PMS 419 RANGER® 570 EFI RANGER® 570 EPS RANGER CREW® 570 EFI RANGER CREW® 570 EPS Owner's Manual for Maintenance and Safety
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
POLARIS®, RANGER® and RANGER CREW® are registered trademarks of POLARIS Industries Inc. 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard.
INTRODUCTION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Long Sleeves Eye Protection Long Pants Gloves Over-the-Ankle Boots Helmet Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
SAFETY Safety Labels and Locations Proper Use Warning (CREW 570) Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license. • Do not let people drive or ride after using alcohol or drugs. • Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur. • Do not exceed seating capacity: 4 occupants.
SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. • Reduce speed and allow greater distance for braking when carrying cargo. • Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control.
SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain. • Never operate on excessively rough, slippery or loose terrain. • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
SAFETY Operator Safety • Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels. • Never modify this vehicle through improper installation or use of non-POLARIS approved accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer.
SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver’s license.
SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always turn off the engine when refueling. • Always refuel outdoors or in a well ventilated area free of any source of flame or sparks. • Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge.
SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use). In some areas it's unlawful to operate this vehicle on public streets, roads and highways. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover.
SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
FEATURES AND CONTROLS Vehicle Components Not all models come with all features. Refer to the specifications section beginning on page 88.
FEATURES AND CONTROLS Console Gear Selector (Shifter) Instrument Cluster Cup Holder Ignition Switch Storage Tray Light Switch AWD/Differential Switch Mode Button 12V Auxiliary Outlet Storage Compartment Cup Holder Auxiliary Outlet The 12-volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood.
FEATURES AND CONTROLS Console Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. This vehicle is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle.
FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats. Always make sure the seat belts are secured for all riders before operating. WARNING! Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER. To wear the seat belt properly, follow this procedure: 1.
FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle. Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover. WARNING! Vehicle rollover could cause severe injury or death.
FEATURES AND CONTROLS Instrument Cluster Speedometer High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Indicator Lamps Speedometer The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 30.
Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is 2 located in the instrument cluster. All segments will light up for one second at start-up. If the instrument E F cluster fails to illuminate, a battery RPM Trip 1 over-voltage may have occurred 1 and the instrument cluster may have 3 shut off to protect the electronic km mi speedometer. If this occurs, take the vehicle to your POLARIS dealer for 4 proper diagnosis.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to display either standard or metric units of measurement. Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to the odometer display. Standard Display Distance Fuel Temperature Time Miles U.S.
Instrument Cluster FEATURES AND CONTROLS Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays only when the Number (SPN) Number (0-9) CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine. If the CHECK ENGINE light illuminates, retrieve the error codes from the display. 1.
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for your new POLARIS RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period.
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Brake system/pedal travel Ensure proper operation Brake fluid Ensure proper level Park gear Ensure vehicle does not roll when in PARK. Ensure PARK light illuminates.
OPERATION Starting Engine 1. 2. 3. 4. Always start the engine outdoors or in a well-ventilated area. Sit in the driver's seat and fasten the seat belt. Secure the cab nets (or doors). Apply the brakes. Place the transmission in PARK. Do not press the throttle pedal while starting the engine. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts. 5.
OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Sit in the driver's seat and fasten the seat belt. 3. Start the engine and allow it to warm up. 4. Always use the cab nets (or doors) while riding in this vehicle. 5. Apply the service brakes and shift the transmission into gear. 6. Check your surroundings and determine your path of travel. 7.
OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Avoid operating over large obstacles such as large rocks and fallen trees.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Exercise extreme caution. 3. Avoid crossing the side of a steep hill. Driving Downhill When driving downhill, follow these precautions: 1. Avoid excessively steep hills. 2. Drive straight downhill.
OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 70, and take the vehicle to your dealer at the first opportunity.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface. 2.
OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.
OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. Always shift to low gear for towing. 3. When towing a disabled RANGER vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 4.
OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Place the transmission in PARK. Dismount the vehicle. 4. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 5. Release the tailgate latches.
OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate at the same speed. The front wheels also rotate at the same speed. See page 46 for AWD operating instructions.
OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100.
WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise. Winch Safety Precautions 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 16.
WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to think through the winching you are about to do. • Proceed slowly and deliberately.
WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” NO YES is designed to stretch. WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks.
WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. A. B. C. D. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.
WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15.
WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement. 2. Always inspect your winch cable before each use.
WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders. Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to “jerk” a load with the winch.
WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware. 2. Permit your winch motor to cool down prior to servicing your winch. 3.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c.
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 100.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Steering Front suspension Rear suspension Tires Brake fluid level Brake pedal travel Brake system Wheels/fasteners Frame fasteners Engine oil level ► Air filter, pre-filter E Coolant Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Pre-Ride Make adjustments as need ed. See Pre-Ride Checklist on page 34.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Cooling system (if applicable) ► Oil lines, fasteners ► Engine oil and filter change ► ► ► ► D E Front Gearcase oil (if equipped) Middle Gearcase oil (if equipped) Rear gearcase oil (if equipped) Transmission oil Fuel system ► Radiator (if applicable) ► Cooling Hoses ► Engine mounts Exhaust muffler/pipe ► Spark plug E D Ignition timing ► Wiring D Clutches ► D Front wheel bearings D Brake fluid Spark arrester Valve clearance Idle speed D To
MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Always use the recommended engine oil. Oil Fill Cap NOTICE: Allowing dirt or debris to enter the engine can result in serious engine damage. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Oil Check The oil dipstick and fill tube is located on the engine. Access the dipstick through the right rear wheel well. 1.
MAINTENANCE Engine Oil Oil and Filter Change Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Clean the area around the drain plug.
MAINTENANCE Engine Oil Oil and Filter Change 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 11.
MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug(s) Torque Drain Plug Torque Main Gearcase (Transmission) AGL Gearcase Lubricant & Transmission Fluid 41 oz. (1200 ml 10-14 ft. lbs. (14-19 Nm) 10-14 ft. lbs. (14-19 Nm) Front Gearcase Demand Drive Fluid 9.3 oz. (275 ml) 8-10 ft. lbs. (11-13.6 Nm 11 ft. lbs.
MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 90 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase. 1.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 88 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark Plug Gap/Torque Model Electrode Gap 570 CREW 570 .030" (.69-.84 mm) .030" (.69-.84 mm) New or Used Plug Torque 7 ft. lbs. (10 Nm) 7 ft. lbs.
MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface. 2. Lift the hood. View the coolant level in the overflow bottle. 3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid.
MAINTENANCE POLARIS Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 8. Rotate the driven clutch by hand until the belt is completely off. Step 8 9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it. 10. Remove all debris wrapped in and around the PVT system. 11. Remove all debris from the entire clutch air duct passage. 12. Check for signs of damage to seals on the transmission and engine.
MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the red drain plug on the outer clutch cover. Allow the water to drain completely. Reinstall the drain plug. 3. Place the transmission in PARK. 4. Start the engine. 5.
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. 1. Lift the cargo box. 2. Clean all dirt and debris from the air box area. 3. Unlatch the two (2) cover clips and carefully remove the air box cover. 4. Inspect the seal between the cover and air box to ensure the seal is not torn and has been maintaining a proper seal. View of Under-Box Area 5.
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. • Remove any combustible materials from the area. • Wear eye protection and gloves. • Do not stand behind or in front of the vehicle while purging.
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 24. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use POLARIS-approved size and type of tires for this vehicle when replacing tires.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. 6. Apply the brakes. Place the transmission in PARK. Stop the engine. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the frame. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The fuse box is located in the electrical compartment under the left rearmost seat. Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer. Fuse Size Feature Supported 7.
MAINTENANCE Lights Headlight Beam Adjustment X X 8" (20 cm) 25 ft. (7.6 m) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the engine. Turn on the headlights. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall.
MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
MAINTENANCE Battery Battery Removal WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 1. Remove the front seat (570) or rear seat (CREW 570) to access the battery compartment. 2. On conventional batteries, remove the battery vent tube. 3.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 83 before installing the battery. If your factory-installed 14 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, please see your POLARIS dealer to purchase a 30 AH battery.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 81. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 82. Make sure the positive terminal is toward the driver’s side of the vehicle.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 57. Battery Maintenance See pages 82-83 for storage and charging procedures. Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 57.
MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 34. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer. 5.
SPECIFICATIONS RANGER 570 EFI/EPS Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories) Dry Weight Test GVW - Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Overall Length Overall Width Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. Turning Radius Towing Capacity Hitch Tongue Capacity Max.
SPECIFICATIONS Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlights Taillights Brake Light Indicator Light RANGER 570 EFI/EPS RANGER CREW 570 EFI/EPS PVT Single Lever (console) 28.84:1 25.83:1 13.58:1 3.
POLARIS PRODUCTS Part Number Description 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) Engine Lubricant 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l) 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures Slow/easy clutch engagement Towing/pushing at low RPM/low ground speed Utility use/plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance Slip
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent line Incorrect fuel Clogged air filter Low fuel pressure Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel Low octane fuel Clogged fuel filter Possible Rich Fuel Cause Fuel is very high octane Solution
WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • • • • • • • • • • • Wheels and tires Suspension
WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 101
INDEX A Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . Adjustment, Shock Spring . . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Cleaning. . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive Switch. . . . . . . . . . . . . . . . . . . . Auxiliary Outlets . . . . . . . . . . . . . . . . . . . . . . . . . Axle Nut Torque . . . . . . . . . . . .
INDEX F Fluid Change Front Gearcase . . . . . . . . . . . . . . . . . . . 64 Main Gearcase . . . . . . . . . . . . . . . . . . . 63 Transmission . . . . . . . . . . . . . . . . . . . . 63 Fluid Check Main Gearcase . . . . . . . . . . . . . . . . . . . 63 Transmission . . . . . . . . . . . . . . . . . . . . 63 Fluid Level Coolant (Overflow Bottle) . . . . . . . . . . 67 Coolant (Radiator) . . . . . . . . . . . . . . . . 67 Front Gearcase . . . . . . . . . . . . . . . . . . . 64 Fluid Levels During Storage. .
INDEX P S Power Steering Unit (Cleaning). . . . . . . . . . . . . . 77 Pre-Filter, Intake . . . . . . . . . . . . . . . . . . . . . . . . . 71 Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . 34 PVT Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-70 PVT System Operation . . . . . . . . . . . . . . . . . . . . 68 PVT Warning. . . . .
PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: • If you are under age 16 and without a valid driver’s license. • Without first viewing safety video and taking a ROHVA training course at www.rohva.org. • On excessively steep hills. • On public roads (unless designated for off-road use). • With a passenger who is not seated in a passenger seat, or with passengers under age 12 or who cannot comfortably reach the floor and hand holds.
