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RANGER ETX INTL 2015
Polaris RANGER ETX INTL 2015 User Manual
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A
Wiring
Diagrams
T
opics
Covered
in
this
Appendix
A.1
Wiring
Diagrams
Click
here
for
Wiring
Diagrams
See
Operation,
page
1
1.24for
Fuse
Block
pin
outs.
37
562
564
Table of Contents
Chapter 1 1 General Information
5
Table of Contents
5
Vehicle Information
6
Model Number Designation (2015 +)
6
Vehicle Identification Number (Vin) Designation (2015+)
6
Vin / Engine Number Location
7
General Specifications
8
Model: 2015 Ranger Etx
8
Model: 2015 Ranger 570
10
Model: 2015 Ranger 570 Crew
12
Model: 2016 Ranger Etx
14
Model: 2016 Ranger 570 4X4
16
Model: 2016 Ranger 570 2X4 (Intl.)
18
2016 Ranger 2X4 (Intl.)
19
Model: 2016 Ranger 570 Crew
20
Misc. Specifications and Charts
22
Publication Numbers
22
Special Tools
23
Replacement Keys
24
Master Special Tools Table
25
Master Torque Table
34
Clutching Chart
37
Conversion Table
38
Standard Bolt Torque Specification
39
Metric Bolt Torque Specification
39
Sae Tap / Drill Sizes
40
Metric Tap / Drill Sizes
41
Decimal Equivalents
42
Maintenance Chapter 2 Maintenance 2
45
General Information
48
Maintenance
48
Special Tools
48
Brake System Break-In
49
Break-In Period
49
Engine and Drivetrain Break-In
49
Pvt Break-In (Clutches / Belt)
49
Vehicle Break-In Period
49
Cold Weather Operation
50
Inspection / Maintenance Intervals
50
Pre-Ride / Daily Inspection
50
Periodic Maintenance Chart
51
Periodic Maintenance Chart Key
51
Grease Lubrication Points
54
Component Quick Reference
56
Polaris Lubricants, Maintenance and Service Products
58
Service Products and Lubricants
58
Frame, Nuts, Bolts, and Fasteners
59
General Maintenance
59
Shift Cable Adjustment
59
Shift Cable Inspection
59
Storage Tips
60
Air Filter Service
61
Fuel Lines
61
Fuel Pump / Filter
61
Fuel System
61
Fuel System and Air Intake
61
Throttle Pedal Inspection
61
Vent Lines
61
Engine Air Intake Inspection
62
Pvt Air Intake Inspection
62
Compression and Leakdown Test
63
Engine Common
63
Engine
64
Engine Oil Level Check - 325
64
Engine Oil Level
69
Oil and Filter Change - 570
69
Valve Clearance - Dohc
70
Breather Hose
71
Breather Valve Inspection
71
Transmission and Gearcases
72
Transmission Lubrication
72
Front Gearcase Lubrication
73
Coolant Level Inspection
74
Cooling System
74
Cooling System Overview
74
50/50 Extended-Life Engine Antifreeze
76
Coolant Strength / Type
77
Cooling System Hoses
77
Coolant Drain / Radiator Removal
78
Radiator Inspection / Cleaning
78
CV Shaft Boot Inspection
80
Final Drive / Wheel and Tire
80
Wheel and Hub Torque Table
80
Wheel Removal
80
Tire Inspection
81
Tire Pressure
81
Wheel Installation
81
Battery Fluid Level (Conventional Battery)
82
Battery Maintenance
82
Battery Removal
82
Electrical and Ignition System
82
Battery Charging
83
Battery Installation
83
Battery Storage
83
Spark Plug Service
83
Main Frame/Engine Ground
84
Steering
85
Steering Inspection Note
85
Tie Rod End / Steering Inspection
85
Toe Adjustment
86
Wheel Toe Alignment Inspection
86
Camber and Caster
87
Spring Pre-Load Adjustment
88
Stabilizer Bar Pivot Lubrication
88
Suspension
88
Suspension Inspection
88
Suspension Pivot Point Lubrication
88
Brake Fluid Inspection
89
Brake Hose and Fitting Inspection
89
Brake Pad Inspection
89
Brake System
89
Brake Disc Inspection
90
Parking Brake Adjustment
90
Chapter 3 Engine / Cooling System
93
Engine Special Tools
98
General Information
98
Engine Lubrication Specifications
99
Oil Pressure Test
99
Engine Oil Flow Chart
100
Engine Specifications
101
Engine Detail - Torque Values - Sequences
103
Engine Fastener Torque Specifications
103
Spark Plug / Throttle Body / Thermostat
105
Stator Cover / Valve Cover / Oil Sump Cover
106
Camshafts / Cam Carrier / Cam Chain Tensioner
107
Cylinder Head / Crankcase
108
Crankshaft / Balance Shaft / Cam Chain Guides
109
Engine Mounting Torque Specifications
110
Engine / Transmission Coupler Bracket Torque Sequence
111
Cylinder Head Torque Specification / Sequence
112
Stator Cover Torque Sequence
113
Oil Sump Cover Torque Sequence
114
Lower Crankcase Sealant Pattern
115
325 Exhaust System
116
Cooling System Flow
117
Engine Cooling System
117
Cooling System Assembly View
118
Cooling System Pressure Test
119
Cooling System Specifications
119
Pressure Cap Test
119
Coolant Drain / Radiator Removal
120
Radiator
120
Thermostat Inspection / Replacement
121
Cooling System Bleeding Procedure
122
Water Pump Service
123
Accessible Engine Components
125
Engine Removal
125
Engine Service
125
Top-End Service (Engine in Chassis)
125
Engine Installation
128
Engine Break-In Period
131
Engine Lubrication Specifications
131
Engine to Transmission Coupler Service
132
Setting Tdc (Top-Dead-Center)
134
Engine / Cooling System
135
Engine Disassembly / Inspection - Top End
135
Valve Cover Inspection
135
Valve Cover Removal
135
Camshaft / Carrier Removal
136
Camshaft Carrier Disassembly
137
Camshaft Inspection
139
Camshaft Sprocket Inspection
139
Camshaft Oil Jet
141
Cylinder Head Disassembly
141
Cylinder Head Removal
141
Cylinder Head Inspection
142
Cylinder Head Warp Inspection
143
Valve Inspection
143
Combustion Chamber Cleaning
144
Valve Sealing Test
144
Valve Seat Reconditioning
145
Cylinder Inspection
147
Cylinder Removal
147
Piston Removal
147
Piston / Rod Inspection
148
Piston-To-Cylinder Clearance
148
Piston Ring Installed Gap
149
Engine Assembly - Top End
150
Piston Ring Installation
150
Cylinder Installation - Piston Installed on Connecting Rod
151
Piston / Connecting Rod Assembly
151
Cylinder Installation - Piston in Cylinder
152
Cylinder Head Assembly
154
Cylinder Head Installation
155
Camshaft Installation / Timing
156
Camshaft Timing - Quick Reference
159
Valve Clearance Adjustment
160
Valve Cover Installation
161
325 Intake Valve Lash - Tappet Selection Matrix
162
325 Exhaust Valve Lash - Tappet Selection Matrix
163
Crankcase Disassembly
164
Engine Disassembly / Inspection - Lower End
164
Stator Cover / Flywheel Removal
164
Starter One-Way Clutch Inspection
165
Stator Removal
165
Oil Pump Removal
166
Oil Pressure Regulator (Bypass) Valve Inspection
167
Stator Cover Oil Seal Inspection
167
Balance Shaft Bearing Service
168
Balance Shaft Removal / Inspection
168
Crankcase Separation
168
Crankshaft Inspection
169
Crankshaft Removal
169
Pto and Mag Side Crankcase Bearing Service
170
Crankcase Inspection
171
Oil Pickup Assembly Inspection
171
Crankcase Assembly
172
Engine Assembly - Lower End
172
Balance Shaft Installation / Timing
173
Flywheel Installation
174
Starter One-Way Clutch Installation
174
Oil Pump Assembly
176
Stator / Stator Cover Installation
176
Engine / Cooling System Troubleshooting
178
Engine Troubleshooting
178
Cooling System Troubleshooting
179
General Information
180
Special Tools
180
Engine Lubrication Specifications
181
Oil Pressure Test
181
Engine Oil Flow Chart
182
Engine Specifications
183
Engine Detail
185
Engine Fastener Torque Specifications
185
Torque Sequence
187
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
188
Camshafts / Cylinder Head / Flywheel / Stator Cover - Black Head Bolts
189
Cylinder / Oil Filter / Oil Pump / Breather
189
Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts
191
Spark Plug / Starter / Throttle Body / Valve Cover
192
Piston / Crankshaft / Balance Shaft
193
Cooling System Assembly View and Coolant Flow Diagram
194
Engine Cooling System
194
Cooling System Pressure Test
195
Cooling System Specifications
195
Pressure Cap Test
196
Radiator
196
Coolant Drain / Radiator Removal
197
Cooling System Bleeding Procedure
198
Thermostat Replacement
198
Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
199
Water Pump Mechanical Seal / Oil Seal Replacement
200
Accessible Engine Components
206
Engine Removal
206
Engine Service
206
Top-End Service (Engine in Chassis)
206
Engine Installation
209
Engine Break-In Period
212
Engine Lubrication Specifications
212
Engine Mounting and Torque Values
213
Setting Tdc (Top-Dead-Center)
214
Camshaft / Carrier Removal
216
Engine Disassembly / Inspection - Top End
216
Valve Cover Removal
216
Camshaft Sprocket Inspection
217
Camshaft Inspection
218
Exhaust Camshaft Decompression Mechanism
218
Cam Chain and Guide Service
219
Cylinder Head Removal
219
Cylinder Head Disassembly
220
Crankcase Identification
221
Cylinder Head Identification
221
Cylinder Head Inspection
222
Cylinder Head Warp Inspection
222
Valve Inspection
222
Combustion Chamber Cleaning
223
Valve Seat Reconditioning
224
Cylinder Inspection
226
Cylinder Removal
226
Piston Removal
227
Piston-To-Cylinder Clearance
227
Piston / Rod Inspection
228
Piston Ring Installed Gap
228
Honing to Oversize
229
Camshaft Installation / Timing
230
Cleaning the Cylinder after Honing
230
Cylinder Hone Selection / Honing Procedure
230
Camshaft Timing - Quick Reference
233
Engine Assembly - Top End
234
Piston Ring Installation
234
Piston / Connecting Rod Assembly
235
Cylinder Head Assembly
236
Cylinder Installation
236
Valve Sealing Test
237
Crankcase Identification
238
Cylinder Head Identification
238
Cylinder Head Installation - Black Bolts
239
Cylinder Head Installation - Silver Bolts
240
Valve Clearance Check / Adjustment
241
Valve Lash - Tappet Selection
244
Exhaust Valve Lash - Tappet Selection Matrix
245
Valve Cover Installation
246
Crankcase Disassembly
247
Engine Disassembly / Inspection - Lower End
247
Starter One-Way Clutch Inspection
247
Stator Cover Removal
247
Stator Removal
249
Oil Pump Removal
250
Crankcase Breather Service
252
Oil Pump Assembly
252
Crankcase Separation
253
Balance Shaft Removal / Inspection
254
Crankshaft Inspection
255
Crankshaft Removal
255
Pto Side Crankcase Bearing Service
256
Mag Side Crankcase Bearing Service
257
Crankcase Inspection
258
Oil Pickup Assembly Inspection
258
Oil Pressure Regulator (Bypass) Valve Inspection
258
Crankcase Assembly - Pto Side
259
Engine Assembly - Lower End
259
Balance Shaft Installation / Timing
261
Final Crankcase Assembly
261
Flywheel Installation
263
Starter One-Way Clutch Installation
263
Stator / Stator Cover Installation
265
Engine Cooling System
266
Troubleshooting
266
Chapter 4 Fuel System
269
Efi Operation Overview
272
General Information
272
Initial Priming / Starting Procedure
272
Principal Components
272
Special Tools
273
Digital Wrench® - Diagnostic Connector
274
Fuel Pressure Gauge Adapter - Pa-48838
274
Fuel Pressure Gauge Kit - Pu-43506-A
274
Digital Wrench® - Download Website
275
Digital Wrench® Diagnostic Softwarepu-47063-B
275
Digital Wrench® Smartlink Module Kitpu-47471
275
Efi Component Locations
276
Efi Component Locations - Right View
276
Efi Component Locations - Left View
277
Fuel Line Routing
278
Line / Hose Routing
278
Air Box / Intake System
279
Air Box / Air Filter Assembly View - 325
280
Air Box / Air Filter Assembly View - 570
282
Air Box Removal / Installation
283
Ecu Overview
284
Ecu Service
284
Electronic Control Unit (Ecu)
284
Rpm Limit
284
Ecu Replacement
285
Electronic Throttle Body (Etc)
286
Etc Learn Procedure
286
Etc Overview
286
Etc Replacement
286
Etc Test
286
Operation Overview
287
Pedal Position Sensor (Pps)
287
Pps Replacement
287
Pps Test
287
Fuel Tank / Pump / Sendor
288
Fuel Tank Assembly View
288
Fuel Tank Removal
288
Fuel Sender Test
289
Fuel Tank Installation
289
Fuel Pump Test
290
Fuel Pump Replacement
291
T-Map Overview
294
T-Map Sensor Replacement
294
T-Map Sensor Test
294
Temperature / Manifold Absolute Pressure (T-Map)
294
Cps Overview
295
Cps Test
295
Crankshaft Position Sensor
295
Resistance Test
295
Air Gap Test
296
Encoder Flywheel / Keyway Inspection
296
Cps Replacement
297
Coil Pack Connections
298
Ignition Coil / Wire Overview
298
Ignition Coil / Wire Test
298
Ignition Coil Overview
298
Spark Plug Wire Connections
298
Fuel Injector
299
Fuel Injector Overview
299
Fuel Injector Replacement
299
Fuel Injector Test
299
Fuel Injector Troubleshooting
301
Ect Overview
302
Ect Sensor Test
302
Engine Coolant Temperature Sensor (Etc)
302
Resistance Vs. Temperature Test
302
System Operation Test
302
Ect Sensor Replacement
303
Ect Sensor Replacement - 570
303
Efi Diagnosis
304
Service Notes - Fuel System
304
Trouble Code Display (Dtc)
305
Digital Wrench® - Diagnostic Connector
312
Digital Wrench® Diagnostic Software Overview
312
Digital Wrench® Operation
312
Digital Wrench® Version and Update
313
Polaris Mobile Digital Wrench (Pmdw)
313
Digital Wrench® Updates
314
Digital Wrench® Communication Errors
317
Guided Diagnostics
317
Digital Wrench® Feature Map
318
Digital Wrench® Serial Number Location
318
Ecu Replacement
319
Ecu Reprogramming (Reflash)
319
Etc Learn Procedure
325
Fuel Starvation / Lean Mixture
326
Fuel System Troubleshooting
326
Rich Mixture
326
Chapter 5 Pvt System
327
General Information
328
Pvt System Fastener Torques
328
Special Tools
328
Clutching Chart
329
General Operation
329
Pvt System Overview
329
Drive Clutch Operation
330
Driven Clutch Operation
330
Maintenance / Inspection
330
Pvt Break-In (Drive Belt / Clutches)
330
Operating in Low Gear
331
Overheating / Diagnosis
331
Pvt Sealing, Guard, and Duct Components
332
Pvt System Service
332
Pvt Disassembly
333
Pvt Assembly
334
Belt Inspection
335
Belt Removal
335
Drive Belt
335
Belt Installation
336
Pvt Break-In (Drive Belt / Clutches)
336
Clutch Alignment / Offset / Center Distance
337
Inspection
337
Adjustment
338
Engine to Transmission Coupler Service
339
Drive Clutch Assembly View
342
Drive Clutch Service
342
Clutch Disassembly
343
Shift Weight Inspection
344
Spider Removal
345
Bearing Inspection
346
Button to Tower Clearance Inspection
346
Clutch Inspection
346
Bushing Service
348
Clutch Assembly
350
Assembly View
352
Driven Clutch Service
352
Clutch Disassembly / Inspection
353
Clutch Assembly
354
Troubleshooting
355
Chapter 6 Transmission
357
General Information
358
Special Tools, Transmission
358
Torque Specifications
358
Special Tools
359
Lubrication
360
Transmission Gears
360
Transmission Mounting and Torque Values
360
Installation
361
Removal
361
Shift Lever
361
Adjustment
362
Inspection
362
Shift Cable
362
Transmission Removal
363
Transmission Installation
368
Differential Operation
374
Transmission Service
374
Transmission Disassembly
375
Planetary Differential Bushing Replacement
380
Planetary Differential Disassembly
380
Planetary Differential Assembly
382
Gear / Shaft / Bearing Inspection
383
Snorkel Gear Backlash Procedure
384
Troubleshooting
391
Troubleshooting Checklist
391
Transmission
392
Transmission Assembly View
392
Chapter 7 Final Drive
395
Final Drive Torque Table
397
General Information
397
Special Tools
397
Front Hub / Bearing
398
Hub Removal / Inspection
398
Hubstrut Bearing Replacement
398
Hub Installation
399
Front Hub/Wheel Exploded View
401
Front Drive Shaft
402
Front Drive Shaft Removal
402
Front Drive Shaft Installation
403
Front Gearcase Removal and Installation
404
Gearcase Installation
404
Gearcase Removal
405
All Wheel Drive Operation
407
Awd Diagnosis
408
Gearcase Disassembly / Inspection
409
Gearcase Assembly
412
Exploded View, Front Gearcase (4Wdc)
415
Front Gearcase (Adc)
415
Operation, Front Gearcase (4Wdc)
417
Disassembly / Inspection, Front Gearcase (Adc)
418
Reassembly, Front Gearcase (Adc)
421
Troubleshooting, Front Gearcase (Adc)
424
Inspection
427
Rear Bearing Carrier
427
Removal
427
Assembly
428
Disassembly
428
Installation
429
Rear Drive Shaft
431
Rear Drive Shaft Installation
431
Rear Drive Shaft Removal
431
Drive Shaft / CV Joint Handling Tips
432
Drive Shaft Service
432
Outer CV Joint / Boot Replacement
432
Inner Plunging Joint / Boot Replacement
435
Drive Shaft Assembly View
437
Chapter 8 Steering / Suspension
443
Torque Specifications
444
Special Tools
445
Steering Assembly
446
Steering Assembly View (Non-Eps)
446
Steering Assembly View (Eps)
448
Steering Shaft Bearing Replacement
450
Steering Wheel Removal (Non-Eps Models)
450
Steering Shaft / Steering Rack Removal (Non-Eps Models)
451
Steering Wheel / Upper Steering Shaft Removal (Eps)
452
Power Steering Unit Installation
453
Power Steering Unit Removal
453
Assembly View
455
Front Strut
455
Front Strut Cartridge Replacement
455
Ball Joint Replacement
456
Rear A-Arms
458
Removal / Replacement
458
Installation
459
Assembly View
460
Rear Stabilizer Bar / Linkage
461
Removal / Installation
461
Assembly View
462
Shock Removal / Installation
462
Shock Replacement
462
Shocks / Springs
462
Chapter 9 Brake System
463
Brake Service Specifications
465
General Information
465
Special Tools
465
Torque Specifications
465
Brake Noise Troubleshooting
466
Brake System Notes
466
Brake System Service Notes
466
Hydraulic Brake System Operation
467
Brake System Assembly View
468
Ranger Crew
469
Brake Pressure Switch
470
Installation
470
Master Cylinder
470
Removal
470
Foot Brake Pedal
471
Pedal Installation
471
Pedal Removal
471
Brake Bleeding / Fluid Change
472
Brake Procedures
472
Brake Burnishing Procedure
473
Brake Pad Inspection
474
Front Brake Pads - Ranger
474
Pad Removal / Disassembly
474
Pad Adjustment- Ranger
475
Pad Assembly / Installation- Ranger
475
Front Caliper - Ranger
476
Front Caliper Assembly View
476
Front Caliper Disassembly - Ranger
477
Front Caliper Removal- Ranger
477
Front Caliper Assembly
478
Front Caliper Inspection- Ranger
478
Front Caliper Installation
479
Front Brake Pads - Crew
480
Pad Removal - Crew
480
Pad Assembly / Installation- Crew
481
Pad Inspection
481
Front Caliper - Crew
483
Front Caliper Assembly View
483
Front Caliper Removal- Crew
483
Front Caliper Disassembly - Crew
484
Front Caliper Inspection - Crew
485
Front Caliper Assembly - Crew
486
Front Caliper Installation - Crew
486
Disc Inspection
488
Front Brake Disc
488
Disc Removal / Replacement
489
Pad Removal
490
Rear Brake Pad Service
490
Brake Pad Inspection
491
Rear Pad Installation
491
Caliper Assembly View
492
Rear Caliper
492
Caliper Removal
493
Rear Caliper Disassembly
493
Rear Caliper Assembly
494
Rear Caliper Inspection
494
Rear Caliper Installation
495
Brake Disc Inspection
496
Disc Runout
496
Rear Brake Disc
496
Disc Removal / Replacement
497
Parking Brake Assembly View
498
Parking Brake System
498
Caliper Removal
500
Parking Brake Adjustment
500
Parking Brake Caliper Exploded View
500
Parking Brake Caliper Service
500
Caliper Disassembly / Inspection
501
New Brake Pad Installation
502
Parking Brake Caliper Installation
503
Disc Inspection / Removal
505
Parking Brake Disc Service
505
Brakes Lock
506
Caliper Overheats (Brakes Drag)
506
Pedal Vibration
506
Troubleshooting
506
Chapter 10 Body / Frame
507
Special Tools
508
Torque Specifications
508
Chassis / Body
509
Frame Assembly View
509
Crew Frame Assembly View
510
Crew Cab Frame
512
Dash Instruments / Controls
513
Hood / Dash / Front Fascia
514
Floor / Rear Fenders
515
Seat Mounting / Seat Belts
516
Crew Floor / Rear Fenders
517
Crew Seat Mounting / Seat Belts
518
Cargo Box - Tailgate / Box Support
519
Rear Cargo Box
519
Box Installation
521
Box Removal
521
Body Component Removal
522
Fenders / Foot Pads
522
Front Bumper
522
Lower Seat Base
522
Hood / Dash
523
Floors
524
Decal Replacement
525
Chapter 11 Electrical
527
Battery Conductance Analyzer
529
Electrical Service Notes
529
General Information
529
Special Tools
529
Components under Hood
530
Awd / 2Wd / Turf Switch
531
Ignition / Headlight Switch
531
Switches / Controls
531
Brake Pressure Switch
532
Differential Solenoid
532
Rear Differential Solenoid Operation
532
All Wheel Drive (Awd) Coil
533
Diagnosing System Failures
533
Operation Overview
533
Speed Sensor Location
534
Speed Sensor Testing
534
Vehicle Speed Sensor
534
Instrument Cluster
535
Overview
535
Rider Information Display
536
Information Display Area
537
Diagnostic Mode
539
Instrument Cluster Installation
540
Instrument Cluster Pinouts
540
Instrument Cluster Removal
540
Headlight Adjustment
542
Headlights
542
Headlight Bulb Replacement
543
Headlight Housing Installation
543
Headlight Housing Removal
543
Led Lamp Replacement
544
Tail Light / Brake Light
544
Cooling System
545
Fan Control Circuit Bypass Test
545
Fan Control Circuit Operation
545
Ignition Coil
546
Ignition Coil Tests
546
Operation Overview
546
Primary Test
546
Secondary Tests
546
Ignition Coil and Ht Lead Replacement
547
Operation
548
Relays
548
Fuses / Circuit Breaker
550
Operation
550
Charging System
551
Charging System "Break Even" Test
551
Charging System Alternator Tests
551
Current Draw - Key off
551
Charging System Testing Flow Chart
553
Battery Activation
554
Battery Service
554
Battery Terminal Block
554
Battery Terminals / Bolts
554
Battery Inspection
555
Battery Removal / Installation
556
Conventional Battery Testing
556
Ocv - Open Circuit Voltage Test
556
Voltage Drop Test
556
Charging Procedure
557
Load Test
557
Off Season Storage
557
Specific Gravity Test
557
Starter Drive
558
Starter Motor Does Not Run
558
Starter Motor Turns - Engine Does Not Rotate
558
Starter Motor Turns over Slowly
558
Starter System
558
Troubleshooting
558
Starter Solenoid Bench Test
559
Starter Solenoid Operation
560
Starting System Testing Flow Chart
561
5
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Polaris RANGER ETX INTL 2015 Specifications
General
Brand
Polaris
Model
RANGER ETX INTL 2015
Category
Offroad Vehicle
Language
English
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Polaris RANGER 800 XP
132 pages
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