2014 Polaris Sportsman 570 EFI ATV OEM Service & Repair 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 August 2013 (PN 9924871 R03) © Copyright 2013 Polaris Sales 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. 2014 Polaris Sportsman® 570 EFI Service Manual

UNDERSTANDING SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION 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 PRODUCT(S) 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 ofTextron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

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

1 1.1 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc. GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION .............................................................................. 1.2 MODEL NUMBER DESIGNATION .................................................................. 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ........................................ 1.2 VEHICLE AND ENGINE SERIAL NUMBERS ....................................................... 1.3 TRANSMISSION I.D. LOCATION ................................................................... 1.4 VEHICLE INFORMATION ................................................................................ 1.5 PUBLICATION PART NUMBERS ................................................................... 1.5 REPLACEMENT KEYS............................................................................. 1.5 SPECIAL TOOLS .................................................................................. 1.5 VEHICLE SPECIFICATIONS ............................................................................. 1.6 2014 SPORTSMAN 570 EFI / EPS.................................................................. 1.6 2014 SPORTSMAN FOREST 570 EFI / EPS ........................................................ 1.7 2014 SPORTSMAN TOURING 570 EFI ............................................................. 1.8 2014 SPORTSMAN TOURING 570 EFI (INTL.) ..................................................... 1.9 CLUTCHING SPECIFICATIONS ........................................................................ 1.10 CLUTCHING CHART.............................................................................. 1.10 MISC. SPECIFICATIONS AND CHARTS ............................................................... 1.11 CONVERSION TABLE ............................................................................ 1.11 STANDARD BOLT TORQUE SPECIFICATION..................................................... 1.12 METRIC BOLT TORQUE SPECIFICATION ........................................................ 1.12 SAE TAP / DRILL SIZES .......................................................................... 1.13 METRIC TAP / DRILL SIZES ...................................................................... 1.14 DECIMAL EQUIVALENTS ......................................................................... 1.15

1.2 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc. VEHICLE IDENTIFICATION Model Number Designation Example: A14KA09AD GROUP MODEL YEAR CHASSIS DRIVE- LINE ENGINE / MOTOR CODE CATEGORY OPTION REGION 1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th A 1 4 K A 0 9 A D * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration. Vehicle Identification Number (VIN) Designation Example: 4XAKA09A0E3000000 WORLD MFG. ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR * MFG. LOCATION INDIVIDUAL SERIAL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 GENERAL INFORMATION

1.3 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc. Vehicle and Engine Serial Numbers The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (1). The vehicle serial number is stamped on the frame on all models (2). GENERAL INFORMATION 1

1.4 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc. Transmission I.D. Location The Transmission I. D. number is located on the RH side of the transmission case; visible from the RH side of the vehicle. GENERAL INFORMATION

1.5 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc. VEHICLE INFORMATION Publication Part Numbers YEAR MODEL MODEL NO. OWNER'S MANUAL PN PARTS MANUAL PN 2014 Sportsman 570 A14MH57AA, AC, AD, FA 9924113 9924637 2014 Sportsman 570 EPS A14MH5EAA, AC, AJ 9924113 9924640 2014 Sportsman 570 Forest A14MH57FA, FJ 9924299 9924638 2014 Sportsman 570 EPS Forest A14MH5EFJ 9924299 9924642 2014 Sportsman Touring 570 A14DH57AA, AJ 9924134 9924605 2014 Sportsman 570 HD INT’L A14MH57TD 9924113 9924639 2014 Sportsman Touring 570 INT’L A14DH57FJ 9924134 9924607 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. Should both keys become lost, ignition switch replacement is required. Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Special Tools Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-328-6657 or on-line at http://polaris. service-solutions.com /. GENERAL INFORMATION 1

1.6 9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual © Copyright 2013 Polaris Sales Inc. VEHICLE SPECIFICATIONS 2014 Sportsman 570 EFI / EPS MODEL NUMBER: A14MH57AA, AC, AD, TD A14MH5EAA, AC, AJ SPORTSMAN 570 EFI / EPS CATEGORY DIMENSION / CAPACITY Gross Vehicle Weight 1200 lbs. (544 kg) Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Dry Weight 702 lbs. (318.4 kg) (570 EFI) 713 lbs. (323.4 kg) (570 EPS) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) Transmission Oil Capacity 32 oz. (948 ml) Demand Drive Fluid Capacity 9 oz. (265 ml) Coolant Capacity 2.7 qts. (2.5 l) Front Rack/Box Capacity 90 lbs. (40.8 kg) Rear Rack/Box Capacity 180 lbs. (81.6 kg) Receiver Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg Hitch Towing Rating 1225 lbs. (555.7 kg) Unbraked Trailer Towing Capacity* 1786 lbs. (810 kg) Overall Length/Width/ Height 83 in. (211 cm) / 48 in. (122 cm) / 48 in. (122 cm) Wheelbase 50.5 in. (128.3 cm) Ground Clearance 11 in. (28 cm) Minimum Turning Radius 65 in. (165 cm) unloaded Engine Dual overhead cam, 4 valve 4 stroke single cylinder Displacement 567 cc SPORTSMAN 570 EFI / EPS CATEGORY DIMENSION / CAPACITY Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM Idle RPM 1200 ± 100 Compression Ratio 10:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug / Gap RG6YC / (0.7-0.8 mm) Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Shift Type H/L/N/R/P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 9.75:1 Drive Ratio, Front 3.82:1 Tires/Pressure, Front 25x8-12 / 5 psi (34.5 kPa) Tires/Pressure, Rear 25x10-12 / 5 psi (34.5 kPa) 25x11-12 / 5 psi (34.5 kPa) (LE models) Brakes, Front/Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc Brake, Parking Hydraulic lock, all wheel Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt) Taillights 8.26 watts Brake Light 26.9 watts Instrument Cluster LCD * Based on EU Directive 76/432/EC GENERAL INFORMATION

2014 Polaris Sportsman 570 EFI ATV OEM Service & Repair Manual

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