Polaris RZR 170 2009 Service Manual
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Polaris RZR 170 2009 Service Manual

Polaris RZR 170 2009 Service Manual

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MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: 2009 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
GENERAL INFORMATION
GENERAL INFORMATION
CHAPTER 1
1
1.1

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Summary of Contents for Polaris RZR 170 2009

  • Page 1: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .

  • Page 2: Model Information

    GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 9 V A 1 7 A D Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...

  • Page 3: Unit Serial Number (Vin) And Emissions Decal Locations

    GENERAL INFORMATION Unit Serial Number (VIN) and Emissions Decal Locations The machine model information decal (A) and vehicle identification number (VIN) are important for identification. The VIN number (B) is stamped on a portion of the front left frame rail close to the left front wheel. The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.

  • Page 4: Vehicle Information

    Indy Red P-293 Replacement Keys Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the original. Should both keys become lost, ignition switch replacement is required. P/N 0453013 SPECIAL TOOLS Special tools may be required while servicing this vehicle.

  • Page 5: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2009 RANGER RZR 170 MODEL NUMBER: R09VA17AA ENGINE MODEL: S35C Category Dimension / Capacity Length 85 in. / 216 cm Width 48 in. / 122 cm Height 55 in. / 139.7 cm Wheel Base 65 in. / 165 cm Ground Clearance 6 in.
  • Page 6 GENERAL INFORMATION MODEL: 2009 RANGER RZR 170 Drivetrain Transmission Type Polaris Automatic CVT MODEL NUMBER: R09VA17AA Shift Type In Line Shift - H / N / R ENGINE MODEL: S35C Transmission Oil Requirements Polaris AGL Engine Main Gearcase 23.7 oz. (700 ml)

  • Page 7: Misc. Specifications And Charts

    GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C...

  • Page 8: Standard Torque Specifications

    GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

  • Page 9: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes...

  • Page 10: Glossary Of Terms

    Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
  • Page 11 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART ........2.3 PERIODIC MAINTENANCE OVERVIEW .
  • Page 12 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.27 BATTERY MAINTENANCE .

  • Page 13: Periodic Maintenance Chart

    Polaris dealer.  = SEVERE USE ITEM -- See Above E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING  Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.

  • Page 14: Pre-Ride - 25 Hour Maintenance Interval

     Transmission Oil 25 H 12 M 250 (400) Inspect level; change yearly  Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

  • Page 15: 30 - 100 Hour Maintenance Interval

    Inspect periodically; adjust when parts are  Toe Adjustment replaced Idle Speed Adjust as needed  Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

  • Page 16: Maintenance References / Service Locations

    MAINTENANCE MAINTENANCE REFERENCES / SERVICE LOCATIONS Front and Rear View Daytime Running Lamps Grease Steering Pivots Grease A-arm Pivots Inspect Brake Pads Trail / Brake Lamp Inspect Exhaust Inspect / Clean Air Filter Inspect Brake Pads Clean / Lubricate Chain...

  • Page 17: Rh And Lh Side Views

    MAINTENANCE RH and LH Side Views...

  • Page 18: Lubricants / Service Products

    (50 ml.) (6 Count) Polaris YOUTH Synthetic 0W-40 4-Cycle Loctite™ Threadlock 242 2876248 2871949 Engine Oil (Quart) (50 ml.) (10 Count) Polaris Semi - Synthetic 20W-40 4-Cycle Loctite™ Threadlock 242 2872175 2871950 Engine Oil (Quart) (6 ml.) (12 Count) Gearcase / Transmission Lubricants Loctite™...

  • Page 19: Maintenance References

    Item Ref. Rec. Lube / Fluid Method Frequency* Change after 10 hrs, and then Polaris YOUTH 40W Engine every 50 hours, 6 months or Oil or 20-W40 Synthetic. Add oil to proper level on 100 hours thereafter; Change Engine Oil Page 2.7...

  • Page 20: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION Locate the shift cable in the rear wheel well area. AND MAINTENANCE Shift Cables Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when Dust Boot servicing the vehicle at each scheduled maintenance. • Tires - check condition and pressures Shift Cable Mount •...

  • Page 21: Shift Cable Replacement

    MAINTENANCE Shift Cable Replacement Raise the vehicle and support it with jackstands in order to access the underside to remove the cables. Shift cable replacement may be necessary if symptoms include: IMPORTANT: Document location of cable ties and routing prior to removal. This is important for •...

  • Page 22: Fuel System And Air Intake

    MAINTENANCE FUEL SYSTEM AND AIR INTAKE Inspect the air filter element for tears or damage. NOTE: Filter is washable. Do not discard. Air Filter Service Wash the filter in warm soapy water and allow it to air dry. It is recommended that the air filter be inspected as part of Apply air filter oil (commercially available) to the filter, pre-ride inspection.

  • Page 23: Choke Cable Adjustment

    MAINTENANCE Choke Cable Adjustment Remove the retaining screws and pull the choke assembly out at the dash. Verify free play of 3/16” (4.76 mm) and smooth operation of the choke cable at the dash. Decrease Increase CHOKE CABLE FREEPLAY Raise the vehicle and support it with jackstands in order to access the underside.

  • Page 24: Idle Speed Adjustment

    MAINTENANCE Idle Speed Adjustment Pilot Air Screw Adjustment Start engine and warm it up thoroughly. CAUTION Adjust idle speed by turning the slide adjustment screw in (clockwise) to increase or out (counterclockwise) to The pilot air screw is calibrated at the factory to decrease RPM.

  • Page 25: Vent Lines

    MAINTENANCE Vent Lines Fuel Filter Check fuel tank, crankcase, carburetor and transmission The fuel filter should be replaced in accordance with the vent lines for signs of wear, deterioration, damage or “Periodic Maintenance Chart” or whenever sediment is visible leakage. Replace every two years. in the filter.

  • Page 26: Fuel Valve Location

    MAINTENANCE Fuel Valve Location Fuel Pump / Fuel Lines NOTE: Thoroughly clean the exterior of all fuel The fuel valve is located on the passenger side of the vehicle below the gas cap. Always turn off the fuel when the vehicle is related components before servicing.

  • Page 27: Throttle Pedal Inspection

    MAINTENANCE Throttle Pedal Inspection Throttle Stop Speed Control If the throttle pedal has excessive play due to cable stretch or Use the following procedure to control how far the throttle cable misadjustment, it will cause a delay in throttle response. opens.

  • Page 28: Throttle Freeplay Adjustment

    MAINTENANCE Throttle Freeplay Adjustment Throttle Cable Replacement Inspection WARNING Place the transmission in the Neutral (N) position. Start the engine and warm it up thoroughly. Follow the factory cable routing as installed to prevent cable pinching, binding or damage. Measure the distance the throttle pedal moves before the engine begins to pick up speed.
  • Page 29 MAINTENANCE Remove the carburetor slide assembly from the carburetor 12. Install the new cable onto the carburetor slide assembly and body and disconnect the throttle cable. install the slide into the carburetor. Hand-tighten the slide cap sufficiently. Raise the vehicle and support it with jack stands in order to access the underside of the vehicle.

  • Page 30: Engine

    MAINTENANCE ENGINE Engine Oil Change Position the vehicle on a level surface. Engine Oil Level Clean area around the drain plug. Maintain the oil level within the safe range on the dipstick. Do not overfill. Run engine until warm. To check the oil level: Stop the engine.

  • Page 31: Engine Crankcase Ventilation System Inspection

    The hoses are form-fitted for a proper fit. 11. Remove the dipstick. Add recommended oil. Do not overfill. Recommended Engine Oil: Polaris Synthetic Youth 4-Stroke Oil SAE 40 (Above 32F) Quart - (PN 2876248) Gallon - (PN 2876249) Polaris Semi-Synthetic Oil 20W-40 (Below 32F)

  • Page 32: Compression / Leakdown Test

    MAINTENANCE Compression / Leakdown Test Intake Valve Clearance Adjustment Remove the valve cover and secondary air pipe assembly. IMPORTANT: Use of a compression tester adaptor Verify cam lobes are pointed down. that is too long WILL CAUSE DAMAGE to the cylinder head.

  • Page 33: Exhaust - Spark Arrestor

    MAINTENANCE Exhaust - Spark Arrestor WARNING Do not clean spark arrestor immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Allow components to cool sufficiently before proceeding. Wear eye protection and gloves.

  • Page 34: Transmission

    MAINTENANCE TRANSMISSION Transmission Specification Chart RAIN EVEL HECK EARCASE UBRICANT APACITY ORQUE ORQUE Transmission AGL - Synthetic ATV 24 oz. (710 ml) 18 ft. lbs. (24 Nm) 30-45 in. lbs. (3-5 Nm) (Main Gearcase) Gearcase Lubricant Transmission Oil Change Transmission Oil Level Check: The fill plug is located on the side of the gearcase next to the shift NOTE: It is important to follow the transmission and lever bell crank.

  • Page 35: Final Drive / Wheel And Tire

    MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Transmission Oil Change: Remove the level check plug (refer to “Lubricant Level Wheel, Hub, and Spindle Torque Table Check”). Place a drain pan under the main gearcase drain plug. Item Nut Type Specification Remove the drain plug and allow to drain completely.

  • Page 36: Tire Inspection

    Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Periodic Maintenance Chart. Lubricate more often under severe use, such Tire Inspection as in dirty or wet conditions.

  • Page 37: Electrical And Ignition System

    MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Pull down on the chain tensioner to move it out of the way, then measure chain deflection. It should have 1/4"-1/2" (6- 12 mm) deflection. Battery Maintenance Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush.

  • Page 38: Battery Removal

    NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the...

  • Page 39: Spark Plug Service

    MAINTENANCE Spark Plug Service Measure gap with a wire gauge. Refer to specifications in the following illustration for proper spark plug type and Clean plug area so no dirt or debris can fall into the gap. Adjust gap if necessary by carefully bending the side cylinder when the plug is removed.

  • Page 40: Steering

    Try to move the wheel by an authorized Polaris MSD-certified technician and hub by pushing inward and pulling outward. when replacing worn or damaged steering parts.

  • Page 41: Toe Alignment Inspection

    MAINTENANCE Toe Alignment Inspection Toe Adjustment Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod Set steering wheel in a straight ahead position and secure needs adjusting.

  • Page 42: Suspension

    MAINTENANCE SUSPENSION BRAKE SYSTEM Spring Preload Adjustment Brake Fluid Inspection The front and rear shock absorber springs are adjustable by Always check the brake pedal travel and inspect the brake fluid rotating the adjustment cam to change spring tension preload. reservoir level before each operation.

  • Page 43: Brake Pad / Disc Inspection

    MAINTENANCE Brake Pad / Disc Inspection Check the brake pads for wear, damage, or looseness. Inspect the brake pad wear surface for excessive wear. Pads should be changed when the friction material is worn to .040” (1 mm). Measure Pad Material Thickness Service Limit: .040"...

  • Page 44: Maintenance Log

    MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2.34...
  • Page 45 ENGINE CHAPTER 3 ENGINE TOOLS..............3.3 SPECIAL TOOLS .
  • Page 46 ENGINE BOTTOM-END DISASSEMBLY ......... . . 3.26 STARTER DRIVE GEAR REMOVAL AND INSPECTION .

  • Page 47: Tools

    ENGINE TOOLS Oil Pump Sprocket Nut 6mm 7-8 (9-11 Nm) Special Tools Oil pump baffle plate 4-5 (5-7 Nm) PART NUMBER TOOL DESCRIPTION Stator Assembly 7-8 (9-11 Nm) 2870390 Piston Support Block PA-45153 Flywheel Puller Stator Housing 7-8 (9-11 Nm) Transmission Output PA-49959 Shaft Collar Tool...

  • Page 48: Engine Information

    ENGINE ENGINE INFORMATION Engine Exploded Views Cylinder / Cylinder Head Crankcase Crankshaft and Piston Valve Train...

  • Page 49: Engine Lubrication

    Accessible Components Oil Type:** The following components can be serviced or removed with the Above 32F engine installed in the frame: Polaris Youth 4-Stroke Oil (40 W) Quart - (PN 2876248) • Flywheel Gallon - (PN2876249) • Alternator/Stator Below 32F •...

  • Page 50: Engine Service Data

    ENGINE Engine Service Data Cylinder Head / Valvetrain ES35C Rocker arm ID .3936 - .4007" (10.00 - 10.18 mm) Rocker Arm/Shaft Rocker shaft OD .3925 - .3931" (9.972 - 9.987 mm) 1.1730" (29.795 mm) Limit 1.1574" (29.40 mm) Camshaft Cam lobe height 1.1637"...
  • Page 51 ENGINE Engine Service Data Cylinder / Piston / Connecting Rod ES35C Surface warpage limit (mating with cylinder head) .002” (0.05 mm) Cylinder bore 2.4015 - 2.4019" (61 - 61.01 mm) Taper limit .002” (0.05 mm) Cylinder Out of round limit .002”...

  • Page 52: Oil Flow Diagram

    ENGINE Oil Flow Diagram...

  • Page 53: Engine Systems Service

    ENGINE ENGINE SYSTEMS SERVICE Breather / Oil Separator The breather / oil separator is located on the upper rear cab support. This system provides ventilation for the valve cover and engine crankcase to the air box. A one-way valve (A) allows pulses from the crankcase to travel in one direction only, thereby vacuuming the crankcase.

  • Page 54: Emissions Secondary Air System

    ENGINE Emissions Secondary Air System The secondary air system is located on the upper rear cab support and engine. This system introduces air into the exhaust system for more complete burning of the exhaust emissions. The air control valve (A) is operated by intake manifold pulses from the intake manifold, which releases the air to the one-way valve (B) to combine with the pull of the exhaust gas stream from the cylinder head.

  • Page 55: Cooling Shroud Removal/Installation

    ENGINE Cooling Shroud Removal/Installation The cooling shroud directs air generated by the fan around the cylinder and casing for cooling. REMOVAL: Remove the carburetor and intake. Remove the exhaust pipe. Remove the screws that attach the fan shroud (A) to the housing (C). Remove the bolts that attach the fan shroud to the stator housing.

  • Page 56: Engine Removal

    4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel. • Use only Polaris Youth (40w) Oil, or API certified “SH” oil equivalent. • Use fuel with a minimum octane of 87 (R+M)/2 method.

  • Page 57: Top-End Disassembly

    ENGINE TOP-END DISASSEMBLY Cam Chain Tensioner Inspection Remove the two cam chain tensioner flange bolts. NOTE: Engine Removal/Installation The plunger is under spring tension. Maintain inward pressure on the tensioner body while removing. Refer to page 3.12 for engine removal / installation notes. Finding Top Dead Center (TDC) Remove the cooling shroud.

  • Page 58: Rocker Assembly Disassembly And Inspection

    ENGINE Rocker Assembly Remove each rocker arm shaft using a hex bolt. NOTE: Disassembly and Inspection Place the hex bolt head in a vise and lightly tap the rocker housing with a non-marring hammer to pull the rocker NOTE: Orientation of the components is important arm shafts.

  • Page 59: Camshaft Removal

    ENGINE Measure I.D. of each rocker arm for out-of-round and Remove the cam chain from the sprocket by tilting the cam visually inspect the I.D. surface. Replace arm if excessive assembly and simultaneously lifting the chain. wear is evident. Inspect the lash adjusters for wear, pitting, or damage to If not removing the cylinder for other service, secure the threads of the adjuster or locknut.

  • Page 60: Cylinder Head Removal

    ENGINE Cylinder Head Removal Visually inspect each cam lobe and bearing for wear, chafing or damage. NOTE: Cam chain and tensioner must be removed. If no crankshaft service is being performed, secure Bearings cam chain with mechanics wire to avoid chain falling into the crankcase.

  • Page 61: Cylinder Head Inspection

    ENGINE Cylinder Head Inspection Cylinder Head Disassembly Thoroughly clean cylinder head surface to remove all WARNING traces of gasket material and carbon. CAUTION Wear eye protection or a face shield during cylinder head disassembly and reassembly. Use care not to damage sealing surface. NOTE: Keep all parts in order with respect to their If there is damage found on the cylinder head location in the cylinder head.

  • Page 62: Valve Inspection

    ENGINE Valve Inspection Measure free length of the inner and outer springs with a Vernier caliper, Ill.1. Check spring for squareness as Remove all carbon from valve with a soft wire wheel. shown in Ill.2. Replace spring if measurements are out of specification.

  • Page 63: Valve Seat Reconditioning

    ENGINE Measure valve guide inside diameter at the top middle and Cylinder Head Reconditioning end of the guide using a small hole gauge and a micrometer. NOTE: Servicing the valve guides and valve seats Measure in two directions, front to back and side to side. requires special tools and a thorough knowledge of reconditioning techniques.
  • Page 64 ENGINE  Place 46 cutter on the pilot and make a light cut. Remove valve and check where the Prussian Blue™ or black marker indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width (A).

  • Page 65: Cylinder Head Assembly

    ENGINE NOTE: When using an interference angle, the seat 12. Clean rocker assembly, cylinder head, valves, and camshaft contact point on the valve will be very narrow, and is oil supply passages thoroughly. a normal condition. Look for an even and continuous contact point on the black marker, all the way around the valve face.

  • Page 66: Valve Sealing Test

    ENGINE Cylinder Removal Dip valve springs and retainer in clean engine oil and install springs with closely spaced coils toward the cylinder head. Follow engine disassembly procedures to remove the valve cover, rocker assembly, camshaft and cylinder head. Remove cam chain guide at front of cylinder. Tap cylinder lightly with a soft-faced hammer in reinforced Closely spaced areas only until loose.

  • Page 67: Piston Removal

    ENGINE Piston Removal Cylinder Inspection Remove circlip from either side of piston. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch.

  • Page 68: Cylinder Hone Selection / Honing Procedure

    Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust. = In. / mm.

  • Page 69: Piston Ring Installed Gap

    ENGINE Piston Ring Installed Gap Measure piston pin bore. Replace piston if out-of-round Place each piston ring inside cylinder using piston to push ring squarely into place as shown. Piston ring end gap installed Feeler Gauge Piston Pin Bore Cylinder 25-50 mm Measure piston pin O.D.

  • Page 70: Bottom-End Disassembly

    ENGINE BOTTOM-END DISASSEMBLY Remove the start drive gear and shaft by pulling the shaft and tilting the gear slightly. Starter Drive Gear Removal and Inspection Remove the fan from the hub. Measure the OD of the starter drive shaft on both ends for out-of-round.

  • Page 71: Flywheel Removal / Inspection

    ENGINE Flywheel Removal / Inspection Inspect the flywheel for loose components, cracks or other damage. Replace flywheel if any damage is found. CAUTION Avoid damage to the flywheel or crankshaft end. Do not strike components or special tools with hammers or heavy objects. Before removing the flywheel, remove the shaft collar (A) from the crankshaft.

  • Page 72: Crankshaft One Way Gear / Drive Sprocket Removal And Inspection

    ENGINE Crankshaft One Way Gear / Drive Sprocket Remove the starter drive one-way gear assembly (A) from Removal and Inspection the crankshaft. Remove the baffle plate. Remove drive sprocket (D) and woodruff key from the Using the Slotted Nut Socket PA-49935, remove the crankshaft.

  • Page 73: Starter Drive One-Way Clutch Removal And Inspection

    ENGINE Starter Drive One-way Clutch Balance Shaft Sprocket Removal and Inspection Removal and Inspection The cooling shroud, stator housing and flywheel must be The cooling shroud, stator housing and flywheel and removed prior to accessing the one-way starter drive. starter drive one-way gear must be removed prior to accessing the balance shaft gear and oil pump gear Pull the starter drive assembly from the crankshaft.

  • Page 74: Oil Pump Removal / Drive Chain Inspection

    ENGINE Oil Pump Removal / Drive Chain Inspection Remove the oil pump galley cover, oil pump gear and chain to facilitate removal of the balance shaft sprocket. NOTE: Oil pump is a replace-only assembly. Remove the oil pump galley cover, pump gear nut, and balancer shaft nut prior to chain and sprocket removal.
  • Page 75 ENGINE Thoroughly clean all oil passages with clean solvent. Install a new pump with the oil galley pointed down as shown. Install with the oil galley pointing down Torque screws to specification. Oil Pump Screw Torque: 4-5 ft. lbs. (5-7 Nm) 3.31...

  • Page 76: Crankcase Disassembly

    ENGINE CRANKCASE DISASSEMBLY NOTE: Tapping the pto end of the crankshaft with a soft-face hammer may also separate the cases. Use NOTE: Engine must be removed from the frame to care not to damage the crankshaft end or cases. perform any crankcase or crankshaft removal. Crankcase Separator Tool PA-46087 NOTE: The starter, starter drive, flywheel, stator, oil...

  • Page 77: Crankshaft / Cam Chain / Sprocket Inspection

    ENGINE Crankshaft / Cam Chain / Sprocket Remove cam chain. Inspect chain for wear or damage. Inspection Replace if worn excessively or as part of any crankshaft repair. Inspect the crankshaft main bearings and cam chain sprocket for wear or damage. Note: Install new chain as a part of crankshaft repair.

  • Page 78: Engine Reassembly

    ENGINE ENGINE REASSEMBLY Install the balance shaft into the mag side of the crankcase. Bearing / Seal Installation Mag-side NOTE: To ease crankcase bearing installation, warm Crankcase the crankcase until hot to the touch. Placing the bearings in a freezer prior to installation will assist the assembly process.

  • Page 79: Chain Guide/Tensioner Installation

    ENGINE Crankshaft, Balance Shaft and Starter Drive Install the two mag side flange bolts and torque to Gear Installation specification. Install woodruff keys on the balancer shaft and crankshaft. Install and align the marks of the balance shaft gear and the crankshaft gear as shown.

  • Page 80: Oil Pump And Chain Installation

    ENGINE Install the Starter Drive one-way gear assembly, washer Install the baffle plate and torque to specification. and slotted nut. Using Slotted Nut Socket PA-49935, tighten the crank shaft nut to the specified torque. NOTE: Slotted nut is left hand threaded.

  • Page 81: Piston Ring Installation

    ENGINE Piston Ring Installation Install the chain (A) over the sprocket on the balance shaft gear (B). NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. If the piston has been in service, clean any accumulated carbon from the ring grooves and oil control ring holes.

  • Page 82: Piston Installation

    ENGINE Piston Installation Place the dowel pins in the PTO side of the crankcase and install a new cylinder base gasket. CAUTION Do not re-use circlips. Circlips become deformed during the removal process. Do not compress the new clip more than necessary to prevent loss of radial tension.

  • Page 83: Cylinder Installation

    ENGINE Cylinder Installation Cylinder Head and Camshaft Installation NOTE: Clean the gasket surfaces on the crankcase NOTE: Verify the gasket surfaces on the cylinder and cylinder. Remove all traces of old gasket head and cylinder are clean. Remove all traces of old material and apply a new base gasket gasket material.

  • Page 84: Camshaft Timing

    ENGINE Camshaft Timing CAUTION Serious engine damage will result if the camshaft is not properly timed to the crankshaft. IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC). This can be accomplished using one of two methods. Install the cam chain over the crankshaft.
  • Page 85 ENGINE Method 1 - Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) Crankshaft Keyway ‘UP’ 3.41...
  • Page 86 ENGINE Camshaft Installation - Timing Method 2 Reference Illustration Page 3.43 Stator housing is installed. NOTE: Use this method only when the stator is installed and cam shaft drive sprocket is in view. Rotate the crankshaft until the single (TDC) timing mark (Top Dead Center) on the flywheel is view in the center of the timing inspection window.
  • Page 87 ENGINE Method 2 - Camshaft Timing Using Flywheel TDC Mark Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) Single TDC Mark Aligned TDC Mark Rotation Cam Timing (View through timing inspection hole) Position crankshaft at TDC 3.43...

  • Page 88: Rocker Arm / Shaft Assembly

    ENGINE Rocker Arm / Shaft Assembly Install cylinder head nuts and torque to specification. Torque in 3 step cross pattern Apply engine assembly lube to all components and assemble the arms, shafts and decompression components into the rocker assembly. IMPORTANT: Install rocker shafts in their correct positions.

  • Page 89: Cam Chain Tensioner Installation

    ENGINE Cam Chain Tensioner Installation Intake Valve Clearance Adjustment Using a small flat blade screwdriver, turn the tensioner Remove the valve cover and secondary air pipe assembly. clockwise to retract the plunger (B) all the way into the Verify cam lobes are pointed down. tensioner body.

  • Page 90: Starter Drive Assembly

    ENGINE Starter Drive Assembly Stator Installation NOTE: The stator, flywheel, and starter drive Be sure the washer is positioned on the back of the drive gear. components can be serviced with the engine in the frame. Install the stator and pulse coil. Route the wires appropriately to avoid contact with any moving parts.

  • Page 91: Stator Housing Installation

    ENGINE Stator Housing Installation Install the fan hub, washer, and flywheel nut. Torque the flywheel nut to specification. NOTE: The stator, flywheel, starter drive, and stator can be serviced with the engine in the frame. Apply a small amount of Crankcase Sealant (PN 2871557) to the mounting surface and install a new gasket.

  • Page 92: Exhaust System

    ENGINE Exhaust System The exhaust silencer should be cleaned of accumulated carbon and all fasteners checked in accordance with the periodic maintenance table in Chapter 2. Replace the exhaust gasket and clean the spark arrestor anytime engine rebuilding is performed. Torque all fasteners to specification.

  • Page 93: Troubleshooting

    ENGINE TROUBLESHOOTING Engine Does Not Turn Over • Dead battery Spark Plug Fouling • Starter motor does not turn • Spark plug cap loose or faulty • Engine seized, rusted, or mechanical failure • Choke cable adjustment or plunger/cable sticking •...
  • Page 94 ENGINE Piston Failure - Scoring • Lack of lubrication • Dirt entering engine through cracks in air filter or ducts • Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance • Worn rings, piston, or cylinder •...
  • Page 95 BODY / SUSPENSION / STEERING CHAPTER 5 BODY / SUSPENSION / STEERING GENERAL INFORMATION ..........5.2 SPECIAL TOOLS .

  • Page 96: General Information

    BODY / SUSPENSION / STEERING GENERAL INFORMATION BODY REMOVAL Special Tools Seat Removal Lift up the seat latch lever located under the right front Description Part Number edge of the driver’s seat. Shock Spring Compressor Tool 2870623 Seat Latch Lever Shock Spanner Wrench N/A - Part of tool kit.

  • Page 97: Seat Installation

    BODY / SUSPENSION / STEERING Seat Installation Remove the (4) screws retaining the front bumper to the frame. Lift up the seat latch lever located under the right front Disconnect the daytime running lights as shown and edge of the driver’s seat. remove the bumper from the vehicle.
  • Page 98 BODY / SUSPENSION / STEERING Remove the (3) fasteners from each side, retaining the front Remove the (2) screws retaining the choke bracket. cab to the rocker panels. Disconnect the indicator lights and key switch harness Using a 6 mm Allen socket, remove the (4) bolts retaining connections under the dash as shown.

  • Page 99: Rocker Panel Removal

    BODY / SUSPENSION / STEERING Rocker Panel Removal Rear Cab Removal Remove the (3) bolts from each side, retaining the lower Remove the driver and passenger seats from the vehicle portion of the rocker panels. (see “Seat Removal”). Remove the (3) push rivets from each side, retaining the Remove the (4) fasteners retaining the front of the rear cab upper portion of the rocker panels.

  • Page 100: Service Panel (Seat Shield) Removal

    BODY / SUSPENSION / STEERING Service Panel (Seat Shield) Removal Console Cover Removal Remove the seats (see “Seat Removal”). Remove the seats (see “Seat Removal”). Remove the (7) bolts and (2) push rivets retaining the Remove the service panel (see “Service Panel Removal”). service panel.

  • Page 101: Key Switch / Indicator Light Replacement

    BODY / SUSPENSION / STEERING Key Switch / Indicator Light Replacement Remove the (2) nuts retaining the front portion of the drivers seat adjustment rail. Disconnect the key switch harness or indicator light connectors located under the dash as shown. Key Switch Remove Indicator...

  • Page 102: Decal Replacement

    BODY / SUSPENSION / STEERING Decal Replacement WARNING The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free of gasoline or flammable residue.

  • Page 103: Body Exploded View

    BODY / SUSPENSION / STEERING Body Exploded View...

  • Page 104: Cab Frame

    BODY / SUSPENSION / STEERING CAB FRAME Exploded View Cab Frame Assembly Install the rear cab frame to the mounting brackets at each Refer to the Owner’s Manual for the “Cab Nets and Storage side of the vehicle. Loosely install the four bolts and Bag”...

  • Page 105: Main Frame

    BODY / SUSPENSION / STEERING MAIN FRAME Exploded View 36 ft. lbs. (49 Nm) 36 ft. lbs. (49 Nm) 17 ft. lbs. (23 Nm) 5.11...

  • Page 106: Front A-Arms

    BODY / SUSPENSION / STEERING FRONT A-ARMS Exploded View 30 ft. lbs. (41 Nm) 30 ft. lbs. (41 Nm) 5.12...

  • Page 107: A-Arm Replacement

    BODY / SUSPENSION / STEERING A-arm Replacement Remove the lower shock mounting bolt. Elevate the front end of the vehicle far enough off the ground to remove the wheel. CAUTION Severe injury could occur if machine tips or falls. Loosen and remove the (4) wheel nuts. Remove the cotter pin, castle nut and washer from the bolt attaching the A-arm to the spindle.

  • Page 108: Front Hub

    BODY / SUSPENSION / STEERING FRONT HUB Remove the (2) bolts retaining the brake caliper and remove the caliper from the disc. CAUTION: Do not hang the caliper by the brake line. Use a strap or mechanics wire Hub Removal to hang caliper to prevent damage to the brake line.

  • Page 109: Hub Installation

    BODY / SUSPENSION / STEERING Hub Installation Remove the outer spacer from the hub. Grease the spindle and reinstall the front hub assembly. Grease Remove the seals from each end of the hub and press the bearings and spacer tube out. Install the brake caliper and torque the mounting bolts to specification.

  • Page 110: Shocks

    BODY / SUSPENSION / STEERING SHOCKS Shock Replacement Using a spring compressor, compress the shock spring far Shock Exploded View enough to remove the spring retainer. Shock Spring Compressor Tool 2870623 Remove the spring and adjustment collar from the existing shock and install the components onto the new shock.

  • Page 111: Rear Swing Arm

    BODY / SUSPENSION / STEERING REAR SWING ARM Exploded View 72 ft. lbs. (98 Nm) 7 ft. lbs. (10 Nm) Replace if Removed 72 ft. lbs. (98 Nm) 22 ft. lbs. (30 Nm) 84 in. lbs. 7 ft. lbs. 16 ft. lbs. (10 Nm) 72 ft.

  • Page 112: Swing Arm Removal

    BODY / SUSPENSION / STEERING Swing Arm Removal Loosen all (4) axle housing bolts. Remove the plastic tie strap retaining the brake lines to the Loosen the outer jam nut and back off the inner adjustment swing arm. nut on each chain adjuster to remove tension. Loosen Remove Loosen...

  • Page 113: Swing Arm Installation

    BODY / SUSPENSION / STEERING Remove the (2) swing arm through-bolts. Install a new tie strap to retain the brake lines. Tie Strap NOTE: Lower the vehicle slightly to ease removal. Line up the upper shock eyelets with the frame mounting holes and install the mounting bolts.

  • Page 114: Rear Axle

    BODY / SUSPENSION / STEERING REAR AXLE Remove the (2) fasteners retaining the LH axle housing to the swing arm. Axle Housing Removal Elevate the rear end of the vehicle far enough off the ground to remove the wheel(s). Remove CAUTION Severe injury could occur if machine tips or falls.

  • Page 115: Axle Housing Service

    BODY / SUSPENSION / STEERING Axle Housing Installation Remove the (2) axle retaining nuts and the (2) fasteners retaining the RH axle housing to the swing arm (see “Axle Install each axle housing and fasteners. Do not torque the Housing Service” if replacing the bearing or seal). fasteners at this time NOTE: Remember to install the chain adjusters onto Remove...

  • Page 116: Axle Removal / Installation

    BODY / SUSPENSION / STEERING Install the rear hub, dome washer, and nut on each side. Remove the axle clamp bolts from each side and remove the clamp brackets to allow for axle removal. NOTE: Be sure the dome on the washer is facing out, away from the rear hub.

  • Page 117: Steering

    BODY / SUSPENSION / STEERING STEERING Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View 11 ft. lbs. (15 Nm) 10 ft. lbs. (13.5 Nm) 16-17 ft. lbs. (22-23 Nm) 16-17 ft. lbs. (22-23 Nm) 29-37 ft. lbs. (39-50 Nm) 17 ft.

  • Page 118: Steering Shaft Removal / Installation

    BODY / SUSPENSION / STEERING Steering Shaft Removal Slide the pivot tube assembly off the steering shaft and remove the shaft out of the vehicle from under the dash. Remove the upper pinch bolt located under the steering pivot tube assembly. Steering Shaft Installation Reinstall the steering shaft.

  • Page 119: Steering Gearbox Removal / Installation

    BODY / SUSPENSION / STEERING Steering Gearbox Removal Remove the (3) bolts retaining the steering gearbox to the frame and remove the gearbox from the vehicle. Remove the steering shaft (see “Steering Shaft Removal”). Remove the front bumper to ease gearbox removal (see “Front Bumper Removal / Installation”).

  • Page 120: Tie Rod

    BODY / SUSPENSION / STEERING TIE ROD Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View 30 ft. lbs. (41 Nm) 25 ft. lbs. (34 Nm) 5.26...

  • Page 121: Tie Rod Removal / Installation

    BODY / SUSPENSION / STEERING Tie Rod Removal / Installation After performing the steering toe adjustment, torque the jam nuts to specification. Steering tie rods can be replaced by removing the rod-end castle nut at the tie rod plate and spindle. Elevate the front end of the vehicle.

  • Page 122: Wheels

    BODY / SUSPENSION / STEERING WHEELS Front Wheel Exploded View Rear Wheel Exploded View 5.28...

  • Page 123: Wheel Removal / Installation

    BODY / SUSPENSION / STEERING Wheel Removal Wheel Installation Position the vehicle on a level surface. Verify the parking brake is still engaged. Set the parking brake and stop the engine. Install the wheel hub, washer(s), and castle nut, if previously removed.
  • Page 124 BODY / SUSPENSION / STEERING NOTES 5.30...
  • Page 125 BRAKES CHAPTER 6 BRAKES GENERAL SPECIFICATIONS..........6.2 TORQUE SPECIFICATIONS.

  • Page 126: General Specifications

    BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .300 ± .007" (7.62 ± .178 mm) .180" (4.6 mm) Front Brake Disc Thickness .160" (4.05 mm) .138" (3.50 mm) Front Brake Disc Runout .010" (.254mm) REAR BRAKE SYSTEM Item Standard...

  • Page 127: Brake System Service Notes

    If noise does not change when brake is applied check other Noise is from other source (axle, hub, disc or wheel) sources. Inspect and repair as necessary Use only Pure Polaris replacement pads. Optional softer or Wrong pad for conditions harder pads may be available...

  • Page 128: Hydraulic Brake System - Overview Of Operation

    Do not fill it beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture.

  • Page 129: Brake System - Hydraulic Components

    BRAKES BRAKE SYSTEM - HYDRAULIC COMPONENTS Banjo Bolts (All): 14.5 ft. lbs. (19.6 Nm). Bleed Screws (All): 47 in. lbs. (5.3 Nm) Caliper Mounting Bolts (All): 18.0 ft. lbs. (24.5 Nm). Brake Pad Guide Pins: 12.0 ft. lbs. (16.2 Nm). 60 in-lbs.

  • Page 130: Brake Bleeding / Fluid Change

    Add clean brake fluid from a sealed container to the indicated MAX level of reservoir. Set reservoir cover loosely in place to keep debris out, but do not secure it. Polaris DOT 4 Brake Fluid (P/N 2872189)

  • Page 131: Brake Pedal

    Visually inspect pedal, bushings, and sleeve for wear and replace as required. Open Pedal Installation Apply Polaris Premium All Season grease to pivot post and install pedal with bushings and sleeve. Close Install washer and a new retaining E-clip. Align pedal with master cylinder clevis and install pin.

  • Page 132: Brake Pedal Inspection / Adjustment

    BRAKES Brake Pedal Inspection / Adjustment PARKING BRAKE Push and release brake pedal. Verify master cylinder Parking Brake Adjustment actuator rod and pedal mechanism returns fully and pedal contacts pedal stop (on left side of pedal pivot bracket) Place vehicle on a flat, level surface. when released.

  • Page 133: Parking Brake Cable Replacement

    BRAKES Parking Brake Cable Replacement Note location of tie strap for assembly. Strap (E) includes parking brake cable and rear brake line. Strap (F) includes Release parking brake. only park brake cable. Cut all tie straps. Loosen jam nut (A) and back out adjuster bolt (B) a few Cable routes on passenger side of shift cables (G) as shown.
  • Page 134 BRAKES 10. At caliper end of parking brake cable, have an assistant push inner cable into the outer cable casing as far as possible to maximize slack at the lever end. 1. Hold 2. Push 11. Remove cable from lever arm. 12.

  • Page 135: Front Brake Pads

    BRAKES FRONT BRAKE PADS Remove brake pad guide pin loosened in Step 3. Push mounting bracket (B) inward (toward piston side of Front Pad Removal caliper). Elevate and support front of vehicle. Slide stationary pad out (away from bracket) and off the threaded post, then rotate pad until it can be removed from CAUTION remaining guide pin (C).

  • Page 136: Front Brake Pad Assembly / Caliper Installation

    30 ft. lbs. (40 Nm) Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Be sure dust boots are fully seated on caliper bracket and on caliper body.

  • Page 137: Front Brake Disc

    BRAKES FRONT BRAKE DISC Disc Replacement Remove front wheel and brake caliper. See “Front Pad Disc Inspection Removal” on page 6.11. Visually inspect disc for scoring, scratches, or gouges. Remove hub assembly. Refer to Chapter 5. Replace the disc if any deep scratches are evident. Remove (6) bolts and disc from hub.

  • Page 138: Front Caliper

    BRAKES FRONT CALIPER Remove caliper mounting bolts and slide caliper off disc. Front Caliper Removal NOTE: The caliper is not serviceable. Each caliper can be replaced as an assembly. Elevate and safely support front of vehicle. Remove (4) wheel nuts and front wheel. CAUTION Use care when supporting vehicle so that it does not tip or fall.

  • Page 139: Rear Brake Pad

    BRAKES Bleed the brake system. See “BRAKE BLEEDING / Remove caliper mounting bolts (A). Lift caliper off disc. FLUID CHANGE” on page 6.6. NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink Install wheel and torque wheel nuts to specification.

  • Page 140: Rear Brake Pad Inspection

    BRAKES Rear Brake Pad Inspection Remove brake pad guide pin (B) loosened in Step 3. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Measure Thickness Slide outer pad toward outside of caliper body until it clears Rear Brake Pad Thickness the threaded stud.

  • Page 141: Rear Brake Pad Assembly / Caliper Installation

    Install caliper and torque mounting bolts to specification. Installation Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Be sure dust boots are fully seated on caliper bracket and on caliper body.

  • Page 142: Brake Burnishing Procedure

    BRAKES Verify fluid level in reservoir is up to the MAX line inside Brake Disc Thickness Variance reservoir and install reservoir cap. Master Cylinder Fluid Service Limit .002” (.051 mm) difference between measurements Up to MAX line inside reservoir Mount a dial indicator and measure disc runout. Slowly Install wheel and torque wheel nuts.

  • Page 143: Rear Caliper Service

    BRAKES REAR CALIPER SERVICE Front routing and clamp shown below. Rear Caliper Removal NOTE: The caliper is not serviceable. The caliper must be replaced as an assembly. Elevate and safely support rear of vehicle. Remove right wheel. CAUTION Use care when supporting vehicle so that it does not tip or fall.

  • Page 144: Rear Brake Caliper Installation

    BRAKES Remove two caliper mounting bolts and caliper assembly. Bleed rear brake system. See “BRAKE BLEEDING / FLUID CHANGE” on page 6.6. Place a container below caliper to catch brake fluid and remove brake line from caliper. Immediately cover and seal Attach parking brake cable to lever arm with one washer end of brake line to prevent contamination.

  • Page 145: Master Cylinder

    After installing the master cylinder, perform the following: Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact • Fill the reservoir with Polaris Dot 4 Brake Fluid (PN with finished surfaces. 2872189) from a new, sealed container.

  • Page 146: Troubleshooting

    BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance Parking Brake Drags or Ineffective Brake • Air in system • Improper adjustment • Water in system (brake fluid contaminated) • Rear brake pads worn • Caliper or disc misaligned or loose •...
  • Page 147 CVT / TRANSMISSION CHAPTER 7 CVT / TRANSMISSION SPECIFICATIONS / TOOLS ..........7.2 TORQUE SPECIFICATIONS .

  • Page 148: Specifications / Tools

    CVT / TRANSMISSION SPECIFICATIONS / TOOLS Torque Specifications TRANSMISSION TORQUE SPECIFICATIONS Fastener Thread Size Ft. Lbs. (Nm) CVT Cover Bolts 6-8 (8-11 Nm) CVT Drain Plug 6-8 (8-11 Nm) Drive Clutch Nut 7/16 - 20 29 (39 Nm) Driven Clutch Nut 7/16 - 20 40 (55 Nm) Output Shaft Cover...

  • Page 149: Cvt System

    During the Driven Clutch Operation development of a Polaris RZR, the CVT system is matched first to the engine power curve; then to average riding conditions and CVT driven clutches primarily sense torque, but also react to the vehicle’s intended usage.

  • Page 150: Cvt System Drying

    CVT / TRANSMISSION CVT System Drying Allow engine RPM to settle to idle speed, shift transmission to lowest available range and test for belt slippage. Repeat NOTE: If operating the RZR in wet conditions, be as needed. sure to check the CVT cover and both air ducts for FRONT CVT Drain Plug proper sealing to reduce the chance of water...

  • Page 151: Clutch (Cvt) Cover Removal / Inspection

    CVT / TRANSMISSION Clutch (CVT) Cover Removal / Inspection Clutch (CVT) Cover Installation Refer to Chapter 5 to remove the seats, rear access panel, Clean gasket surfaces and install a new gasket with cover and battery tray panel to access the CVT cover. alignment dowels (E) in place.

  • Page 152: Drive Belt Removal

    CVT / TRANSMISSION Drive Belt Removal Drive Belt Installation Remove CVT cover. See “Clutch (CVT) Cover Removal / Do not attempt to install drive belt with drive clutch Inspection” on page 7.5 stationary sheave installed. Pull moveable (outer) sheave of driven out and push belt Push moveable sheave and spacer sleeve of drive clutch as far down as possible to create belt slack.

  • Page 153: Drive Clutch Service

    CVT / TRANSMISSION DRIVE CLUTCH SERVICE Hold belt as high as possible on sheaves. Install stationary sheave over shaft splines. Start nut and tighten finger tight while moving belt and sheave to ensure FULL engagement Drive Clutch Removal, Disassembly and of stationary sheave splines with shaft splines.

  • Page 154: Drive Clutch Assembly

    CVT / TRANSMISSION Drive Clutch Assembly Refer to Fig. 1. Inspect cam plate for wear on all roller track surfaces (D). Do not grease clutch components. Clean any belt material from sheaves with isopropyl Install rollers in moveable sheave. alcohol or brake parts cleaner. Install cam plate guides (H, Fig.

  • Page 155: Driven Clutch Service

    CVT / TRANSMISSION DRIVEN CLUTCH SERVICE Measure inside diameter of drive hub. Driven Clutch Removal, Disassembly, Inspection Remove belt. See “Drive Belt Removal” on page 7.6. Use a strap wrench to hold drive hub and remove driven clutch retaining nut. Pull outward on driven clutch and tap shaft with a soft faced hammer to release drive hub from splines.
  • Page 156 CVT / TRANSMISSION Remove (3) rollers and pins (D). Inspect roller tracks (E) 13. Measure thickness of friction shoe material. Replace shoes in moveable sheave. as a set if worn beyond service limit. Refer to Fig. 2. Driven Clutch Friction Shoe Thickness Service Limit: .039”...

  • Page 157: Driven Clutch Assembly

    CVT / TRANSMISSION Driven Clutch Assembly Secure clutch in a clamping device and torque nut. Press new seals (A) into moveable sheave with seal lips facing inward. Press seals flush with edge of seal bore. Fill outer cavity between seals (roller area) with grease and slide moveable sheave onto post of stationary sheave (B).

  • Page 158: Transmission Service

    CVT / TRANSMISSION TRANSMISSION SERVICE Remove angle drive inspection / oil fill cover. Transmission Disassembly and Inspection NOTE: Angle drive removal is not required for transmission cover removal or access to internal IMPORTANT: To ensure proper shifting, verify shift transmission components. Drive pinion gear (D) and cables are in good condition, routed properly, and adjusted properly after transmission is assembled shaft will stay with cover when removed.
  • Page 159 CVT / TRANSMISSION Turn output shaft by hand to check for smooth rotation. 10. Remove retaining ring from drive pinion. Push on splined end and gear end of shaft. There should be no detectable up and down or side to side movement. Check splines and gear teeth for wear or damage.
  • Page 160 CVT / TRANSMISSION 14. Remove detent bolt with ball and spring. 17. Remove shift fork shaft. Pull fork out of shift drum track. 15. Pull shift shaft from case. 18. Remove shift drum. 16. Push and release the spring loaded gear position switch 19.

  • Page 161: Input Shaft Removal / Inspection

    CVT / TRANSMISSION 20. Inspect shift drum track (G), paying close attention to 25. Inspect input pinion gear for tooth damage. Push on shaft corner areas where track changes direction. Inspect shift to check for play in bearing. Rotate the shaft to check for fork guide (H) for wear or damage.

  • Page 162: Transmission Main Shaft Assembly View

    CVT / TRANSMISSION Transmission Main Shaft Assembly View Refer to Fig. 3 for assembly view. Replace all retaining rings if removed. Remove flat washer (A), circlip (B), shaft collar (C), washers (D) (one washer on each side of gear E), sliding dog gear (F), snap ring retainer (G), splined washer (H), gear with needle bearing (I), and thrust washer (J).

  • Page 163: Transmission Assembly

    CVT / TRANSMISSION Transmission Assembly • Install gear position switch plunger (E) with spring in end of shift shaft. Use light grease to hold parts in place To assemble transmission, reverse disassembly procedure, and carefully install shaft in gear case. and read the following assembly notes.
  • Page 164 CVT / TRANSMISSION Assemble output shaft housing to case with existing shims. After installation in the frame, adjust shift cables in the If components were replaced you must inspect output gear following manner: pinion depth. See “Output Gear Pinion Depth Adjustment” •...

  • Page 165: Output Gear Pinion Depth Adjustment

    CVT / TRANSMISSION Output Gear Pinion Depth Adjustment The specified pinion depth is .012 - .016 inch (0.3mm- 0.4mm) from the bottomed position. Therefore, you will NOTE: This procedure sets pinion depth only. There need to install a shim pack with a thickness of .012 - .016 are no provisions for backlash adjustment.

  • Page 166: Output Shaft Housing Disassembly / Assembly

    CVT / TRANSMISSION Output Shaft Housing Disassembly / Assembly If housing is removed from transmission case, temporarily re-install with all 3 screws (A). Remove collar nut (B) using special socket PA-49959. Push shaft out of bearings. Inspect shaft and housing for wear. Clean housing and inspect for wear in the bearing bore areas.
  • Page 167 ELECTRICAL CHAPTER 8 ELECTRICAL GENERAL INFORMATION ..........8.2 SPECIAL TOOLS .

  • Page 168: General Information

    ELECTRICAL GENERAL INFORMATION SWITCHES AND CONTROLS Key Switch Special Tools The key switch can be tested with an ohm meter. PART NUMBER TOOL DESCRIPTION When the key is turned to the “OFF” position, there should no Fluke™77 Digital PV-43568 continuity between any of the wires. Multimeter When the key switch is turned to the “ON”...

  • Page 169: Brake Pedal / Parking Brake Switches

    ELECTRICAL Brake Pedal / Parking Brake Switches Locate the parking brake and brake pedal switches. The brake pedal switch when closed, illuminates the rear brake Disconnect wire harness from each switch and connect an lamp and completes the START command circuit. The brake ohmmeter across the two switch wires.

  • Page 170: Electronic Throttle Control (Etc)

    ELECTRICAL Electronic Throttle Control (ETC) ETC Switch Adjustment Always check the throttle pedal for smooth operation before Slide the boot off the throttle cable adjuster and jam nut. riding. Periodically check the throttle free play. It should be kept between 1/16” and 1/8” (1.5mm – 3.2mm). If adjustment is required, turn the throttle cable adjuster until the free play falls within the acceptable limit.

  • Page 171: Daytime Running Lights

    ELECTRICAL DAYTIME RUNNING LIGHTS “DRL” Lamp Replacement If the daytime running lights do not operate, lamp replacement “DRL” Test may be required. Install only the recommended replacement lamps. The daytime running lights are powered by an AC current from the Generator / Stator. If running lights are not working, perform the following: Disconnect the harness from the faulty light.

  • Page 172: Tail Light

    ELECTRICAL TAIL LIGHT INDICATOR LAMPS Tail Light Lamp Replacement Indicator Lamp Replacement If the tail light lamp does not work, the lamp may need to be The indicator lamps are located on the dash. replaced. Disconnect the indicator light wire connections from the harness.

  • Page 173: Transmission Switch

    ELECTRICAL TRANSMISSION SWITCH Transmission Switch - Circuit Breakout Testing With the switch installed, use an ohmmeter to test continuity between the switch leads and engine ground. First, shift the transmission into “neutral” and test for continuity between the DG/WH wire and ground. Then shift the transmission into “reverse”...

  • Page 174: Removal

    ELECTRICAL Removal IGNITION SYSTEM Remove the CVT cover. The indicator switch will be Overview visible between the drive and driven clutch. Refer to CVT Chapter for CVT cover removal and installation. The ignition system consists of a simple magneto-driven system that includes a stator pulser coil, CDI Box, ignition coil and Remove the (2) screws and pull on switch to release from related wiring / connectors.

  • Page 175: Ignition System Testing

    ELECTRICAL Ignition System Testing Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight. Use the following flow chart as a guide for troubleshooting. NOTE: The brown (BN) wire on youth models carries 12V key-on power. Condition: No spark or intermittent spark.

  • Page 176: Rpm Ignition Limiter Functions

    ELECTRICAL RPM Ignition Limiter Functions NOTE: The CDI box reads the RPM signal from the stator. The CDI box acts as a limiter by retarding the ignition timing if RPM reaches the specified limit. In reverse gear, the CDI box retards ignition timing and limits RPM once it receives a ground path from the transmission switch dark blue (DB) wire indicating the vehicle is in reverse.

  • Page 177: Rpm Limiter Specifications

    ELECTRICAL RPM Limiter Specifications Pulser Coil Output / Resistance Tests Disconnect the 4-wire connector at the CDI box. Install the Peak Ignition Model Max RPM Reading Adaptor (PV-39991) to your meter and connect one Timing meter lead to the dark blue / black wire (DB/YEL) and the other 170cc 8000 to engine ground.

  • Page 178: Charging System

    ELECTRICAL CHARGING SYSTEM Charging System Testing Whenever charging system problems are suspected, proceed with the following system checks: Remove the battery and properly Using a volt meter, set it to read D.C. volts, service. Reinstall the fully charged measure the battery open circuit voltage battery or a fully charged shop battery.

  • Page 179: Main Fuse / Fuse Holder Location

    ELECTRICAL Main Fuse / Fuse Holder Location Stator / Alternator Tests A 15 Amp fuse protects the main electrical system. The fuse is Two tests can be performed using a multimeter to determine the located in the battery compartment. condition of the stator: Take Measurements on 15 Amp Fuse Stator Side of Harness...

  • Page 180: Battery

    ELECTRICAL BATTERY New Battery Activation Battery Maintenance Service Notes WARNING WARNING Battery electrolyte is poisonous. It contains sul- furic acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from External: Flush with water.

  • Page 181: Battery Load Test

    ELECTRICAL Battery Removal Battery Installation Place the fully charged battery in its holder. WARNING Attach the hold-down strap(s). Connect and tighten the red positive (+) cable first. Improperly connecting or disconnecting battery Connect and tighten the black negative (-) cable last. cables can result in an explosion and cause Torque the battery terminal bolts to 3.5 ft.

  • Page 182: Starter System

    Watch charging times carefully, or use a charger with limited charging time/current capabilities. Polaris recommends using the Christie Multi Battery Charger (PV-67030), available from tool provider SPX for charging batteries. Always stop charging if the battery becomes warm to the touch.

  • Page 183: Starter Motor Service

    ELECTRICAL Starter Motor Service Remove the three screws and washers. The starter motor is a complete service part. If it is determined that the starter motor is the failed part, replace as needed. See the parts manual for correct part number. Although the starter motor is not serviceable, it can be disassembled, tested and cleaned.

  • Page 184: Starter Brush Inspection / Replacement

    ELECTRICAL Starter Brush Inspection / Replacement Using a digital multi-tester, measure the resistance between each of the commutator segments. The reading should be Using an Ohm meter, measure the resistance between the .3 ohms or less. cable terminal and the insulated brush. The reading should be .3 ohms or less.

  • Page 185: Starter Reassembly

    ELECTRICAL Starter System Troubleshooting Inspect the permanent magnets in starter housing. Make sure they are not cracked or separated from housing. Starter Motor Does Not Turn CAUTION • Battery discharged - low specific gravity • Loose or faulty battery cables or corroded connections Use care when handling the starter housing.

  • Page 186: Starter System Testing

    ELECTRICAL Starter System Testing Condition: Starter motor fails to turn engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. Locate the starter relay. See “Starter Relay”...
  • Page 187 WIRE DIAGRAM 2009 RANGER RZR 170 WD-1...

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