Polaris RANGER ETX 2016 User Manual

3
9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual
© Copyright Polaris Industries Inc.
3.3
PTO AND MAG SIDE CRANKCASE BEARING SERVICE ......... ... .... ... ... . . . . . .. ........... ...... . . . .3.78
OIL PICKUP ASSEMBLY INSPECTION . . . . .............. . . . . . ............. . . . . . ............. .... ... ... . . . .3.79
CRANKCASE INSPECTION ....... ... .... ... ... .... ... ... . . . . . ............. .... ... ... .... ... ... . . . . . . .....3.79
ENGINE ASSEMBLY - LOWER END .. . . ............. ... ... . . . . . ............. .... ... ... .... ... ... . . . . . ......3.80
CRANKCASE ASSEMBLY . . . ............ . . . . . . . ........... ...... . . . . . ............. ... ... . . . . . .............3.80
BALANCE SHAFT INSTALLATION / TIMING ........... . . . . . ............. . . . . . .............. . . . . . ..........3.81
STARTER ONE-WAY CLUTCH INSTALLATION .... . . . . . ............. ... . . . . . ............. ...... . . . . . ......3.82
FLYWHEEL INSTALLATION ... .... . . . . . .............. . . . . . ............. . . . . . ............. ...... . . . . . ......3.82
OIL PUMP ASSEMBLY . . . .. ............. . . . . . .. ........... ... .... ... ... . . . . . ............. ...... . . . . . ......3.84
STATOR / STATOR COVER INSTALLATION . . . . . ............. . . . . . .. ........... . . . . . . . ............ . . . . . ...3.84
ENGINE / COOLING SYSTEM TROUBLESHOOTING... . . . .. ........... ... .... ... ... .... ... .... . . . . . .....3.86
ENGINE TROUBLESHOOTING. . .. ............. ... . . . . . ............. .... ... ... . . . . . .. ........... ...... . . . .3.86
COOLING SYSTEM TROUBLESHOOTING .. ............. . . . . . ............. ... . . . . . .. ........... ..... . . . . .3.87
GENERAL INFORMATION... . . . . . ............. . . . . . .. ............ . . . . . . ............ . . . . . . ............ .... ...3.88
SPECIAL TOOLS ......... . . . . . ............. . . . . . ............. .... ... ... . . . . . ............. ...... . . . . . ......3.88
ENGINE LUBRICATION SPECIFICATIONS . . . ............ . . . . . ............. .... ... ... .... ... ... . . . . . . .....3.89
OIL PRESSURE TEST. . . . .. ............. . . . . . .. ........... ... .... . . . . . .. ............ . . . . . ............. . . . .3.89
ENGINE OIL FLOW CHART .. . . . .. ............. .... . . . . . .. ............ . . . . . ............. . . . . . .............3.90
ENGINE SPECIFICATIONS.. . . . ............. . . . . . .............. . . . . . ............. . . . . . ............. .... ...3.91
ENGINE DETAIL. . .. ........... ... ... . . . . . ............. ...... . . . . . ............. . . . . . .............. . . . . . .......3.93
ENGINE FASTENER TORQUE SPECIFICATIONS .. ............. . . . . . ............. ... .... . . . . . ............3.93
TORQUE SEQUENCE. . . . .. ............. . . . . . ............ . . . . . ............. .... ... ... .... ... .... . . . . . .....3.95
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE............ . . . . . .............3.96
CYLINDER / OIL FILTER / OIL PUMP / BREATHER ........... ... . . . . . ............. ... .... ... ... . . . . . ......3.97
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER - BLACK HEAD BOLTS .......... .... ...3.97
CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS ......... . . . . . . ............ . . . .3.99
SPARK PLUG / STARTER / THROTTLE BODY / VALVE COVER .. . . . . ............. ... .... . . . . . .......... 3.100
PISTON / CRANKSHAFT / BALANCE SHAFT ... ........... ...... . . . . . ............. . . . . . .............. . . . 3.101
ENGINE COOLING SYSTEM.... .... ... ... . . . . . .. ........... ...... . . . . . ............ . . . . . . ............ .... . 3.102
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM..... . . . . . ............. . . . . . .... 3.102
COOLING SYSTEM SPECIFICATIONS .. . . ............ .... ... ... . . . . . . ............ ...... . . . . . ........... 3.103
COOLING SYSTEM PRESSURE TEST ............ . . . . . ............. ... . . . . . ............. ... .... ... ... . . 3.103
PRESSURE CAP TEST. . . . . . ............. . . . . . . ............. . . . . . ............. . . . . . .. ........... ...... . . 3.104
RADIATOR .. . . ............ . . . . . . ............ ...... . . . . . ............. ... . . . . . ............. ... .... ... ... . . 3.104
COOLANT DRAIN / RADIATOR REMOVAL ............ ... . . . . . ............. .... . . . . . . ............. . . . . . . 3.105
THERMOSTAT REPLACEMENT. . . . .. ............. . . . . . ............. .... . . . . . .............. . . . . . ........ 3.106
COOLING SYSTEM BLEEDING PROCEDURE . . . .. ............ . . . . . . ............ . . . . . ............. .... . 3.106
WATER PUMP COVER AND IMPELLER SERVICE (STATOR COVER REMAINS ON ENGINE) ... ... .... . 3.107
WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT .......... ... . . . . . .. ........... ... .... . 3.108
ENGINE SERVICE . . ............. .... . . . . . .............. . . . . . ............. . . . . . ............. ...... . . . . . .... 3.114
ACCESSIBLE ENGINE COMPONENTS . . . . . . .. ........... ..... . . . . . ............. . . . . . ............. .... . 3.114
TOP-END SERVICE (ENGINE IN CHASSIS) ........ . . . . . .. ............ . . . . . ............. . . . . . ........... 3.114
ENGINE REMOVAL .... .... ... ... . . . . . ............. ...... . . . . . ............. . . . . . ............ .... ... .... . 3.114
ENGINE INSTALLATION.. . . . .. ........... ... ...... . . . . . ............. . . . . . .. ............ . . . . . ............ 3.117
ENGINE BREAK-IN PERIOD ......... .... ... ... .... ... ... . . . . . ............. .... ... ... .... ... ... . . . . . . ... 3.120
ENGINE LUBRICATION SPECIFICATIONS . . . ............ . . . . . ............. .... ... ... .... ... ... . . . . . . ... 3.120
ENGINE MOUNTING AND TORQUE VALUES ..... . . . . . ............. .... . . . . . .............. . . . . . ........ 3.121
ENGINE / COOLING SYSTEM

Polaris RANGER ETX 2016 Specifications

General

Brand	Polaris
Model	RANGER ETX 2016
Category	Offroad Vehicle
Language	English