Polaris RANGER RZR 170 Manuals

Polaris RANGER RZR 170 Manuals

Manuals and User Guides for Polaris RANGER RZR 170. We have 1 Polaris RANGER RZR 170 manual available for free PDF download: Service Manual

Polaris RANGER RZR 170 Service Manual

Polaris RANGER RZR 170 Service Manual (231 pages)

2012-2013

Brand: Polaris | Category: Utility Vehicle | Size: 9 MB

Table of Contents

General Information Chapter 1 1

5
- Table of Contents
  5
- Chapter 1 Model Number Designations
  6
- Model Number Designation
  6
- Vehicle Identification Number
  6
- Vehicle Information
  8
  - Publication Numbers
    8
  - Paint Codes
    8
  - Replacement Keys
    8
- Special Tools
  9
- General Specifications
  10
- Miscellaneous Specifications and Charts
  14
  - Standard Bolt Torque Specification
    14
  - Metric Bolt Torque Specification
    14
  - Conversion Table
    15
  - General Information
    15
  - Sae Tap Drill Sizes
    16
  - Metric Tap Drill Sizes
    16
  - Decimal Equivalents
    16
Maintenance Chapter 2 Maintenance 2

17
- Maintenance
  17
- Chapter 2
  19
- Maintenance Chart Key
  19
- Periodic Maintenance Chart
  19
- Periodic Maintenance Overview
  19
- Brakes
  20
- Pre-Ride - 25 Hour Maintenance Interval
  20
- 30 - 100 Hour Maintenance Interval
  21
- Fuel System
  21
- Maintenance References / Service Locations
  22
  - Front and Rear View
    22
  - Rh and Lh Side Views
    23
- Lubricants / Service Products
  24
  - Polaris Lubricants, Maintenance and Service Products
    24
- Maintenance References
  25
- General Vehicle Inspection and Maintenance
  26
- Fuel System and Air Intake
  28
  - Air Filter Service
    28
  - Choke Cable Adjustment
    29
  - Choke Cable Replacement
    29
  - Idle Speed Adjustment
    30
  - Pilot Air Screw Adjustment
    30
  - Vent Lines
    31
  - Fuel System
    31
  - Fuel Filter
    31
  - Fuel Valve Location
    32
  - Carburetor Draining
    32
  - Fuel Pump / Fuel Lines
    32
  - Throttle Pedal Inspection
    33
  - Throttle Stop Speed Control
    33
  - Throttle Freeplay Adjustment
    34
  - Throttle Cable Replacement
    34
- Engine
  36
- Transmission
  40
  - Transmission Specification Chart
    40
  - Transmission Oil Change
    40
- Final Drive / Wheel and Tire
  41
  - Wheel, Hub, and Spindle Torque Table
    41
  - Wheel Removal
    41
  - Wheel Installation
    41
  - Tire Inspection
    42
  - Tire Pressure
    42
  - Drive Chain Lubrication and Adjustment
    42
- Electrical and Ignition System
  44
  - Battery Maintenance
    44
  - Battery Removal
    44
  - Battery Installation
    44
  - Battery off Season Storage
    45
  - Battery Charging (Maintenance Free)
    45
  - Spark Plug Service
    45
  - Engine to Frame Ground
    46
- Steering
  46
  - Steering Inspection
    46
  - Steering Wheel Freeplay
    46
  - Steering Inspection / Tie Rod Ends and Hubs
    47
  - Toe Alignment Inspection
    47
  - Toe Adjustment
    48
- Suspension
  48
  - Spring Preload Adjustment
    48
- Brake System
  49
- Maintenance Log
  52
Engine

53
- Chapter 3
  55
- Engine Torque Specifications
  55
- Tools
  55
- Torque Specifications
  55
- Torque Patterns
  56
- Engine Information
  57
  - Engine Exploded Views
    57
  - Engine Lubrication
    58
  - Piston Identification
    58
  - Accessible Components
    58
  - Engine Service Data
    59
  - Oil Flow Diagram
    61
- Engine Systems Service
  62
  - Breather / Oil Separator
    62
  - Emissions Secondary Air System
    63
  - Cooling Shroud Removal/Installation
    64
  - Engine Removal
    65
  - Engine Installation Notes
    65
- Top-End Disassembly
  66
  - Engine Removal/Installation
    66
  - Finding Top Dead Center (Tdc)
    66
  - Cam Chain Tensioner Inspection
    66
  - Rocker Assembly
    67
- Disassembly and Inspection3.15
  67
  - Camshaft Removal
    68
  - Camshaft Inspection
    68
  - Cylinder Head Removal
    69
  - Cylinder Head Inspection
    70
  - Cylinder Head Warp Inspection
    70
  - Combustion Chamber Inspection
    70
  - Cylinder Head Disassembly
    70
  - Valve Inspection
    71
  - Valve Seat Reconditioning
    72
  - Cylinder Head Assembly
    74
  - Valve Sealing Test
    75
  - Cylinder Removal
    75
  - Cam Chain Follower / Tensioner Guide Removal
    75
  - Piston Removal
    76
  - Cylinder Inspection
    76
  - Cylinder Hone Selection / Honing Procedure
    77
  - Honing to Deglaze
    77
  - Piston Inspection
    77
  - Piston Ring Installed Gap
    78
- Bottom-End Disassembly
  79
- Crankcase Disassembly
  85
- Engine Reassembly
  87
  - Bearing / Seal Installation
    87
  - Crankcase Reassembly
    87
  - Chain Guide/Tensioner Installation
    88
  - Crankshaft, Balance Shaft and Starter Drive Gear Installation
    89
  - Oil Pump and Chain Installation
    90
  - Piston Ring Installation
    91
  - Piston Installation
    91
  - Cylinder Installation
    92
  - Cylinder Head and Camshaft Installation
    93
  - Camshaft Timing
    93
  - Camshaft Timing Using Flywheel
    96
  - Rocker Arm / Shaft Assembly
    97
  - Rocker Assembly Installation
    97
  - Cam Chain Tensioner Installation
    98
  - Intake Valve Clearance Adjustment
    98
  - Exhaust Valve Clearance Adjustment
    98
  - Starter Drive Assembly
    99
  - Flywheel Installation
    99
  - Stator Installation
    99
  - Stator Housing Installation
    100
  - Exhaust System
    101
- Troubleshooting
  102
  - Spark Plug Fouling
    102
  - General Troubleshooting
    102
Fuel System Chapter 4 Fuel System

105
- Carburetion
  106
- Carburetor Function
  106
- Chapter 4
  106
- Special Tools
  106
- Torque Specifications
  106
- Carburetor Assembly
  107
- Carburetor Service
  108
  - Carburetor Float Bowl Draining
    108
  - Carburetor Removal
    108
  - Fuel Cap
    108
  - Carburetor Disassembly - Keihin
    109
  - Carburetor Cleaning
    110
  - Carburetor Inspection
    110
  - Float Height Adjustment
    111
  - Carburetor Assembly
    112
  - Needle and Seat Leak Test
    112
- Fuel Tank
  113
  - Assembly View
    113
  - Fuel Tank Removal
    114
  - Fuel Valve Service
    115
  - Fuel Filter
    115
  - Fuel Pump Assembly
    115
- Air Filter
  116
  - Assembly View
    116
  - Secondary Air Injection System
    117
  - Crankcase Ventilation System
    118
- Troubleshooting
  119
  - Fuel Starvation / Lean Mixture
    119
  - Rich Mixture
    119
  - Poor Idle
    119
Body / Suspension / Steering Chapter 5 Body / Suspension / Steering

121
- Body / Suspension / Steering
  121
- Chapter 5
  122
- General Information
  122
- Special Tools
  122
- Torque Specifications
  122
- Body Removal
  123
  - Seat Removal
    123
  - Seat Installation
    123
  - Front Bumper Removal / Installation
    124
  - Front Cab Removal / Installation
    124
  - Rocker Panel Removal
    126
  - Rear Bumper Removal / Installation
    126
  - Rear Cab Removal
    126
  - Service Panel (Seat Shield) Removal
    127
  - Console Cover Removal
    127
  - Key Switch / Indicator Light Replacement
    129
  - Decal Replacement
    129
  - Body Exploded View
    130
- Cab Frame
  131
  - Exploded View
    131
  - Cab Frame Assembly
    131
- Main Frame
  132
- Front A-Arms
  133
- Front Hub
  135
  - Hub Removal
    135
  - Hub Seal and Bearing Replacement
    136
  - Hub Installation
    136
- Shocks
  137
  - Shock Exploded View
    137
  - Shock Removal
    137
  - Shock Replacement
    138
  - Shock Installation
    138
- Rear Swing Arm
  139
  - Exploded View
    139
  - Swing Arm Removal
    140
  - Swing Arm Installation
    141
- Rear Axle
  142
  - Axle Housing Removal
    142
  - Axle Housing Service
    143
  - Axle Housing Installation
    143
  - Axle Removal
    144
  - Axle Installation
    144
- Steering
  146
  - Steering Shaft Removal
    147
  - Steering Shaft Installation
    147
  - Steering Gearbox Removal
    148
  - Steering Gearbox Installation
    149
- Tie Rod
  150
  - Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View
    150
  - Tie Rod Removal / Installation
    151
- Wheels
  152
Brakes Chapter 6 Brakes

155
- Brake Noise Troubleshooting
  157
- Brake System Service Notes
  157
- Chapter 6
  157
- Hydraulic Brake System - Overview of Operation
  158
- Brake System - Mechanical Components
  159
- Brake System - Hydraulic Components
  160
- Brake Bleeding / Fluid Change
  161
- Brake Pedal
  163
  - Brake Pedal Removal
    163
  - Pedal Installation
    163
  - Brake Pedal Inspection / Adjustment
    163
- Parking Brake
  164
- Front Brake Pads
  167
  - Front Pad Removal
    167
  - Pad Inspection
    167
  - Front Brake Pad Assembly / Caliper Installation
    168
- Front Brake Disc
  169
  - Disc Inspection
    169
  - Disc Replacement
    170
- Front Caliper
  170
  - Front Caliper Removal
    170
  - Caliper Installation
    171
- Rear Brake Pad
  172
  - Rear Brake Pad Removal
    172
  - Rear Brake Pad Inspection
    173
  - Rear Brake Pad Assembly / Caliper Installation
    174
  - Brake Burnishing Procedure
    175
- Rear Brake Disc
  175
  - Disc Inspection
    175
  - Rear Brake Disc Replacement
    176
- Rear Caliper Service
  177
  - Rear Caliper Removal
    177
  - Rear Brake Caliper Installation
    178
- Master Cylinder
  179
  - Removal
    179
  - Installation
    180
- Troubleshooting
  181
  - Brakes Squeal / Poor Brake Performance
    181
  - Pedal Vibration
    181
  - Caliper Overheats (Brakes Drag)
    181
  - Brakes Lock
    181
  - Parking Brake Drags or Ineffective Brake
    181
Cvt / Transmission Chapter 7 Cvt / Transmission

183
- Chapter 7
  184
- Special Tools
  184
- Specifications / Tools
  184
- Torque Specifications
  184
- Cvt System
  185
  - Cvt Maintenance / Inspection
    185
  - Drive Clutch Operation
    185
  - Driven Clutch Operation
    185
  - Cvt System Drying
    186
  - Cvt Overheating / Water Ingestion Diagnostics
    186
  - Clutch (Cvt) Cover Removal / Inspection
    187
  - Clutch (Cvt) Cover Installation
    187
  - Drive Belt Removal
    188
  - Drive Belt Inspection
    188
  - Drive Belt Installation
    188
- Drive Clutch Service
  190
  - Drive Clutch Removal, Disassembly and Inspection
    190
  - Drive Clutch Assembly
    191
- Driven Clutch Service
  191
- Transmission Service
  195
Electrical Chapter 8 Electrical

205
- Chapter 8
  206
- Electrical System Service Notes
  206
- General Information
  206
- Special Tools
  206
- Switches and Controls
  206
  - Key Switch
    206
  - Brake Pedal / Parking Brake Switches
    207
  - Throttle Release Switch (Trs)
    208
  - Trs Operation
    208
  - Trs Switch Adjustment
    208
- Daytime Running Lights
  209
- Indicator Lamps
  210
- Tail Light
  210
- Transmission Switch
  211
  - Transmission Switch - Circuit Breakout
    211
  - Testing
    211
  - Removal
    212
  - Installation
    212
- Ignition System
  212
  - Overview
    212
  - Ignition System Troubleshooting
    212
  - Ignition System Testing
    213
  - Rpm Ignition Limiter Functions
    214
  - Rpm Limiter Specifications
    215
  - Ignition Coil Test
    215
  - CDI Output Test Using Peak Reading Adaptor
    215
  - Pulser Coil Output / Resistance Tests
    215
- Charging System
  216
  - Charging System Testing
    216
  - Main Fuse / Fuse Holder Location
    217
  - Voltage Regulator / Rectifier
    217
  - Stator / Alternator Tests
    217
- Battery
  218
  - Battery Maintenance Service Notes
    218
  - New Battery Activation
    218
  - Battery Removal
    219
  - Battery Cleaning
    219
  - Battery Installation
    219
  - Battery Voltage Test
    219
  - Battery Load Test
    219
  - Battery Charging Procedure
    220
  - Battery Storage
    220
- Starter System
  221
  - Starter Relay
    221
  - Starter Motor Service
    221
  - Starter Disassembly
    221
  - Starter Brush Inspection / Replacement
    222
  - Armature Test
    223
  - Starter Reassembly
    223
  - Voltage Drop Test
    223
  - Starter System Troubleshooting
    224
  - Starter System Testing
    225

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