. .............. ... ........... .. .3.96
CYLINDER HEAD REMOVAL ........ .. . . ............. . . . . . ............ .. .. ............. . . . . . .........3.96
CYLINDER HEAD DISASSEMBLY . .. ............. .............. .. .. ............. . . . . . ............. . . .3.97
CYLINDER HEAD INSPECTION ..... ... ............. . . . . . ............. .............. .. . ........... .. .3.98
CYLINDER HEAD WARP INSPECTION........ ... ........... .. . ............. . . . . . ............. .. .. ...3.98
VALVE INSPECTION ........... . . . . . ............. .. .. ............. . . . . . ............. . . . . . ............3.98
COMBUSTION CHAMBER CLEANING . .. . . ............. . . . . . ............. . . . . . . ........... .. . . ......3.99
VALVE SEAT RECONDITIONING ... . . . . . .. ........... ... ........... .. . ............. . . . . . ........... 3.100
CYLINDER REMOVAL........... .............. .. . . ............ . . . . . ............. .. .. ............. . . 3.102
CYLINDER INSPECTION. ........... .. . . ............. . . . . . .............. . . . . . ............. . . . . . .... 3.102
PISTON REMOVAL........... ... ............. . . . . . ............. .............. ... ........... .. . ..... 3.103
PISTON-TO-CYLINDER CLEARANCE ............ .. .. ............. . . . . . ............. . . . . . .......... 3.103
PISTON / ROD INSPECTION ........... ... ........... ... ........... .. . . ............ . . . . . ........... 3.104
PISTON RING INSTALLED GAP ....... . . . . . ............. .. .. ............. . . . . . ............. . . . . . ... 3.105
ENGINE ASSEMBLY - TOP END. .. ............. .. ............ .. .. ............. . . . . . ............. . . . . . ... 3.106
PISTON RING INSTALLATION............. .. ............ .. .. ............. . . . . . ............. . . . . . ... 3.106
PISTON / CONNECTING ROD ASSEMBLY .. .. ............. . . . . . ............. .. . ........... .. . . .... 3.107
CYLINDER INSTALLATION .. . . . . ............. . . . . . ............. .. .. ............ . . . . . . ............ . . 3.108
CYLINDER HEAD IDENTIFICATION . . . . . ............. . . . . . .............. . . . . . ............. . . . . . .... 3.108
CRANKCASE IDENTIFICATION .. ............. .. . ............. . . . . . ............. .. .. ............. . . 3.109
CYLINDER HEAD INSTALLATION - BLACK BOLTS . .. ............ . . . . . . ............ . . . . . ........... 3.110
CYLINDER HEAD INSTALLATION - SILVER BOLTS.. . ............. . . . . . ............. .. . . ............3.111
VALVE SEALING TEST .. . . . .. ............. .............. .............. .. .............. . . . . . ........ 3.112
VALVE CLEARANCE CHECK / ADJUSTMENT . ............. . . . . . ............. ... ........... ... ..... 3.112
VALVE LASH - TAPPET SELECTION . .. ............. . . . . . ............. .. .............. . . . . . ........ 3.115
CAMSHAFT INSTALLATION / TIMING .. . . . . ............. .. ............ .. .. ............. . . . . . ....... 3.116
CAMSHAFT TIMING - QUICK REFERENCE ... ............. . . . . . ............. ... ........... ... ..... 3.119
VALVE COVER INSTALLATION. . . . .. ............. .............. .. .............. . . . . . ............. . . 3.120
ENGINE DISASSEMBLY / INSPECTION - LOWER END.. .. ............. . . . . . ............. . . . . . .......... 3.121
CRANKCASE DISASSEMBLY ... ............. . . . . . ............. .............. ... ........... .. . . .... 3.121
STATOR COVER REMOVAL......... ... ............. . . . . . ............. .............. ... ........... . 3.121
ENGINE / COOLING SYSTEM