Polaris RANGER 500 2018 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 September 2017 (PN 9928485 R01)
© Copyright 2018 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.
2017-2018 RANGER 500 / 570
Service Manual

SAFETY WARNINGS
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 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 Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX
REV DATE CHANGES
08/22/2017 Preliminary release.
1 09/26/2017 Initial Release

2017-2018 RANGER 500 / 570
Service Manual
Chapter Summary
CHAPTER 1: GENERAL INFORMATION
CHAPTER 2: MAINTENANCE
CHAPTER 3: ENGINE / COOLING SYSTEM
CHAPTER 4: FUEL SYSTEM
CHAPTER 5: PVT SYSTEM
CHAPTER 6: TRANSMISSION
CHAPTER 7: FINAL DRIVE
CHAPTER 8: STEERING / SUSPENSION
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL

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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE INFORMATION...... . . ....... . . ........ . ....... . . . ....... . ......... ........ . . ....... . . ........ 1.2
MODEL NUMBER DESIGNATION (2015 +) . . ....... . ........ . ....... . . . ........ ........ . . ....... . . . ... 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) ..... ........ . . ....... . . . ....... . .. 1.2
VIN / ENGINE NUMBER LOCATION ..... . ....... . . . ....... . . ........ ........ . . . ...... . . ........ . ...... 1.3
REFERENCE INFORMATION . . ........ ........ . . . ...... . . . ........ ........ . . ....... . . ........ ........ . . 1.4
REPLACEMENT KEYS . ....... . ......... . ....... . . . ....... . ........ . ....... . . . ....... . ......... . ...... 1.4
PUBLICATION NUMBERS....... . . ....... . . ........ ........ . . ....... . . ......... ........ . . ....... . . .... 1.5
SPECIAL TOOLS .... . . ........ ........ . . . ....... . ........ . ....... . . . ....... . . ........ ........ . . . ...... 1.6
MASTER SPECIAL TOOLS TABLE .......... . ........ . ....... . . . . ....... . ........ . ....... . . . ....... . .. 1.7
MASTER TORQUE TABLE .... ........ . . . ....... . . ........ ........ . . ....... . . ........ ........ . . . .....1.15
CLUTCHING CHART ......... . ....... . . . ........ ........ . . ....... . . . ....... . ........ . ....... . . . ......1.17
GENERAL SPECIFICATIONS ... . . . . ....... . ........ . ....... . . . ....... . ........ . . ...... . . . . ....... . ....1.18
2018 ...... . . . ....... . ........ . ....... . . . ........ ......... . ....... . . . ....... . ........ . ....... . . . ......1.18
2018 RANGER 500 ....... . . ........ . ....... . . . ....... . ......... ........ . . . ...... . . ........ . .....1.18
2018 RANGER 570 2X4 ...... . ........ . ....... . . . ....... . . ........ . ....... . . . ....... . ........ . ..1.20
2018 RANGER 570 4X4 ...... . ........ . ....... . . . ....... . . ........ . ....... . . . ....... . ........ . ..1.22
2017 RANGER 570 4X4 (INTL.) ...... . . ........ ........ . . ....... . . . ........ ........ . . ....... . . ...1.24
2018 RANGER 570 4X4 TRACTOR (INTL.) .......... . ....... . . . ....... . . ........ ........ . . . .....1.26
2018 RANGER 570 CREW...... . ....... . . . . ...... . . ........ . ....... . . . ....... . ........ . ....... . .1.28
MISC. SPECIFICATIONS AND CHARTS .. . . . ....... . ........ . ....... . . . ........ ......... . ....... . . . ..1.30
CONVERSION TABLE........ . ....... . . . . ....... . ........ . ....... . . . ....... . ........ . ....... . . . . .....1.30
SAE TAP / DRILL SIZES ....... ........ . . . ....... . . ........ ........ . . ....... . . ........ ........ . . . .....1.32
METRIC TAP / DRILL SIZES ....... . . . ....... . ........ . ....... . . . ........ ........ . . ....... . . . ....... . .1.33
DECIMAL EQUIVALENTS .. ........ . . ....... . . ........ ........ . . . ....... . . ........ ........ . . ....... . .1.34

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VEHICLE INFORMATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5R U E 57A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th 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 (2015+)
Example: 4XARUE573FG000000
WORLD MFG. ID
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
CHASSIS
DRIVELINE
CHASSIS
MODIFIER
ENGINE SIZE
ENGINE MODIFIER
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 R U E 5 7 3 F G 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018
GENERAL INFORMATION

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VIN / ENGINE NUMBER LOCATION
Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the Vehicle Identification Number
(VIN) and the engine model and serial number.
The VIN qcan be found stamped on the upper frame rail on the rear LH side of the vehicle below the cargo box.
The engine model and serial number wcan be found on a decal applied to the engine’s magneto cover.
GENERAL INFORMATION
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REFERENCE INFORMATION
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.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.
SERIES# PART NUMBER
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
GENERAL INFORMATION

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PUBLICATION NUMBERS
MODEL MODEL NO. OWNER’S
MANUAL PN
PARTS MANUAL
PN
2017 RANGER 500 2X4 R17RM250A1 9927516 9927162
2017 RANGER 500 R17RMA50A4
2016 RANGER 570 / EPS R17RMA57A1/A9,
R17RME57AK
9927170 9927159
2016 RANGER 570 HD INTL R17RMH57A4 9927158
2016 RANGER 570 CREW R17RNA57A1
9927160
2016 RANGER 570 CREW EPS
R17RNE57AM,
R17RNE57NM,
R17RNA57A9
2016 RANGER 570 (Intl.) R17RMA57N1,
R17RMT57C1 9927385 9927369
2016 RANGER 570 EPS (Intl.) R17RME57F1,
R17RMS57F1
2016 RANGER 570 Tractor (Intl.) R17RMT57C1 9927386
2016 RANGER 570 EPS Tractor (Intl.) R17RMS57C1,
R17RMS57CK
NOTE
When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.
GENERAL INFORMATION
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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 the Polaris official tool supplier.
Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com
GENERAL INFORMATION

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MASTER SPECIAL TOOLS TABLE
ENGINE / COOLING SYSTEM
GENERAL
Bench Mount Engine Stand Adapter
PW-47053
Rolling Engine Stand
PU-50624
Engine Stand Adapter
(Mounts To The Engine)
PU-50824-A
Engine Stand Sleeve Adapter
(Use With 2” Bore Stand)
PU-50625
Engine Stand Sleeve Adapter
(Use With 2.375” Bore Stand)
PW-47054
Flywheel Puller
PA-49316
Stator Cover Removal Handles
PA-49317
Valve Spring Compressor
PV-1253
Water Pump Seal Installation Tool
PU-50869
GENERAL INFORMATION
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ENGINE / COOLING SYSTEM
GENERAL
Crankshaft Removal / Installation
Tool Kit
PU-50784
Oil Filter Wrench
PU-50105
Oil Pressure Gauge
PV-43531
Oil Pressure Gauge Adapter
PU-50569
Valve Spring Compressor Adapter
PV-43513-A
570 ONLY
Cylinder Holding &
Camshaft Timing Plate
PU-50563
GENERAL INFORMATION

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FUEL SYSTEM
Digital Wrench Kit
PU-47063-C
Digital Wrench Smart
Link Module Kit
PU-47471
(Includes: PU-47470,PU-47469,
PU-47468)
*Serial Number Registration Card
PU-48731-A
*Digital Wrench® PC Interface Cable
PU-47470
*Digital Wrench® Vehicle
Interface Cable
PU-47469
*Digital Wrench® SmartLink Module
PU-47468
Digital Wrench® Wireless
Vehicle Link
PU-51435
Fuel Pressure Gauge Kit
PU-43506-A
Fuel Pressure Gauge Adapter
PV-48656
GENERAL INFORMATION
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FUEL SYSTEM
Fuel Pressure Gauge Adapter
PS-48762
Fluke 77 Digital Multi-Meter
(Fluke 77: PV-43568)Throttle Position Sensor Tester Kit
2201519-A
(Includes: 547927, PU-47466)
Laptop or Desktop Computer USB/
Serial Adaptor: Saelig RS-232
Commercially Available (refer to
diagnostic software user manual or
HELP section for minimum
requirements)
GENERAL INFORMATION

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PTV SYSTEM
Clutch Bushing Replacement
Tool Kit
2871226
Drive Clutch Puller - Short
PA-48595
Drive Clutch Holding Tool
9314177-A
Drive Clutch Spider Removal
and Install Tool
2870341
Piston Pin Puller
2870386
Roller Pin Tool
2870910-A
Universal Clutch Compressor Tool
PU-50518-A
Standard Clutch Alignment Tool
2870654
Clutch Center Distance Tool
PU-50658-A
GENERAL INFORMATION
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TRANSMISSION
Bearing Seal Driver (50 mm)
2871282
Backlash Setting Tool
2871695 (Part of 2871702 Kit) Rear Driveshaft Seal Guide 2871699 (Part of 2871702 Kit)
Rear Output Seal Driver
2871698 (Part of 2871702 Kit) Snorkel Tool PA-50231
Transmission Nut Socket
PU-50566
FINAL DRIVE
1 3/4” Straight Wrench
2870772
ADC Gearcase Piston
Installation Tool
PA-48542
CV Boot Clamp Pliers
8700226 or PU-48951
Roller Pin Removal Tool
2872608
GENERAL INFORMATION

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STEERING / SUSPENSION
Ball Joint Removal / Installation Tool
2870871
Strut Compression Tools
2871573,2871574
Shock Absorber Spring
Compression Tool
2870623
BRAKES
Mity Vac® Pressure Test Tool
2870975
BODY / FRAME
Multi-Function Pliers
2876389
GENERAL INFORMATION
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ELECTRICAL
Battery Conductance Analyzer
PU-50296
Battery Hydrometer
PU-50338
Fluke® 77 Digital Multimeter
PV-43568
Hall Sensor Probe Harness
2460761
Static Timing Light Harness
2871745
Timing Light
2870630
Relay Bypass
PU-49466
Connector Test Kit
PV-43526
GENERAL INFORMATION

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MASTER TORQUE TABLE
ITEM TORQUE
Ball Joint Nut 30 ft-lbs (41 Nm)
Ball Joint Retaining Plate
Screws 8 ft-lbs (11 Nm)
Bearing Carrier Fasteners 40 ft-lbs (54 Nm)
Body Screws (T-40) 8 ft-lbs (11 Nm)
Brake Disc Mounting Bolts
(front) 18 ft-lbs (25 Nm)
Brake Disc Mounting Bolts
(rear) 27 ft-lbs (36 Nm)
Brake Bleed Screws 47 in-lbs (5 Nm)
Brake Caliper Mounting Bolts 46 ft-lbs (62 Nm)
Brake Line Banjo Bolts 15 ft-lbs (20 Nm)
Brake Line Flare Fittings 14 ft-lbs (19 Nm)
Brake Switch 15 ft-lbs (20 Nm)
Cam Chain Tensioner 30 ft-lbs (41 Nm)
Cam Chain Guide Fasteners 9 ft-lbs (12 Nm)
Camshaft Carrier Bolts 8 ft-lbs (11 Nm)
Camshaft Sprocket Bolts 33 ft-lbs (45 Nm)
Chassis Ground Fastener 54 in-lbs (6 Nm)
Control Arm Fasteners
(front and rear) 40 ft-lbs (54 Nm)
Coolant Bleed Screw 72 in-lbs (8 Nm)
Coolant Temperature Sensor 17 ft-lbs (23 Nm)
CPS Retaining Bolt 9 ft-lbs (12 Nm)
Crankcase Bolts 22 ft-lbs (30 Nm)
Crankshaft Bearing Retainer
(PTO) 8 ft-lbs (11 Nm)
Cylinder Head Bolts - Black
Torque in sequence for
all steps
Step 1: 21 ft-lbs (28 Nm)
Step 2: 26 ft-lb (35 Nm)
Step 3: Additional 135°
Torque The Outer M6
Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm)
Cylinder Head Bolts - Silver
Apply light coat of
engine oil to bolt
threads and under bolt
head
Torque in Sequence for
all steps
Step 1: 18 ft-lbs (25 Nm)
Step 2: 30 ft-lbs (40 Nm)
ITEM TORQUE
Step 3: Loosen all
fasteners until they are
unseated
Step 4: 15 ft-lbs (20 Nm)
Step 5: 26 ft-lbs (35 Nm)
Step 6: Additional 180°
Step 7: Additional 180°
Torque The Outer M6
Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm)
Differential Cover Screws 22 ft-lbs (30 Nm)
Drive Clutch Retaining Bolt 45 ft-lbs (61 Nm)
Driven Clutch Retaining Bolt 38 ft-lb (52 Nm)
Drive Clutch Cover Plate
Screw 8 ft-lbs (10 Nm)
Drive Clutch Spider 290 ft-lbs (393 Nm)
Drive Clutch Spring Retaining
Ring Bolts 12 ft-lbs (16 Nm)
Driven Clutch Retaining Bolt 38 ft-lbs (51 Nm)
ETC Fasteners 7 ft-lbs (10 Nm)
ECU Mounting Screws 10 in-lbs (1 Nm)
Engine Oil Plug 14 ft-lbs (19 Nm)
Engine Oil Gallery Plug 11 ft-lbs (15 Nm)
Engine Mount (front) 40 ft-lbs (54 Nm)
Engine/Transmission
Mounting Bolts (570)
In Sequence:
55 ft-lb (75 Nm)
*see procedure for sequence
Exhaust Head Pipe Bolts 18 ft-lbs (25 Nm)
Flywheel Nut 133 ft-lbs (180 Nm)
Frame Bolts (front to rear)
CREW 40 ft-lbs (54 Nm)
Front Bumper / Fender
Screws 5 ft-lbs (7 Nm)
Front Gearcase Cover Plate
Screws 11 ft-lbs (15 Nm)
Front Gearcase Drain/Fill
Plugs 10 ft-lbs (14 Nm)
Front Gearcase Mounting
Bolts 33 ft-lbs (56 Nm)
Fuel Pump PFA Nut 70 ft-lbs (90 Nm)
Fuel Rail Mounting Screws 7 ft-lbs (10 Nm)
Fuel Tank Mounting Screw 17 ft-lbs (23 Nm)
Hub Castle Nut (front) 90 ft-lbs (122 Nm)
Hub Castle Nut (rear) 110 ft-lbs (150 Nm)
IAC Mount Screw 18 in-lbs (2 Nm)
Master Cylinder Mount Bolts 17 ft-lbs (23 Nm)
GENERAL INFORMATION
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ITEM TORQUE
Oil Pump Cover Bolt 8 ft-lbs (11 Nm)
Power Steering Bracket to
Frame Nuts 15 ft-lbs (20 Nm)
Power Steering Unit to Mount
Bracket 30 ft-lbs (41 Nm)
Prop Shaft Support Bearing
Fasteners 36 ft-lbs (49 Nm)
Prop Shaft Support Bearing
Set Screws 35 in-lbs (4 Nm)
PVT Inner Cover Screws
(Phillips) 50 in-lbs (5 Nm)
PVT Inner Cover Screws
(Hex) 12 ft-lbs (16 Nm)
PVT Outer Cover Screws 50 in-lbs (5 Nm)
Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm)
Shift Cable Bracket Bolts 37 ft-lbs (50 Nm)
Shock Mounting Fasteners
(rear) 40 ft-lbs (54 Nm)
Skid Plate Fasteners 8 ft-lbs (11 Nm)
Spark Plug 9 ft-lbs (12 Nm)
w/o anti-seize
Speed Sensor Screw 10 ft-lbs (14 Nm)
Stabilizer Bar Linkage (rear) 17 ft-lbs (23 Nm)
Stabilizer Bar Mounting
Bracket Bolts (rear) 17 ft-lbs (23 Nm)
Starter Mounting Bolts 3 ft-lbs (4 Nm)
Starter Power Wire Nut 54 in-lbs (6 Nm)
Starter One-Way Clutch Bolts 9 ft-lbs (12 Nm)
Stator Cover Screws 9 ft-lbs (12 Nm)
Stator Mounting Bolts 9 ft-lbs (12 Nm)
Stator Wire Retainer 6 ft-lbs (9 Nm)
Steering Rack Mounting Bolts 16 ft-lbs (22 Nm)
Steering Shaft to EPS Unit 20 ft-lbs (27 Nm)
Steering Shaft to Steering
Rack 46–51 ft-lbs (62-69 Nm)
Steering Wheel Nut 65 ft-lbs (88 Nm)
Strut Casting Pinch Bolt 17 ft-lbs (23 Nm)
Strut Mounting Nut (top) 15 ft-lbs (21 Nm)
Thermostat Cover Bolts 8 ft-lbs (11 Nm)
Tie Rod End to Knuckle 40 ft-lbs (54 Nm)
Tie Rod Jamb Nuts 14 ft-lbs (19 Nm)
TMAP Retaining Bolt 24 in-lbs (3 Nm)
TPS Mounting Screws 18 in-lbs (2 Nm)
Transmission Bell Crank Nut 15 ft-lbs (20 Nm)
ITEM TORQUE
Transmission Case Screws 18 ft-lbs (24 Nm)
Transmission Drain / Fill
Plugs 14 ft-lbs (19 Nm)
Transmission Isolator Bolt
(rear) 40 ft-lbs (54 Nm)
Transmission Rear Mount
Bracket Fasteners 17 ft-lbs (23 Nm)
Transmission Joint Bracket
Bolts ft-lbs ( Nm)
Transmission Park Flange
Screws 8 ft-lbs (11 Nm)
Transmission Sector Gear
Cover 11 ft-lbs (15 Nm)
Transmission Shift Fork
Screws 10 ft-lbs (14 Nm)
Transmission Snorkel Bearing
Retaining Plate Screws 8 ft-lbs (11 Nm)
Transmission Snorkel Tube
Locking Screw 8 ft-lbs (11 Nm)
TRS Retaining Nuts 7 ft-lbs (10 Nm)
TPS Mounting Screws 18 in-lbs (2 Nm)
Valve Cover Bolts 9 ft-lbs (12 Nm)
Water Pump Impeller Finger Tight
*LH threads
Water Pump Cover Bolts 9 ft-lbs (12 Nm)
(Apply Loctite® 204™ to
bolt threads)
Wheel Lug Nuts (Steel
Wheels) 36 ft-lbs (49 Nm)
Wheel Lug Nuts (Aluminum
Wheels) 30 ft-lbs + 90º (41 Nm + 90º)
GENERAL INFORMATION