Polaris RANGER ETX 2016 User 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 October 2015 (PN 9926806 R03)
© Copyright 2015 Polaris Industries 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.
2015 - 2016 RANGER ETX / 570 2-SEAT
2015 - 2016 RANGER 570 CREW

Polaris RANGER ETX 2016 Specifications

General

Brand	Polaris
Model	RANGER ETX 2016
Category	Offroad Vehicle
Language	English

Summary

SAFETY WARNINGS

CHAPTER 1: GENERAL INFORMATION

Torque Specifications

Tables detailing torque values for various fasteners and components.

CHAPTER 2: MAINTENANCE

Break-in Periods, Intervals, and Procedures

Guidelines for vehicle break-in, maintenance intervals, and inspection procedures.

CHAPTER 3: ENGINE / COOLING SYSTEM

Engine Component Assembly and Disassembly

Stator Cover, Valve Cover, Oil Sump, Camshafts, Cylinder Head, Crankcase, Exhaust System.

Engine Mounting and Timing Procedures

Torque specs for mounting, coupler brackets, cylinder head, stator cover, and oil sump.

Cooling System Operation and Service

Cooling system flow, assembly, specs, pressure tests, radiator, thermostat, water pump service.

Engine Service and Break-in

Accessible components, engine removal/installation, break-in period, lubrication specs.

Top-End Engine Disassembly and Inspection

Procedures for valve cover, camshafts, cylinder head, piston, and rings.

Engine Assembly Procedures

Piston, cylinder, cylinder head, and crankshaft assembly steps.

CHAPTER 4: FUEL SYSTEM

EFI System Overview and Components

EFI operation, principal components, initial priming, and troubleshooting.

Electronic Control Unit (ECU) and Throttle Body (ETC)

ECU overview, service, replacement, and ETC learn procedure.

Fuel Tank, Pump, and Sender Service

Fuel tank assembly, removal, installation, sender test, pump test, and replacement.

Sensor Testing and Replacement

T-MAP, CPS sensor overview, testing, and replacement.

Ignition System Components and Testing

Ignition coil overview, tests, replacement, fuel injector overview, tests, replacement, troubleshooting.

EFI Diagnosis and Trouble Codes

Service notes, trouble code display, and diagnostic trouble code table.

CHAPTER 5: PVT SYSTEM

PVT System Operation and Maintenance

Clutching chart, general operation, break-in, maintenance, and overheating diagnosis.

PVT System Service Procedures

Sealing/Guard/Ducts, Disassembly, Assembly, Drive Belt, Clutch Alignment, Drive Clutch, Driven Clutch Service.

Clutch Component Service and Inspection

Clutch disassembly, shift weights, spider removal, rollers, bearings, bushing service, clutch assembly.

PVT System Troubleshooting

Troubleshooting guide for common PVT issues like overheating and belt slippage.

CHAPTER 6: TRANSMISSION

Transmission Operation and Service

Lubrication, mounting, shift lever, and shift cable inspection/adjustment.

Transmission Removal and Installation

Procedures for removing and installing the transmission for 325 and general models.

Transmission Internal Service

Differential operation, disassembly, planetary differential, gear/shaft/bearing inspection, snorkel gear backlash, crankcase assembly, balance shaft, starter clutch, flywheel, stator, oil pump.

Transmission Troubleshooting

Checklist for diagnosing shifting difficulties.

CHAPTER 7: FINAL DRIVE

Front Gearcase Service

Gearcase removal, installation, assembly views, AWD operation, diagnosis, disassembly, inspection, reassembly.

Rear Drive Shaft Service

Final Drive Troubleshooting

CHAPTER 8: STEERING / SUSPENSION

Steering System Service

CHAPTER 9: BRAKE SYSTEM

Master Cylinder and Brake Pressure Switch Service

Brake Procedures

Front Brake Pad Service

Front Caliper Service

Rear Caliper Service

Parking Brake System Service

CHAPTER 10: BODY / FRAME

Dash, Instruments, and Controls

Hood, Dash, and Front Fascia Service

Body Component Removal

CHAPTER 11: ELECTRICAL

AWD Coil Operation and Diagnosis

Vehicle Speed Sensor and Instrument Cluster

Ignition Coil and Starting System