2012-2015 Polaris Ranger RZR 570/RZR 570 INTL UTVs OEM Service & Repair Manual

2012 RANGER RZR 570 / INTL SERVICE 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 de signed primarily for use by certified Polaris Master Service Dealer technicians in a p roperly equipped shop and should be kept available for ref erence. All re ferences to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some pro cedures ou tlined i n th is man ual re quire a sou nd kn owledge of me chanical t heory, to ol use, and sho p 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 ha ve any doubt as to yo ur ability to perform any of th e procedures outlined in th is 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 'Publications Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING ind icates a po tential h azard that may result in se vere inju ry or dea th to the o perator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALER T CAUTION indicates a potential h azard tha t may r esult in min or personal in jury or damage to th e vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Pola ris factor y pu blications can be do wnloaded fro m www.polarisindustries.com, pu rchased fr om www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE / COOLING SYSTEM 4 ELECTRONIC FUEL INJECTION 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2012 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2012 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

1.2 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number 1204286.............................................................................. Single Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification Vehicle and Engine Serial Number Location Whenever corresponding about a Pola ris ORV, refe r to the ve hicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the left-hand rear upper frame rail, above the left rear wheel. (see Figure 1-1) The engine model and serial number can be found on a decal applied to the crankcase on the front of the engine. (see Figure 1-2) } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 1 2 V H 5 7 A D } 4 X A V H 5 7 A * B P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier Check Digit Model Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions Figure 1-1 Engine Serial Figure 1-2 Number

1.3 GENERAL INFORMATION 1 VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris fa ctory pu blications c an be fo und at www.pola risindustries.com or p urchased f rom www.purepolaris.com. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe su bstituted with a similar to ol, if ava ilable. Polaris r ecommends the use of Pola ris Special Tools whe n servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Model Model No. Owner’s Manual Parts Manual 2012 RANGER RZR 570 R12VH57AD 9923521 9923522 2012 RANGER RZR 570 INTL. R12VH57FX 9923521 9924058 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

1.4 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2012 RANGER RZR 570 MODEL NUMBER: R12VH57AD ENGINE NUMBER: 1204286 Category Dimension / Capacity Length 107.5 in. / 273.05 cm Width 50 in. / 127 cm Height 69 in. / 175.26 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 970 lbs. / 440 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension (LxWxH) 20 x 40 x 9" (51 x 102 x 23 cm) Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.5 GENERAL INFORMATION 1 MODEL: 2012 RANGER RZR 570 MODEL NUMBER: R12VH57AD ENGINE NUMBER: 1204286 CLUTCH CHART Engine Platform Domestic Single Cylinder, Liquid Cooled, 4-Stroke, DOHC Engine Number 1204286 Engine Displacement 567cc Number of Cylinders 1 Bore & Stroke (mm) 99 x 73.6 mm Compression Ratio 10:1 Compression Pressure 80 - 120 psi (decompression) Engine Idle Speed 1200 ± 100 RPM Engine Max Operating RPM 7750 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 Plus Synthetic Oil Capacity 2 qts. / 1.9 liters Coolant Capacity 4.25 qts. (4 l) Overheat Warning Instrument Cluster Indicator Exhaust System Single Headpipe / Single Silencer Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43-48 psi (296.5 - 331 KPA) Fuel Filters In tank, See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output 650 Watts @ 7000 RPM Headlights 2 - Halogen: Single Beam 55W Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Ignition Timing (Variable) ECU Controlled Spark plug / Gap RG4YCX / .0276” - .0315” (.7 - .8 mm) Battery (RZR) Yuasa YB14-B2 / 14 Amp Hr. / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays EFI / Chassis / Fan / Fuel Pump / Headlight Circuit Breaker Fan Motor: 20 Amp Fuses (Fuse/Relay Box) Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Holder) EFI: 30 Amp Chassis: 30 Amp Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Fluid Type / Capacity Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission: Main Gearcase Fluid Type / Capacity Polaris AGL Plus 44 oz. (1300 ml) Belt 3211143 Steering / Suspension Front Suspension Independent Dual A-arm w/Anti-Sway Bar Front Travel 9 in. / 23 cm Rear Suspension Independent Dual A-arm w/Anti-Sway Bar Rear Travel 9.5 in. / 24 cm Shock Preload Adjustment Front / Rear Cam Adjustment Cam Adjustment Toe Out 1/8 - 1/4 in. (3 - 6.4 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Steel Ancla / 25 x 8 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Steel Ancla / 25 x 10 R12 Tire Pressure Front: 10 psi (69 kPa) Rear: 12 psi (83 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Meters (Feet) 0-1500 (0-5000) 25-52 (5632409) Black (7043594) 1500-3700 (5000 - 12000) 25-48 (5632408) Black (7043594)

1.6 GENERAL INFORMATION MODEL: 2012 RANGER RZR 570 INTL MODEL NUMBER: R12VH57FX ENGINE NUMBER: 1204286 Category Dimension / Capacity Length 107.5 in. / 273.05 cm Width 50 in. / 127 cm Height 69 in. / 175.26 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 1001 lbs. / 454 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension (LxWxH) 20 x 40 x 9" (51 x 102 x 23 cm) Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

2012-2015 Polaris Ranger RZR 570/RZR 570 INTL UTVs OEM Service & Repair Manual

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