Polaris RANGER RZR 170 Service Manual Download Page 159

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6.5

BRAKES

9923983 - 2012-2013 RZR 170 Service Manual

BRAKE SYSTEM - MECHANICAL COMPONENTS

Brake System - Mechanical Components

Parking Brake Switch

Brake Light Switch Spring

Parking Brake Cable

Pedal Return Spring

12 ft-lb
(16 Nm)

Summary of Contents for RANGER RZR 170

Page 1: ...outlined in this Service Manual contact an authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Service Manual Service Literature Question Consumers pl...

Page 2: ...to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark ...

Page 3: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE TRANSMISSION 4 FUEL SYSTEM 5 BODY SUSPENSION STEERING 6 BRAKES 7 CVT 8 ELECTRICAL ...

Page 4: ......

Page 5: ...RIAL NUMBER VIN AND EMISSIONS DECAL LOCATIONS 1 3 VEHICLE INFORMATION 1 4 PUBLICATION NUMBERS 1 4 PAINT CODES 1 4 REPLACEMENT KEYS 1 4 SPECIAL TOOLS 1 5 GENERAL SPECIFICATIONS 1 6 MODEL 2012 RANGER RZR 170 1 6 MODEL 2012 RANGER RZR 170 1 7 MODEL 2013 RANGER RZR 170 1 8 MODEL 2013 RANGER RZR 170 1 9 MISCELLANEOUS SPECIFICATIONS AND CHARTS 1 10 STANDARD BOLT TORQUE SPECIFICATION 1 10 METRIC BOLT TOR...

Page 6: ...EAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION 1st digit 2 3rd digit 4th digit 5th digit 6th digit 7th digit 8th digit 9th digit R RANGER 12 13 V RZR A 2x4 Chain Displacement in cc i e 17 170cc A ORV A digits that would transfer to 17 digit VIN and are used in digits 4 8 respectively 9th digit will be used on color featured versions of models not including the base First 3 digits and 9th digit are u...

Page 7: ...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 A B C ...

Page 8: ...des 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 Model Model No Owner s Manual PN Parts Manual PN 2012 RANGER RZR 170 R12VA17AA R12VA17AC 9923583 9923584 2013 RANGER RZR 170 R13VA17AA R13VA17AB 9923980 9923981 Painted Part C...

Page 9: ...cted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation by phone at 1 800 328 6657 or on line at http polaris spx com Select SPX Website Tools diagnostics from the Service and Warranty drop dow...

Page 10: ...R RZR 170 MODEL NUMBER R12VA17AA R12VA17AC 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 15 2 cm Dry Weight 500 lbs 227 kg Gross Vehicle Weight 840 lbs 381 kg Maximum Weight Capacity 300 lbs 81 7 kg Includes people cargo accessories ...

Page 11: ...adlights 2 Single Beam Daytime Running Lamps DRL Tail Brake 5 Watts 21 Watts Starting System Electric Start Ignition System CDI Ignition Timing Non Adjustable Spark plug Gap NGK CR6HSA 024 028 in 0 6 0 7 mm Battery GTX12 BS Low Maintenance 12 Amp Hr 12 Volt Fuses Main 20 Amp Drivetrain Transmission Type Polaris Automatic CVT Shift Type In Line Shift H N R Transmission Oil Requirements Main Gearcas...

Page 12: ...DEL NUMBER R13VA17AA R13VA17AB 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 15 2 cm Dry Weight 500 lbs 227 kg Gross Vehicle Weight 840 lbs 381 kg Maximum Weight Capacity 300 lbs 81 7 kg Includes people cargo accessories ...

Page 13: ...Ignition Timing Non Adjustable Spark plug Gap NGK CR6HSA 024 028 in 0 6 0 7 mm Battery GTX12 BS Low Maintenance 12 Amp Hr 12 Volt Fuses Main 20 Amp Drivetrain Transmission Type Polaris Automatic CVT Shift Type In Line Shift H N R Transmission Oil Requirements Main Gearcase Polaris AGL 23 7 oz 700 ml Drive Belt 0454497 Drive Chain Type Links 520 30 Steering Suspension Front Suspension Single A arm ...

Page 14: ... 26 29 40 3 8 16 20 27 30 40 45 62 3 8 24 23 32 35 48 50 69 7 16 14 30 40 50 69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Bolt Size GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LB NM DRY THREADS M3 3 5 5 7 1 1 3 1 5 2 1 5 2 M4 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 18 M8 7 9 5 10 13 18 25 26 35 33 45 M10 14 19 1...

Page 15: ... lb x 454 kg kg x 2 2046 lb Cubic inches cu in x 16 387 Cubic centimeters cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 L...

Page 16: ...10 24 24 1 1 4 12 1 11 64 10 32 21 1 1 2 6 1 11 32 12 24 17 1 1 2 12 1 27 64 12 28 4 6mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 Tap Size Drill Size Decimal Equivalent Nearest Fraction 3x 50 39 0 0995 3 32 3x 60 3 32 0 0937 3 32 4x 70 30 0 12...

Page 17: ... CABLE ADJUSTMENT 2 13 CHOKE CABLE REPLACEMENT 2 13 IDLE SPEED ADJUSTMENT 2 14 PILOT AIR SCREW ADJUSTMENT 2 14 VENT LINES 2 15 FUEL SYSTEM 2 15 FUEL FILTER 2 15 FUEL VALVE LOCATION 2 16 CARBURETOR DRAINING 2 16 FUEL PUMP FUEL LINES 2 16 THROTTLE PEDAL INSPECTION 2 17 THROTTLE STOP SPEED CONTROL 2 17 THROTTLE FREEPLAY ADJUSTMENT 2 18 THROTTLE CABLE REPLACEMENT 2 18 ENGINE 2 20 ENGINE OIL LEVEL 2 20...

Page 18: ...ARK PLUG SERVICE 2 29 ENGINE TO FRAME GROUND 2 30 STEERING 2 30 STEERING INSPECTION 2 30 STEERING WHEEL FREEPLAY 2 30 STEERING INSPECTION TIE ROD ENDS AND HUBS 2 31 TOE ALIGNMENT INSPECTION 2 32 TOE ADJUSTMENT 2 32 SUSPENSION 2 33 SPRING PRELOAD ADJUSTMENT 2 33 BRAKE SYSTEM 2 33 BRAKE FLUID INSPECTION 2 33 BRAKE PAD DISC INSPECTION 2 34 BRAKE HOSE AND FITTING INSPECTION 2 34 PARKING BRAKE CABLE FR...

Page 19: ...nd serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level be...

Page 20: ...e Lamp Tail Lamp Daily Throttle Daily Wheels Fasteners Daily Frame Fasteners Daily E Engine Oil Level Daily Fuel Level Daily E Air Filter main element Daily Inspect clean often replace as needed CVT Housing Weekly Open CVT drain as needed check often if operating in wet conditions Brake Pad Wear 10 H 1 M 100 160 Inspect regularly Idle Speed 10 H 1 M 100 160 Check adjust as needed E Choke 10 H 1 M ...

Page 21: ...oke Cable 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary E CarburetorAir Intake Ducts Flange 50 H 6 M 500 800 Inspect for proper sealing air leaks Shift Cables 50 H 6 M 500 800 Inspect lubricate adjust Brake Pad Wear 50 H 6 M 500 800 Inspect replace as needed Drive Belt 50 H 500 800 Inspect replace as needed E Fuel System 100 H 12 M 600 1000 Check for leaks at tank cap lines fuel v...

Page 22: ... 2012 Polaris Sales Inc MAINTENANCE REFERENCES SERVICE LOCATIONS Front and Rear View Grease Steering Pivots Grease A arm Pivots Inspect Brake Pads Inspect Replace Air Filter Inspect Brake Pads Clean Lubricate Chain Inspect Exhaust Daytime Running Lamps Tail Brake Lamp ...

Page 24: ...unt 2872276 ATV Angle Drive Fluid 2 5 Gal 2 Count 2871654 Premium Demand Drive Fluid LT 1 Qt 12 Count 2870465 Oil Pump for 1 Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871329 Dielectric Grease Nyogel 2872348 Chain Lubricant...

Page 25: ...ynthetic PS 4 Extreme Duty Oil Add oil to proper level on dipstick Change after 10 hrs and then every 50 hours 6 months or 100 hours thereafter Change more often in extremely dirty conditions or short trip cold weather operation Brake Fluid Page 2 7 DOT 4 PN 2872189 Fill reservoir between MAX and MIN lines Fill as required Change brake fluid every 2 years Transmission Page 2 7 AGL Plus Synthetic G...

Page 26: ...ins are in place Refer to specific fastener torques listed in each chapter Shift Cable Inspection Adjustment Shift cable adjustment may be necessary if symptoms include Ratcheting noise on deceleration Inability to engage into a gear Excessive gear clash noise Gear selector moving out of desired range 1 Locate the shift cable in the rear wheel well area 2 Inspect shift cable clevis pin pivot bushi...

Page 27: ...r console cover removal in order to access the shift cable mount on the lever assembly 6 Loosen the lower and upper jam nuts and remove the cables 7 Inspect shift lever assembly Replace parts as required if worn or damaged 8 Raise the vehicle and support it with jack stands in order to access the underside to remove the cables IMPORTANT It is important for reassembly to document location of cable ...

Page 28: ...or at high throttle openings for extended periods 1 Move or remove the storage bag Remove the four 4 access cover fasteners and then remove the access cover 2 Release the air box cover spring clips and remove the cover Verify the cover seal is not damaged 3 Loosen the air filter gear clamp and remove the filter Discard the filter 4 Clean the air box and remove any sediments contaminants 5 Apply a ...

Page 29: ...l and apply the parking brake 2 Remove the cable end from the carburetor 3 Remove the retaining screws and pull the choke assembly out at the dash 4 Raise the vehicle and support it with jack stands in order to access the underside IMPORTANT It is important for reassembly to document location of cable ties and routing prior to removal 5 Pull the cable out from under the dash and the underside of t...

Page 30: ...st the pilot air screw setting turn the screw clockwise until engine idle RPM begins to decrease Stop turning at this point and note the screw setting 3 Slowly turn mixture screw counterclockwise until idle speed returns to Idle RPM Continue turning counterclockwise until idle RPM begins to drop Stop turning at this point and note the screw setting 4 Center the mixture screw between points in Step...

Page 31: ...es from filter 4 Install new filter and clamps onto fuel lines 5 Turn fuel valve to ON 6 Start engine and inspect for leaks WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do n...

Page 32: ...en drain screw and allow fuel in the float bowl and fuel line to drain completely 4 Tighten drain screw 5 Turn fuel valve to ON and check for fuel leaks 6 Start engine and re check for leaks Fuel Pump Fuel Lines NOTE Thoroughly clean the exterior of all fuel related components before servicing The RZR170 fuel pump is located in the right rear wheel well 1 Check the fuel lines for signs of wear det...

Page 33: ...speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust if necessary Throttle Stop Speed Control Use the following procedure to control how far the throttle opens IMPORTANT This procedure should be performed by consumers only when they determine that their child is capable of handling the additional speed 1 Loosen the jam nut 2 T...

Page 34: ...n and out 5 Re tighten the jam nut 6 Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position Throttle Cable Replacement 1 Turn engine off then place the vehicle in neutral and apply the parking brake 2 Remove the foot pedal TRS cover screws and ONE left side housing mounting screw NOTE Pivot bearing inside the housing is a slip fit and...

Page 35: ...a general guide 11 Use cable ties to retain the throttle cable using the same locations they were previously removed NOTE Be sure to route the throttle cable inside the retainers 12 Install the new cable onto the carburetor slide assembly and install the slide into the carburetor Hand tighten the slide cap sufficiently 13 Place the throttle cable end into the foot pedal housing 14 Place a new gask...

Page 36: ... operating range because it could cause a mist of oil to enter the air box 6 Reinstall the dipstick Engine Oil Change 1 Position the vehicle on a level surface 2 Clean area around the drain plug 3 Run engine until warm 4 Stop the engine 5 Place a drain pan beneath the engine crankcase 6 Remove the drain plug and pre filter screen and allow the oil to drain completely 7 Wash the oil pre filter scre...

Page 37: ...T Over filling engine crankcase will result in oil entering the air box Maintain the recommended oil level Engine Crankcase Ventilation System Inspection The engine is equipped with a crankcase ventilation Follow the breather hoses from the airbox to the engine and inspect the hoses for possible kinks or wear The hoses are form fitted for a proper fit NOTE Make sure lines are not kinked or pinched...

Page 38: ...epeat adjustment procedure if necessary until clearance is correct with locknut secured Exhaust Valve Clearance Adjustment 1 Remove the valve cover and secondary air pipe assembly 2 Verify cam lobes are pointed down 3 Insert the correct thickness feeler gauge between end of exhaust valve stem and adjuster screw 4 Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge 5...

Page 39: ...t the screen for wear and damage Replace if required 4 Reinstall the arrestor and torque the fasteners to specification 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 Never ru...

Page 40: ...ition vehicle on a level surface 2 Remove the fill plug 3 Add the recommended fluid through the fill plug hole until it is even with the bottom of the check plug hole 4 Reinstall the check fill plug and torque to 30 45 in lbs 3 5 Nm or tighten by hand sufficiently Transmission Oil Change 1 Remove the level check plug refer to Lubricant Level Check 2 Place a drain pan under the main gearcase drain ...

Page 41: ... and stop the engine 3 Loosen the wheel nuts slightly If wheel hub removal is required remove the cotter pin and loosen the hub nut slightly 4 Elevate the appropriate side of the vehicle by placing a suitable jack and stand under the frame 5 Remove the wheel nuts and remove the wheel 6 If hub removal is required remove the hub nut and washers Wheel Installation 1 Verify the transmission is in gear...

Page 42: ...t Lubricate more often under severe use such as in dirty or wet conditions IMPORTANT Washing the drive chain with a high pressure washer or solvents can cause premature wear and chain failure Do not use a high pressure washer or gasoline to clean the drive chain Operating the vehicle with improper rear drive chain deflection can result in severe damage to the transmission and CAUTION If wheels are...

Page 43: ...ouching the ground This establishes the tightest chain position 3 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 4 Loosen the four rear housing mount bolts two on each end of axle 5 Loosen the chain adjuster locknuts 6 Turn the chain adjusters evenly to achieve 1 4 1 2 6 12 mm chain deflection 7 Torque the chain ad...

Page 44: ...damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging procedure before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the battery holder and secure with rubber strap 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable first 5 Connect and tighten ...

Page 45: ...sure the DC voltage at the battery terminals 1 Check the battery voltage with a voltmeter or multimeter The battery voltage should read 12 8 VDC or higher 2 If the voltage is less than 12 8 volts charge the battery at 1 2 amps or less until battery voltage is 12 8 VDC or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for battery charging directions Wh...

Page 46: ...on The steering components should be checked periodically for loose fasteners worn tie rod ends ball joints and damage Also check that all cotter pins are in place If cotter pins are removed do not re use always use new cotter pins Replace any worn or damaged steering components Steering should move freely through the entire range of travel without binding Check routing of all cables hoses and wir...

Page 47: ...and secure the steering wheel in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measurement Call this measurement...

Page 48: ...ont and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload Suspension Spring Adjustment 1 Position the vehicle on a level surface and stop the engine 2 Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend NOTE The tires should not be touching the ground 3 To adjust the shock spring p...

Page 49: ...d MIN level lines 4 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds then check for fluid leaks around the master cylinder and brake caliper fittings Brake Pad Disc Inspection 1 Check the brake pads for wear damage or looseness 2 Inspect the brake pad wear surfa...

Page 50: ...king brake lever is down 2 Inspect the freeplay between the cable end and caliper bracket by pulling back on the cable 3 Freeplay should be 1 16 1 8 1 5 3mm 4 To adjust the cable freeplay loosen the in line adjuster jam nut Turn the adjuster nut outwards to decrease cable freeplay Turn the adjuster inwards to increase cable freeplay 5 After setting the correct amount of freeplay tighten the in lin...

Page 51: ...tment bolt 5 While rotating the rear wheels by hand tighten the adjustment bolt B until significant brake drag is detected 6 Back the adjustment bolt out 1 4 turn 7 Hold adjustment bolt in place and tighten jam nut securely against lever arm 8 Check parking brake lever movement Verify the rear wheels rotate freely with the parking brake off parking brake lever is in the DOWN position and that the ...

Page 53: ...EMBLY DISASSEMBLY AND INSPECTION3 15 CAMSHAFT REMOVAL 3 16 CAMSHAFT INSPECTION 3 16 CYLINDER HEAD REMOVAL 3 17 CYLINDER HEAD INSPECTION 3 18 CYLINDER HEAD WARP INSPECTION 3 18 COMBUSTION CHAMBER INSPECTION 3 18 CYLINDER HEAD DISASSEMBLY 3 18 VALVE INSPECTION 3 19 VALVE SEAT RECONDITIONING 3 20 CYLINDER HEAD ASSEMBLY 3 22 VALVE SEALING TEST 3 23 CYLINDER REMOVAL 3 23 CAM CHAIN FOLLOWER TENSIONER GU...

Page 54: ...AFT BALANCE SHAFT AND STARTER DRIVE GEAR INSTALLATION 3 37 OIL PUMP AND CHAIN INSTALLATION 3 38 PISTON RING INSTALLATION 3 39 PISTON INSTALLATION 3 39 CYLINDER INSTALLATION 3 40 CYLINDER HEAD AND CAMSHAFT INSTALLATION 3 41 CAMSHAFT TIMING 3 41 ROCKER ARM SHAFT ASSEMBLY 3 46 ROCKER ASSEMBLY INSTALLATION 3 46 CAM CHAIN TENSIONER INSTALLATION 3 47 INTAKE VALVE CLEARANCE ADJUSTMENT 3 47 EXHAUST VALVE ...

Page 55: ...de Pivot Bolt 6mm 5 7 7 9 Nm Camshaft Chain Tensioner 6mm 5 7 7 9 Nm Chain Tensioner Cap 6mm 5 7 7 9 Nm Carburetor Intake 6mm 7 8 9 11 Nm Cylinder Head Nuts 10mm 18 25 Nm Cylinder Base Screws 6mm 5 7 7 9 Nm Crankcase inner 6mm 14 15 19 21 Nm Crankshaft Slotted Nut 14mm 43 58 Nm Balancer Shaft Nut 14mm 43 58 Nm Exhaust Nuts 6mm 7 8 9 11 Nm Flywheel Nut 14mm 43 58 Nm Cooling Fan 6mm 4 5 5 7 Nm Oil D...

Page 56: ...Patterns Tighten cylinder head cylinder base and crankcase fasteners in 3 steps following the sequence outlined Refer to the table for torque specifications 2 4 5 6 1 6 mm Cylinder Base Head and Rocker Assembly 3 2 RH Crankcase Inside Stator Cover 1 1 2 3 4 5 6 7 8 9 RH Crankcase Stator Cover ...

Page 57: ...3 5 ENGINE 3 9923983 2012 2013 RZR 170 Service Manual Copyright 2012 Polaris Sales Inc ENGINE INFORMATION Engine Exploded Views Crankshaft Cylinder and Piston Cylinder Head Crankcase Valve Train ...

Page 58: ...p The letters IN must always be toward the intake side of the engine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile Any numbers or letters on the rings except oil control rings must be positioned upward See text for oil control ring upper rail installation Accessible Components The following components can be serviced...

Page 59: ...574 29 40 mm Ex Std 1 1637 29 56 mm Limit 1 1480 29 16 mm Cylinder Head Surface warpage limit 002 05 mm Valve Clearance In Std 003 07 mm Ex Std 003 07 mm Valve Seat Angle Contacting width In Std 039 1 0 mm Limit 063 1 6 mm Ex Std 039 1 0 mm Limit 063 1 6 mm Valve Stem diameter In 1958 1960 4 975 4 980 mm Ex 1950 1956 4 955 4 970 mm Limit 1921 4 9 mm Valve Guide Inner Diameter In 1968 1973 5 0 5 01...

Page 60: ...iameter clearance in piston 00015 00047 004 012 mm Degree of fit Piston Pin must be a push by hand fit at 68 F 20 C Piston Ring Piston Ring Installed gap Top ring Std 0059 013 15 35 mm Limit 0196 0 5 mm Second ring Std 0059 013 15 35 mm Limit 0196 0 5mm Oil ring Std 0079 0314 0 2 0 8 mm Limit 059 1 5 mm Piston Ring Standard clearance piston ring to ring groove Top ring Std 00078 0023 0 02 06 mm Li...

Page 62: ... 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 NOTE Over filling of crankcase will result in oil in the air box Always keep oil volume at recommended level To Valve Cover To Crank Case A 7 8 ft lbs 9 11 Nm 7 8 ft lbs 9 11 Nm To Air Box To One Way ...

Page 63: ... 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 Check the air control valve A one way valve B filter housing C and related components according to the maintenance schedule in Chapter 2 for proper operation and emissions compliance A B C Air To Cylinder Hea...

Page 64: ...e the upper and lower housings at the snap hooks and lift housings away from the engine INSTALLATION 8 Install the upper and lower housings C making sure the snap hooks are secure Install the housing screws and attaching bolt into the engine case Hand tighten sufficiently using care not to over tighten 9 Install the fan shroud A and attaching screws to housing C Install the fan shroud bolts to the...

Page 65: ...s 17 Using the aid of an assistant lift and remove engine out the rear of the vehicle Engine Installation Notes After the engine is installed in the frame review this checklist and perform all steps that apply General Items Install previously removed components using new gaskets seals and fasteners where applicable Perform checks on fluid levels controls and all important areas on the vehicle as o...

Page 66: ...e slowly while watching the camshaft sprocket marks and timing mark in the inspection hole 6 The engine is at Top Dead Center when the single TDC mark on flywheel is visible within the inspection hole and the cam sprocket hole is facing upward NOTE The sprocket marks should align with the gasket surface the cam lobes must be pointed downward and the rockers must have valve clearance at this point ...

Page 67: ... until loose 3 Remove the nuts and tap the rocker assembly with a plastic hammer to loosen then remove Mark or tag rocker arms to keep them in order for assembly 4 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobes if rocker arms are worn or damaged 5 Remove each rocker arm shaft using a hex bolt NOTE Place t...

Page 68: ...move the assembly 3 Remove the cam chain from the sprocket by tilting the cam assembly and simultaneously lifting the chain 4 If not removing the cylinder for other service secure the cam chain with a wire to prevent it from falling into the crankcase Camshaft Inspection 1 Inspect cam sprocket teeth for wear or damage Replace if necessary 2 Inspect the compression release mechanism This is a one w...

Page 69: ...r and tensioner are removed 2 Remove the two 6mm cylinder head base screws 3 Loosen each of the four cylinder head nuts evenly 1 4 turn each time in a cross pattern until loose 4 Remove the nuts and tap the rocker assembly with a plastic hammer until loose Remove 5 After removing the camshaft and securing the cam chain tap the cylinder head lightly with a plastic hammer until loose CAUTION Tap onl...

Page 70: ... from foreign debris Cylinder Head Disassembly NOTE Keep all parts in order with respect to their location in the cylinder head NOTE Valves have inner and outer springs 1 Using a valve spring compressor compress the valve springs and remove the split keeper NOTE To prevent loss of tension do not compress the valve spring more than necessary 2 Remove spring retainer and spring NOTE The valve spring...

Page 71: ...bon from valve with a soft wire wheel 2 Check valve face for runout pitting and burned spots To check for bent valve stems mount valve in a drill or use V blocks and use a dial indicator 3 Check end of valve stem for flaring pitting wear or damage A 4 Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves cannot be re faced or end ground Valves must be replaced i...

Page 72: ...ructions provided with the valve cutting kit commercially available Abrasive stone seat reconditioning equipment can also be used Keep valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper width all th...

Page 73: ...the entire valve face A 6 Insert valve into guide and tap valve lightly into place a few times 7 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 If the indicated seat contact is at the top edge of the valve face and contacts the margin ...

Page 74: ...section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for the other valve 12 Clean rocker assembly cylinder head valves and camshaft oil supply passages thoroughly 13 Sp...

Page 75: ...k for leakage around each valve The valve seats should hold fluid with no leaking Cylinder Removal Follow engine disassembly procedures to remove the valve cover rocker assembly camshaft and cylinder head 1 Remove cam chain guide at front of cylinder 2 Tap cylinder lightly with a soft faced hammer in reinforced areas only until loose NOTE Orientation of the dowels arrows is important for oil flow ...

Page 76: ...sh up on the opposite side Use care to not scratch the ring lands 4 Repeat procedure for second ring 5 The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section Remove the top rail first followed by the bottom rail and expander Cylinder Inspection 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cyli...

Page 77: ...t allow cylinder to heat up during honing After honing has been completed inspect cylinder for thinning or peeling IMPORTANT Clean the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry ...

Page 78: ...Installed Gap 1 Place each piston ring inside cylinder using piston to push ring squarely into place as shown 2 Measure the gap with a feeler gauge at both the top and bottom of the cylinder NOTE Measure at two points in the cylinder A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round Piston Pin Bore Piston Pin Measurement Locations...

Page 79: ...fter re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with an oil rag immediately to remove residue and prevent rust BOTTOM END DISASSEMBLY Starter Drive Gear Removal and Inspection 1 Remove the fan from the hub 2 Remove the fan hub by removing the flywheel nut washer and p...

Page 80: ...starter drive if gear teeth are cracked worn or broken 8 Inspect the stator housing bearing Replace if worn rough or damaged Flywheel Removal Inspection 1 Before removing the flywheel remove the shaft collar A from the crankshaft NOTE Shaft collar installation is important for proper loading of the flywheel upon reassembly 2 Install Flywheel Adapter PA 49936 and Puller PA 45153 and remove the flyw...

Page 81: ...fle plate 2 Using the Slotted Nut Socket PA 49935 remove the crankshaft slotted nut C and washer B from the starter drive one way gear assembly A NOTE Slotted nut is left hand thread 3 Remove the starter drive one way gear assembly A from the crankshaft 4 Remove drive sprocket D and woodruff key from the crankshaft Flywheel Special Tools Flywheel Adapter PA 49936 Flywheel Puller PA 45153 Slotted N...

Page 82: ...ly if it is not working properly Assembly should turn in one direction only NOTE One way clutch components are not serviceable Replace the component as an assembly 3 Do not add specialized lubricants or greases to the bearing or one way components as this may cause undesirable operation Balance Shaft Sprocket Removal and Inspection 1 The cooling shroud stator housing and flywheel and starter drive...

Page 83: ...oodruff key for wear 8 Replace any worn or damaged parts Oil Pump Removal Drive Chain Inspection NOTE Oil pump is a replace only assembly 1 Remove the oil pump galley cover pump gear nut and balancer shaft nut prior to chain and sprocket removal 2 Inspect the sprockets and chain for wear or damage Inspect chain for wear or damage Replace chain anytime the oil pump is replaced or if excessively wor...

Page 84: ...3 RZR 170 Service Manual Copyright 2012 Polaris Sales Inc 5 Install a new pump with the oil galley pointed down as shown 6 Torque screws to specification T Oil Pump Screw 4 5 ft lbs 5 7 Nm Install with the oil galley pointing down ...

Page 85: ...lts circled from the magneto side crankcase 2 Separate crankcase using a press or by pressing on the pto end of the crankshaft using special tool PA 46087 NOTE Tapping the pto end of the crankshaft with a soft face hammer may also separate the cases Use care not to damage the crankshaft end or cases 3 Watch the gap along the crankcase mating surface and separate the crankcase evenly 4 Once the cra...

Page 86: ...pect chain for wear or damage Replace if worn excessively or as part of any crankshaft repair Crankcase Bearing Inspection NOTE Removal and installation of new seals is recommended anytime the crankcase is disassembled 1 Inspect the bearings in the crankcase NOTE Due to extremely close tolerances and minimal side wear the bearing must be inspected visually and by feel Look for signs of discolorati...

Page 87: ...he crankshaft using a hydraulic tool Press on the pto end of the crankshaft Use care not to damage the crankshaft end NOTE Tapping the end of the crankshaft with a soft face hammer may also install the crankshaft Use care not to damage the crankshaft end 2 Install the balance shaft into the mag side of the crankcase 3 Install a new gasket onto the pto case half Applying a thin amount of crankcase ...

Page 88: ...care not to damage the crankshaft end 6 Loop the cam chain through the chain room and secure with mechanic s wire 7 Install the two mag side flange bolts and torque to specification Chain Guide Tensioner Installation 1 Install the chain guide and tighten the mounting bolt to specified torque T Crankcase Bolt Torque 14 15 ft lbs 19 21 Nm Crankcase Sealant PN 2871557 T Chain Guide Bolt 5 6 5 ft lbs ...

Page 89: ...il pump drive sprocket washer and slotted nut onto the balance shaft 4 Using Slotted Nut Socket PA 47344 tighten the nut to the specified torque 5 Install the Starter Drive one way gear assembly washer and slotted nut 6 Using Slotted Nut Socket PA 49935 tighten the crank shaft nut to the specified torque NOTE Slotted nut is left hand threaded T Balance Shaft Slotted Nut 43 ft lbs 59 Nm Special Too...

Page 90: ...s shown Install and torque screws to specification 3 Install the chain A over the sprocket on the balance shaft gear B 4 Loop the chain around the oil pump drive sprocket C and install the sprocket onto the oil pump shaft NOTE The oil pump sprocket and shaft have a D configuration for alignment 5 Install the pump gear washer and nut Torque to specification 6 Install the oil baffle plate Item D See...

Page 91: ... ring with the chamfered edge facing up if applicable 6 Check to make sure the rings rotate freely in the groove when compressed by hand Verify that the ring gaps are 120 degrees apart from each other before installation Piston Installation 1 Install a new circlip on one side of the piston with the end gap facing up or down 2 Apply clean engine oil all components before assembly Generously lubrica...

Page 92: ... during cylinder installation NOTE Route cam chain through the cylinder chain room and secure it holding it up while rotating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade 2 Apply clean engine oil liberally to the bore and tapered area of the cylinder Place the cylinder on to the studs 3 Loop the cam chain through the cylinder chain room and secure with mechanic s...

Page 93: ...d and the crankshaft keyway is in view The camshaft sprocket alignment marks are parallel to the gasket surface and camshaft lobes are pointing down Cam chain plate links are not used to time the camshaft When the stator housing is installed use Method 2 This method establishes Top Dead Center TDC by aligning the single mark on the flywheel in the timing inspection hole see Method 2 illustration T...

Page 94: ...arallel to the gasket surface 6 Verify all cam timing marks to verify proper cam timing and install the rocker arm assembly see Method 1 illustration Torque the cylinder stud nuts to specification NOTE Do not rotate engine until rocker assembly and tensioner are installed 7 Install the tensioner Torque fasteners to specification 8 After tensioner installation rotate engine at least two revolutions...

Page 95: ...13 RZR 170 Service Manual Copyright 2012 Polaris Sales Inc Crankshaft Keyway UP Method 1 Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward ...

Page 96: ...bly lubricant to the camshaft main journals and cam lobes Lubricate automatic compression release mechanism with clean engine oil 4 Orientate the camshaft for installation with the lobes facing downward 5 Disconnect the wire securing the cam chain and loop the cam chain over the sprocket while verifying the cam is inserted with the alignment marks parallel to the gasket surface 6 Check all cam tim...

Page 97: ...hafts and cam follower surfaces Rocker Assembly Installation 1 Apply engine lube to all components and assembly arms shafts and decompression components of the rocker assembly 2 Verify the cam is still in the TDC position before installing the rocker assembly onto the cylinder studs 3 Install cylinder head nuts and torque to specification 4 Torque the cylinder base screws to specification 5 Adjust...

Page 98: ...hickness feeler gauge between end of intake valve stem and adjuster screw 4 When clearance is correct hold adjuster screw and tighten locknut securely 5 Re check the valve clearance 6 Repeat adjustment procedure if necessary until clearance is correct with locknut secured Exhaust Valve Clearance Adjustment 1 Remove the valve cover and secondary air pipe assembly 2 Verify cam lobes are pointed down...

Page 99: ...dy installed IMPORTANT Flywheel spacer installation is critical for proper clamp load when applying torque to the flywheel nut Verify spacer is installed before assembly of the stator housing to the crankcase Stator Installation NOTE The stator flywheel and starter drive components can be serviced with the engine in the frame 1 Install the stator and pulse coil Route the wires appropriately to avo...

Page 100: ...nstall the dowel pins if removed 2 Install the housing Torque bolts in sequence to specification 3 Install the fan hub washer and flywheel nut Torque the flywheel nut to specification 4 Install the fan and fan bolts Tighten bolts evenly to specification 5 Install the cooling shroud and tighten the fasteners sufficiently Use care not to over tighten T Stator Housing Bolt 7 8 ft lbs 9 11 Nm 3 4 5 6 ...

Page 101: ...eaned 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 7 8 ft lbs 9 11 Nm 7 8 ft lbs 9 11 Nm 7 8 ft lbs 9 11 Nm Gasket Silencer Spark Arrestor ...

Page 102: ...take system Restricted engine breather system Oil contaminated with fuel Restricted crankcase vent General Troubleshooting Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperative restricted Tank vent plugged Carb starter circuit Engine flooded Low compression high cylinder leakage No spark Spark plug fouled Engine Does No...

Page 103: ...r filter dirty or contaminated Low Compression Decompressor stuck Cylinder head gasket leak No valve clearance or incorrectly adjusted Cylinder or piston worn Piston rings worn leaking broken or sticking Bent valve or stuck valve Valve spring broken or weak Valve not seating properly bent or carbon accumulated on valve area Rocker arm sticking Backfiring TRS or speed limiter system malfunction Fou...

Page 105: ... REMOVAL 4 4 CARBURETOR DISASSEMBLY KEIHIN 4 5 CARBURETOR CLEANING 4 6 CARBURETOR INSPECTION 4 6 FLOAT HEIGHT ADJUSTMENT 4 7 CARBURETOR ASSEMBLY 4 8 NEEDLE AND SEAT LEAK TEST 4 8 FUEL TANK 4 9 ASSEMBLY VIEW 4 9 FUEL TANK REMOVAL 4 10 FUEL VALVE SERVICE 4 11 FUEL FILTER 4 11 FUEL PUMP ASSEMBLY 4 11 AIR FILTER 4 12 ASSEMBLY VIEW 4 12 SECONDARY AIR INJECTION SYSTEM 4 13 CRANKCASE VENTILATION SYSTEM 4...

Page 106: ...r clothing immediately wash with soap and water and change clothing Carburetor Component Function System Main Components Main Function Main Effect Float System Level Control Inlet Pipe Needle and Seat Float and Float Pin Maintains specified fuel level in float chamber carburetorfloat bowl Allsystems all throttle ranges Venting Passages in carburetor and vent lines Supplies atmospheric pressure to ...

Page 107: ...mbly CAP AND GASKET SPRING JET NEEDLE RETAINER JET NEEDLE E CLIP SLIDE THROTTLE VALVE NEEDLE JET NEEDLE VALVE PILOT JET FLOAT VALVE ASSEMBLY FLOAT BOWL BOWL DRAIN MAIN JET PILOT AIR SCREW THROTTLE STOP SCREW O RINGS COVER CHOKE LEVER SPRING CHOKE CABLE SUPPORT FUEL INLET FLOAT BOWL VENT NIPPLE ENGINE AIRBOX ...

Page 108: ...for water or sediment 5 Tighten drain screw 6 Turn fuel valve to ON 7 Inspect carburetor for fuel leaks 8 Start machine and re check for leaks Carburetor Removal 1 Turn the fuel valve OFF and drain the fuel from the carb through the drain screw 2 Loosen or remove screw A retaining the choke cable from the choke cable bracket and disconnect the cable end from the choke arm 3 Remove the carburetor m...

Page 109: ...nd float bowl 2 Remove the float pin B float C and inlet needle D 3 Remove the pilot jet E 4 Remove the main jet F emulsion tube G and needle jet H from the carburetor body NOTE Typically the needle jet H can be left in the carburetor body and only requires removal if damaged 5 Note the position of both the pilot mixture screw J and idle speed adjustment screw K and remove both from the carb body ...

Page 110: ... area that looks different than the rest of the needle The middle to upper portion of the needle contacts the needle jet and is the most likely wear point If slide needle shows signs of wear replace both the needle and needle jet to prevent a rich condition 2 Inspect the inlet needle tapered surface for any sign of wear or damage Be sure the spring loaded pin is free moving and returns freely when...

Page 111: ...slightly outward 2 With the carburetor at rest and level slightly tilt the carburetor back The float should fall into the correct position with the float tongue resting lightly on the inlet needle valve pin without compressing the spring The bottom of the float should be parallel with the float bowl mating surface IMPORTANT When measuring the height verify the inlet needle valve spring is not comp...

Page 112: ...crews by hand sufficiently using care not to over tighten NOTE The final pilot idle mixture must be adjusted with the engine running Refer to Chapter 2 for procedure Needle and Seat Leak Test 1 Install the float bowl 2 Invert the carburetor and install a Mity Vac PN 2870975 to the fuel inlet fitting 3 Apply 5 PSI pressure to inlet fitting The needle and seat should hold pressure indefinitely If no...

Page 113: ...s Inc FUEL TANK Assembly View NOTE The fuel tank and pickup are supplied as an assembly The pickup cannot be replaced separately and should not be removed from the tank T Fuel Tank Strap Fastener Torque 17 ft lbs 23 Nm FUEL TANK STRAPS VENTED FUEL CAP FUEL TANK w PICKUP ROCK GUARD PICKUP ...

Page 114: ...t the majority of the fuel drained from the tank 2 Remove the main M and reserve R fuel pickup hoses from the pickup assembly Mark the hoses to aid assembly 3 Remove the two tank straps by removing the four fasteners securing them to the frame Front Strap Fasteners 4 Rear Strap Fasteners 5 To reinstall the tank reverse the removal procedure Be sure to torque the tank mounting strap bolts 6 Finish ...

Page 115: ...install fuel valve Fuel Filter The fuel filter is located in line on the carburetor fuel feed hose The filter should be inspected and replaced as outlined in the periodic maintenance table in Chapter 2 When installing a new filter verify the arrow points in the direction of the carburetor Fuel Pump Assembly The fuel pump assembly is secured to the frame behind the seat shield panel on the RH side ...

Page 116: ...R 170 Service Manual Copyright 2012 Polaris Sales Inc AIR FILTER Assembly View COVER COVER GASKET AIR FILTER SEDIMENT TRAP AIR BOX INTAKE TUBE OIL SEPARATOR HOSE NIPPLE AIR FILTER SPACER MID INTAKE TUBE MESH SCREEN INLET COVER INLET MOUNT ...

Page 117: ...tion system adds additional air to the exhaust system while the engine is running The air injection filter housing houses a filter element and screen and should be cleaned as part of periodic maintenance as outlined in Chapter 2 AIR INJECTION FILTER SCREEN DUAL INTAKE VALVE HOSE TO CYLINDER HEAD IMPULSE HOSE TO INTAKE MANIFOLD NIPPLE SCREEN FILTER ...

Page 118: ...e crankcase ventilation system is sensitive to excessive engine oil volume Never over fill the oil level in the engine Doing so may cause oil to accumulate inside the airbox OIL SEPARATOR DUAL INTAKE VALVE HOSE TO AIR FILTER BOX HOSE INTAKE VALVE TO CRANKCASE HOSE INTAKE VALVE TO OIL SEPARATOR HOSE VALVE COVER TO OIL SEPARATOR ...

Page 119: ...ing incorrectly adjusted choke Choke cable binding or improperly routed Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets Worn jet needle needle jet or other carburetor parts Dirty carburetor air bleed passages or jets Weak or damaged choke plate return spring Fouled spark plug Poor Idle...

Page 121: ...11 CAB FRAME ASSEMBLY 5 11 MAIN FRAME 5 12 FRONT A ARMS 5 13 FRONT HUB 5 15 HUB REMOVAL 5 15 HUB SEAL AND BEARING REPLACEMENT 5 16 HUB INSTALLATION 5 16 SHOCKS 5 17 SHOCK EXPLODED VIEW 5 17 SHOCK REMOVAL 5 17 SHOCK REPLACEMENT 5 18 SHOCK INSTALLATION 5 18 REAR SWING ARM 5 19 EXPLODED VIEW 5 19 SWING ARM REMOVAL 5 20 SWING ARM INSTALLATION 5 21 REAR AXLE 5 22 AXLE HOUSING REMOVAL 5 22 AXLE HOUSING ...

Page 122: ...t Pinch Bolts 29 37 ft lbs 39 50 Nm Tie Rod Plate Pinch Bolt 17 ft lbs 23 Nm Steering Gearbox Mounting Bolts 21 ft lbs 28 Nm Steering Wheel Fasteners 11 ft lbs 15 Nm Tie Rod End Castle Nuts 25 ft lbs 34 Nm Tie Rod End Jam Nuts 12 14 ft lbs 17 19 Nm Suspension Fasteners A Arm to Frame Fasteners 30 ft lbs 41 Nm A Arm to Spindle Castle Nuts 30 ft lbs 41 Nm Front Shock Mounting Bolts 36 ft lbs 49 Nm R...

Page 123: ...of the seat up and slide it forward to remove it from the vehicle Seat Installation 1 Lift up the seat latch lever located under the right front edge of the driver s seat 2 While holding the lever upward line up the seat guides with the seat mounting rails and slide the seat rearward to install it Adjust the seat to the appropriate distance and be sure the seat is latched 3 To install the passenge...

Page 124: ...time running lights as shown and remove the bumper from the vehicle 4 Reverse this procedure to reinstall the front bumper Tighten all fasteners securely Front Cab Removal Installation 1 Remove the 6 push rivets retaining the rear portion of the front cab to the frame 2 Remove the 2 push rivets from each side retaining the front cab to the front bumper 3 Remove the 3 fasteners from each side retai...

Page 125: ...pacers during removal 6 Carefully remove the front cab frame from the vehicle 7 Remove the 2 screws retaining the choke bracket 8 Disconnect the indicator lights and key switch harness connections under the dash as shown 9 Remove the front cab from the vehicle 10 Reverse this procedure to reinstall the front cab Tighten all fasteners securely 11 Torque the cab frame bolts and fasteners to specific...

Page 126: ...et from each side of the rear bumper 2 Remove the 6 screws retaining the rear bumper to the frame 3 Reverse this procedure to reinstall the rear bumper Tighten all fasteners securely Rear Cab Removal 1 Remove the driver and passenger seats from the vehicle see Seat Removal 2 Remove the 4 fasteners retaining the front of the rear cab to the frame 3 Remove the 2 fasteners retaining the top portion o...

Page 127: ...ining the service panel 3 Disengage the service panel from the sides of the rear cab and remove the panel from the vehicle Console Cover Removal 1 Remove the seats see Seat Removal 2 Remove the service panel see Service Panel Removal 3 Remove the 2 bolts retaining the seat support to the frame 4 Disconnect the battery leads and unhook the fuse holder from the console cover Service Panel Seat Suppo...

Page 128: ...the 2 nuts retaining the front portion of the drivers seat adjustment rail 7 Remove the shift knob cap Remove the fastener and shift knob from the shift lever 8 Lift the console cover out from the vehicle as an assembly IMPORTANT Route the battery cables through the console cover prior to removal to prevent from damaging the cables or fuse holder Console Cover Remove Shift Knob ...

Page 129: ...es left after a plastic component is bent flexed or damaged To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold the torch too close to the surface 2 3 inches from the flame tip is recommended Keep the ...

Page 131: ...nstall the Allen bolts using a 6 mm Allen wrench 3 Install the front cab frame mounting hardware with the bolt and cam to the outside of the frame and the nut and washer to the inside 4 Install the side bars LH or RH frame to the mounting brackets at the rear frame and hip bars Install the side nets according to the procedure listed in the Owner s Manual 5 Attach the basket frame to the rear frame...

Page 134: ...ock mounting bolt 5 Remove the cotter pin castle nut and washer from the bolt attaching the A arm to the spindle 6 Carefully remove the spindle assembly from the A arm 7 Remove the front and rear A arm mounting fasteners refer to the Exploded View and remove the A arm from the vehicle 8 To reinstall reverse steps 1 7 Torque fasteners to specification CAUTION Severe injury could occur if machine ti...

Page 135: ...eel nuts and remove the black rubber dust boot 3 Remove the cotter pin castle nut and washers 4 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 to hang caliper to prevent damage to the brake line 5 Remove the hub assembly from the spindle CAUTION Severe injury could occur if machine ...

Page 136: ...w bearings along with the spacer tube back into the hub 5 Install new seals on each end of the hub Press the seals into the hub until the top of the seal is just past the chamfer 6 Reinstall the brake disc with new mounting bolts Torque the bolts to specification 7 Reinstall outer spacer into the outer hub seal Hub Installation 1 Grease the spindle and reinstall the front hub assembly 2 Install th...

Page 137: ... wheel nuts to specification SHOCKS Shock Exploded View Shock Removal 1 Elevate the front or rear end of the vehicle off the ground to remove shock spring tension 2 Remove the shock mounting bolts and remove the shock from the vehicle 3 Replace the shock compression spring or adjustment collar as required see Shock Replacement T Front Hub Nut 40 ft lbs 55 Nm T Wheel Nuts 27 ft lbs 37 Nm Replace Wa...

Page 138: ... shock and install the components onto the new shock 3 Compress the shock spring and install the spring retainer Shock Installation 1 Install the shock assembly and torque the mounting bolts to specification 2 If the adjustment collar was moved or replaced adjust the spring preload evenly between both front or rear shocks refer to Chapter 2 Maintenance T Front Shock Mounting Bolt 36 ft lbs 49 Nm T...

Page 139: ...SWING ARM Exploded View 84 in lbs 10 Nm 84 in lbs 10 Nm 72 ft lbs 98 Nm 72 ft lbs 98 Nm 72 ft lbs 98 Nm 72 ft lbs 98 Nm 16 ft lbs 22 Nm 16 ft lbs 22 Nm 16 ft lbs 22 Nm 16 ft lbs 22 Nm Replace if Removed 22 ft lbs 30 Nm 36 ft lbs 49 Nm 36 ft lbs 49 Nm 72 ft lbs 98 Nm 7 ft lbs 10 Nm 72 ft lbs 98 Nm 7 ft lbs 10 Nm ...

Page 140: ...iper from the disc CAUTION Do not hang the caliper by the brake line Use a strap or mechanics wire to hang caliper to prevent damage to the brake line 4 Loosen all 4 axle housing bolts 5 Loosen the outer jam nut and back off the inner adjustment nut on each chain adjuster to remove tension 6 Using mechanics wire or a long Panduit strap tie the chain tensioner back out of the way 7 Remove the upper...

Page 141: ...the swing arm bolts to specification 3 Install a new tie strap to retain the brake lines 4 Line up the upper shock eyelets with the frame mounting holes and install the mounting bolts Torque the rear shock mounting bolts to specification 5 Install the rear brake caliper and torque the mounting bolts to specification 6 Remove the wire or strap retaining the chain tensioner allowing it to return to ...

Page 142: ... chain adjuster to remove tension 6 Remove the 2 fasteners retaining the LH axle housing to the swing arm 7 Remove the LH axle housing from the axle see Axle Housing Service if replacing the bearing or seal 8 Remove the 2 bolts retaining the rear 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 to hang caliper to pre...

Page 143: ...tallation 1 Install each axle housing and fasteners Do not torque the fasteners at this time NOTE Remember to install the chain adjusters onto the lower axle housing fasteners and install the spacer behind the LH axle housing 2 Install the axle retaining nuts onto the RH side of the axle Torque the inner retaining nut to specification then torque the outer jam nut to specification 3 Install the re...

Page 144: ...e housing fasteners see Axle Housing Removal NOTE There is no need to remove the large axle nuts retaining the RH axle housing if removing the rear axle assembly from the swing arm 2 Remove the axle clamp bolts from each side and remove the clamp brackets to allow for axle removal 3 Remove the rear fastener and front lower fastener retaining the chain guard 4 Pull the chain tensioner back to allow...

Page 145: ... 5 9923983 2012 2013 RZR 170 Service Manual Copyright 2012 Polaris Sales Inc 2 Torque the axle clamp bolts to specification 3 Install the rear axle housing fasteners see Axle Housing Installation T Axle Clamp Bolts 36 ft lbs 49 Nm ...

Page 146: ...Service Manual Copyright 2012 Polaris Sales Inc STEERING Steering Wheel Steering Shaft Steering Gearbox Assembly Exploded View 16 17 ft lbs 22 23 Nm 17 ft lbs 23 Nm 21 ft lbs 28 Nm 11 ft lbs 15 Nm 10 ft lbs 13 5 Nm 29 37 ft lbs 39 50 Nm 16 17 ft lbs 22 23 Nm ...

Page 147: ...ing Shaft Installation 1 Reinstall the steering shaft 2 Install the shaft to the steering gearbox assembly and install the pinch bolt Torque the pinch bolt to specification 3 Ensure the wheels are pointing straight ahead Install the pivot tube stub shaft into the upper portion of the steering shaft with the steering wheel properly aligned 4 Install the pivot tube bolts and steering wheel adjustmen...

Page 148: ...the front bumper to ease gearbox removal see Front Bumper Removal Installation 3 Remove the pinch bolt from the tie rod plate 4 Carefully pry up on the tie rod plate and remove it from the steering gearbox 5 Loosen the brake line retainer and remove the brake line from the gearbox assembly 6 Remove the 3 bolts retaining the steering gearbox to the frame and remove the gearbox from the vehicle ...

Page 149: ...e retainer and securely tighten the retaining bolt 3 Align the boss splines on the gearbox stub shaft and the tie rod plate 4 Install the tie rod plate Torque pinch bolt to specification 5 Install the front bumper if previously removed see Front Bumper Removal Installation 6 Install the steering shaft see Steering Shaft Installation T Steering Gearbox Mounting Bolts 21 ft lbs 28 Nm T Tie Rod Plate...

Page 151: ...nd castle nuts and remove the tie rod from the vehicle 4 If replacing the tie rod ends loosen the jam nut s and replace the end s 5 Install the tie rod and torque the castle nuts to specification Install a new cotter pin in each castle nut NOTE Refer to Chapter 2 Maintenance for the steering toe alignment procedure 6 After performing the steering toe adjustment torque the jam nuts to specification...

Page 153: ...top the engine 3 Loosen the wheel nuts slightly If wheel hub removal is required remove the cotter pin and loosen the castle nut slightly 4 Elevate the front or rear end of the vehicle off the ground placing a suitable stand or floor jack under the frame 5 Remove the wheel nuts and remove the wheel 6 If removing the hub take off the castle nut and washers s CAUTION Severe injury could occur if mac...

Page 154: ... point toward forward rotation 4 Attach the wheel nuts and finger tighten them 5 Carefully lower the vehicle to the ground 6 Torque the wheel nuts and or hub nut to the proper torque specification 7 If hub nut was removed install a new cotter pin after the hub nut has been tightened T Wheel Nuts 27 ft lbs 37 Nm T Front Hub Castle Nut 40 ft lbs 55 Nm T Rear Hub Castle Nut 40 ft lbs 55 Nm CAUTION If...

Page 155: ...BRAKE CABLE REPLACEMENT 6 11 FRONT BRAKE PADS 6 13 FRONT PAD REMOVAL 6 13 PAD INSPECTION 6 13 FRONT BRAKE PAD ASSEMBLY CALIPER INSTALLATION 6 14 FRONT BRAKE DISC 6 15 DISC INSPECTION 6 15 DISC REPLACEMENT 6 16 FRONT CALIPER 6 16 FRONT CALIPER REMOVAL 6 16 CALIPER INSTALLATION 6 17 REAR BRAKE PAD 6 18 REAR BRAKE PAD REMOVAL 6 18 REAR BRAKE PAD INSPECTION 6 19 REAR BRAKE PAD ASSEMBLY CALIPER INSTALL...

Page 156: ... 6 mm Rear Brake Disc Thickness 160 4 05 mm 138 3 50 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Brake Disc to Hub Front 7 0 9 5 Brake Disc to Hub Rear 21 0 28 5 Brake Line Banjo Bolts Caliper and master cylinder 14 5 19 6 Brake Pad Guide Pins All 10 0 13 5 Brake Pedal Mounting Bracket to Frame 15 0 20 0 Caliper Mounting Bolts Front and Rear 18 0 24 5 Master Cylinder to Frame...

Page 157: ...OTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brak...

Page 158: ...ure If the fluid level is too high pressure could build in the brake system causing the brake pads to drag due to fluid expansion Brake fluid and brake system parts expand and contract due to the heating and cooling during normal operation A very small hole called the compensating port located inside the master cylinder is opened and closed by the master cylinder piston When the brake pedal is rel...

Page 159: ...13 RZR 170 Service Manual Copyright 2012 Polaris Sales Inc BRAKE SYSTEM MECHANICAL COMPONENTS Brake System Mechanical Components Parking Brake Switch Brake Light Switch Spring Parking Brake Cable Pedal Return Spring 12 ft lb 16 Nm ...

Page 160: ... Bleed Screws All 47 in lbs 5 3 Nm Master Cylinder LH Front Caliper 2 RH Front Caliper 1 1 2 Caliper Mounting Bolts All 3 18 0 ft lbs 24 5 Nm Brake Pad Guide Pins 4 12 0 ft lbs 16 2 Nm 4 3 2 3 1 60 in lbs 6 8 Nm Adaptor Clamps 2 17 0 ft lbs 23 0 Nm 60 in lbs 6 8 Nm 15 in lbs 1 7 Nm 1 Rear Caliper 3 4 1 All Banjo Bolts 52 in lbs 5 8 Nm 60 in lbs 6 8 Nm 4 ...

Page 161: ... end of a clean clear hose on bleed screw and place the other end in a clean container Be sure hose fits tightly 5 Have an assistant slowly pump the brake pedal until pressure builds then hold light pressure on the pedal 6 While assistant is holding light pressure open bleed screw until brake pedal travels to the end of its stroke and no more fluid moves into the clear hose attached to the bleed s...

Page 162: ...eps 4 8 for each front caliper 11 Perform Steps 4 8 for the rear caliper 12 Add brake fluid to MAX level inside reservoir 13 Install master cylinder reservoir cover securely 14 Field test the vehicle at low speed before putting into service Check for proper braking action and inspect pedal travel 15 Perform brake pedal inspection See Brake Pedal Inspection Adjustment on page 6 9 16 Check brake sys...

Page 163: ...inder actuator rod and pedal mechanism returns fully and pedal contacts pedal stop on left side of pedal pivot bracket when released 2 If pedal does not return freely remove pedal and lubricate parts See Brake Pedal Removal on page 6 9 Pedal Free Play and Pedal Travel 1 Place vehicle on a flat level surface 2 Shift transmission into Neutral 3 Carefully lift rear tires off the ground with a stable ...

Page 164: ... adjuster Parking Brake Adjustment 1 Place vehicle on a flat level surface 2 Shift transmission into Neutral 3 Carefully lift rear tires off the ground with a stable platform jack or set vehicle on stable jack stands 4 Loosen jam nut A on parking brake adjustment bolt 5 While rotating the rear wheels by hand tighten the adjustment bolt B until significant brake drag is detected 6 Back the adjustme...

Page 165: ...r access panel and battery tray panel to reach the parking brake cable and brake lever from the top 4 Have an assistant help tip the vehicle toward the passenger side or secure vehicle to a lift that allows access to the underside 5 Secure the vehicle in position and place jack stands under the front and rear areas of the frame 6 Note location of tie straps for assembly Cut all tie straps 7 Cable ...

Page 166: ...exposed Screw jam nut against the adjuster nut Hold adjuster and tighten jam nut securely 2 Turn the cable adjuster located near the rear brake caliper inwards until it is fully seated 3 Route cable to passenger side of shift cables and through holder on park brake lever bracket 4 Pull inner cable and attach it to parking brake lever arm 5 Refer to routing photos in the cable removal process to ro...

Page 167: ...r cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Remove brake pad guide pin loosened in Step 3 7 Push mounting bracket B inward toward piston side of caliper 8 Slide stationary pad out away from bracket and off the threaded post then rotate pad until it can be removed from remaining guide pin C 9 Remove inner pad 10 Inspect caliper...

Page 168: ...ide freely on the pin The guide pin will be fully tightened after caliper is installed Be sure boots C are seated on caliper and on bracket 4 Install caliper onto front hub Torque both mounting bolts 5 Torque brake pad guide pin s that were loosened or removed 6 Slowly pump brake pedal until pressure builds Maintain at least 1 2 inch 12 7 mm of brake fluid in reservoir to prevent air from entering...

Page 169: ...t replace the disc 2 Use a 0 1 0 25mm micrometer to measure disc thickness at multiple locations around pad contact surface Replace disc if worn beyond service limit at any measurement point 3 Mount a dial indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds service limit T Front Wheel Nut 27 ft lbs 37 Nm Brake Disc...

Page 170: ...raking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation FRONT CALIPER Front Caliper Removal NOTE The caliper is not serviceable Each caliper can be replaced as an assembly 1 Elevate and safely support front of vehicle 2 Remove 4 wheel nuts and front wheel 3 Cle...

Page 171: ...rake disc Align caliper mounting holes and install bolts Torque mounting bolts to specification 2 Place new sealing washers on each side of brake line banjo fitting and install banjo bolt 3 Orient brake line to proper angle and torque to specification 4 Bleed the brake system See BRAKE BLEEDING FLUID CHANGE on page 6 7 5 Install wheel and torque wheel nuts to specification NOTE If new brake pads a...

Page 172: ...aliper so as not to kink or bend brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE It may be necessary to back the parking brake adjuster screw out a few turns NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir...

Page 173: ...lide inner pad toward outside of caliper body until it clears the threaded stud Rotate pad and remove 9 Inspect caliper piston seals for signs of brake fluid leakage Replace caliper if leaking Rear Brake Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn beyond the service limit Rear Brake Pad Thickness 300 007 7 6 mm 178 mm Service Limit 180 4 6 mm Measure Thickness ...

Page 174: ...nst bracket B Pads must slide freely on the pin The guide pin will be fully tightened after caliper is installed Be sure boots C are seated on caliper and on bracket 4 Install caliper and torque mounting bolts to specification 5 Torque brake pad guide pin s that were loosened or removed 6 Slowly pump the brake pedal until pressure builds Maintain at least 1 2 inch 12 7 mm of brake fluid in the res...

Page 175: ...at this procedure 10 times REAR BRAKE DISC Disc Inspection 1 Visually inspect disc for scoring scratches or gouges If any deep scratches are evident replace the disc 2 Use a 0 1 micrometer and measure the disc thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit 3 Mount a dial indicator and measure disc runout Slowly rotate the disc and read ...

Page 176: ...ear brake caliper See Rear Brake Pad Assembly Caliper Installation on page 6 20 4 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation T Rear Brake Disc 21 ft lbs 28 5 Nm CAUTION Always use new brake disc mounting bolts The bolts ...

Page 177: ...e removal and note how rear brake line fitting is oriented on caliper If brake line is being replaced note how brake line is routed and secured 4 Tie straps secure brake line with throttle cable in areas A Secure with parking brake cable to frame in area B 5 Front routing and clamp shown below 6 Remove two bolts and separate parking brake lever arm assembly from caliper or see NOTE below CAUTION U...

Page 178: ...m caliper Immediately cover and seal end of brake line to prevent contamination Rear Brake Caliper Installation 1 Install caliper and torque mounting bolts to specification 2 Bleed rear brake system See BRAKE BLEEDING FLUID CHANGE on page 6 7 3 Attach parking brake cable to lever arm with one washer A on each ends of spring If lever arm plate was removed install plate and torque bolts B to 12 ft l...

Page 179: ...n master cylinder reservoir cover and surrounding area under front left cab thoroughly to prevent debris from entering the reservoir Remove the cover 2 Draw as much fluid as possible from the reservoir to minimize spillage 3 Place a container under the master cylinder to catch brake fluid Loosen hose clamps A and remove hoses from hose adaptors Drain remaining fluid from reservoir and hoses Immedi...

Page 180: ...pecifications in the removal steps Install new sealing washers on brake lines 2 After installing the master cylinder perform the following Fill the reservoir with Polaris Dot 4 Brake Fluid PN 2872189 from a new sealed container Bleed the master cylinder and both front and rear brake lines and calipers See BRAKE BLEEDING FLUID CHANGE on page 6 7 Inspect pedal free play and pedal travel See Brake Pe...

Page 181: ...ats Brakes Drag Compensating port plugged in front or rear chamber of master cylinder Parking brake applied or misadjusted Brake pedal binding or unable to return fully Caliper piston s not returning properly binding Operator riding brakes Brakes Lock Mechanical parts sticking brake pedal parking brake lever etc Caliper pistons sticking Master cylinder piston sticking Improper assembly of brake sy...

Page 183: ...CH CVT COVER INSTALLATION 7 5 DRIVE BELT REMOVAL 7 6 DRIVE BELT INSPECTION 7 6 DRIVE BELT INSTALLATION 7 6 DRIVE CLUTCH SERVICE 7 8 DRIVE CLUTCH REMOVAL DISASSEMBLY AND INSPECTION 7 8 DRIVE CLUTCH ASSEMBLY 7 9 DRIVEN CLUTCH SERVICE 7 9 DRIVEN CLUTCH REMOVAL DISASSEMBLY INSPECTION 7 9 DRIVEN CLUTCH ASSEMBLY 7 11 DRIVEN CLUTCH INSTALLATION 7 12 TRANSMISSION SERVICE 7 13 TRANSMISSION DISASSEMBLY AND ...

Page 184: ...ze ft lbs Nm CVT Cover Bolts 6mm 6 8 8 11 Nm CVT Drain Plug 6mm 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 6mm 6 8 8 11 Nm Output Shaft Housing Screws 8mm 12 16 Nm Oil Drain Bolt Crankcase 14mm 18 18 23 Nm Output Shaft Collar Nut 72 98 Nm Shimming Required Shift Detent Bolt 10mm 14 19 Nm Transmission Cover Bolts 6mm 6 8 8 11 Nm PART NUMBER T...

Page 185: ...speed is sufficient centrifugal friction shoes on the driven clutch overcome the return spring pressure and swing outward against the transmission drive hub and the vehicle if in gear begins to move At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves changing the ratio of the...

Page 186: ...nsmission to neutral and rev the engine slightly to expel the moisture This will also air dry the belt and clutches 3 Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Repeat as needed CVT Overheating Water Ingestion Diagnostics During routine maintenance or whenever CVT system overheating is evident check the inlet and outlet ducts fo...

Page 187: ...de cover to clear shift cables and tank 6 Inspect bearing C It should rotate freely without binding Replace if rough if inner race is loose or if bearing is loose in the cover Be sure screws for air duct plate D are tight Clutch CVT Cover Installation 1 Clean gasket surfaces and install a new gasket with cover alignment dowels E in place 2 Install drive and driven clutch with belt Refer to clutch ...

Page 188: ...ng belt from drive clutch to prevent rollers from falling out of the clutch ramps Remove belt from driven clutch Drive Belt Inspection 1 Inspect surface of drive belt for uneven wear or grease deposits Measure width Replace belt if worn or glazed Drive Belt Installation 1 Do not attempt to install drive belt with drive clutch stationary sheave installed 2 Push moveable sheave and spacer sleeve of ...

Page 189: ...d force belt as far down as possible Hold belt down in driven sheaves and loop front of belt over drive clutch shaft 5 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 of stationary sheave splines with shaft splines 6 Hold stationary sheave with a strap wrench 7 Tighten nu...

Page 190: ...sides of guide posts on moveable sheave for wear Replace guides as a set Refer to Fig 1 6 Inspect cam plate for wear on all roller track surfaces D 7 Clean any belt material from sheaves with isopropyl alcohol or brake parts cleaner 8 Inspect both sheave faces E for grooves wear or damage 9 Inspect splines of stationary sheave F for wear Temporarily install stationary sheave on crankshaft to verif...

Page 191: ... together to prevent rollers from dislodging 6 See Drive Belt Installation on page 7 6 to install belt and complete the installation of drive clutch stationary sheave DRIVEN CLUTCH SERVICE Driven Clutch Removal Disassembly Inspection 1 Remove belt See Drive Belt Removal on page 7 6 2 Use a strap wrench to hold drive hub and remove driven clutch retaining nut 3 Pull outward on driven clutch and tap...

Page 192: ...roller pin cover to remove 8 Remove 3 rollers and pins D Inspect roller tracks E in moveable sheave Refer to Fig 2 9 Separate moveable and fixed sheave Clean all parts and sheave faces with isopropyl alcohol or brake parts cleaner 10 Inspect both sheave faces F for grooves wear or damage 11 Replace seals G and O rings H upon assembly 12 Inspect spring free length Replace if less than service limit...

Page 193: ...n Clutch Assembly 1 Press new seals A into moveable sheave with seal lips facing inward Press seals flush with edge of seal bore 2 Fill outer cavity between seals roller area with grease and slide moveable sheave onto post of stationary sheave B 3 Align and insert 3 roller pin assemblies C 4 Lubricate and install new O rings in grooves of driven sheave then install outer roller pin cover D until f...

Page 194: ... nut Driven Clutch Installation 1 Install belt on driven clutch with numbers readable from centrifugal hub side of clutch 2 Compress driven clutch and force belt into the sheaves as far as possible and hold belt in position 3 Loop the belt over drive clutch and install driven clutch on transmission shaft 4 Install drive hub and engage splines of drive hub to splines of transmission input shaft 5 I...

Page 195: ...e 2 Remove shift cable bracket B and shift arm screw C 3 Mark shift shaft and shift cable arm orientation before removing the arm 4 Remove angle drive inspection oil fill cover NOTE Angle drive removal is not required for transmission cover removal or access to internal transmission components Drive pinion gear D and shaft will stay with cover when removed 5 Remove 3 angle drive output housing scr...

Page 196: ...ssembly Assembly on page 7 22 9 Remove all transmission cover screws Tap lightly with a soft faced hammer Pry points E can be used carefully to help release cover and gasket 10 Remove retaining ring from drive pinion 11 Remove spacer and gear 12 Push shaft out of cover housing 13 Inspect gear teeth and bearing If components are replaced inspect output gear pinion depth and adjust with shims as req...

Page 197: ...ent bolt with ball and spring 15 Pull shift shaft from case 16 Push and release the spring loaded gear position switch plunger F Be sure it moves freely inward and extends under spring pressure when released 17 Remove shift fork shaft Pull fork out of shift drum track 18 Remove shift drum 19 Remove shift fork F ...

Page 198: ...pad area of shift fork J and replace if bent worn discolored scored or damaged 23 Pull main shaft from case with thrust washer on inside end 24 Remove countershaft 25 Inspect input pinion gear for tooth damage Push on shaft to check for play in bearing Rotate the shaft to check for smooth bearing rotation 26 Inspect all bearings in case They should rotate freely without binding Bearing inner race ...

Page 199: ...9923983 2012 2013 RZR 170 Service Manual Copyright 2012 Polaris Sales Inc Input Shaft Removal Inspection 1 Remove bearing stop screw and washer A 2 Tap input shaft from CVT side to remove shaft with bearing A 87 in lbs 9 8 Nm ...

Page 200: ...n 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 3 Inspect forward reverse dog gear Closely inspect outer corners of dogs for rounding or damage K 4 Inspect edges of slots L in forward and reverse gears for severe rounding that would reduce contact area of sliding gear dog Compare leading and trailing edges of slots to de...

Page 201: ...d bolt into bottom of transmission case but do not fully tighten the bolt Leave just enough tension on detent ball to keep shift drum from rotating out of Neutral Install gear position switch plunger E with spring in end of shift shaft Use light grease to hold parts in place and carefully install shaft in gear case Align center teeth of shift shaft and drum F 2 Torque detent bolt to specification ...

Page 202: ...s clear After installing engine in frame route and secure hose lightly as shown with open end G pointing down 9 After installation in the frame adjust shift cables in the following manner Place gear selector in NEUTRAL Verify transmission shift arm is in NEUTRAL Attach cables to bracket and to shift arm Adjust each cable until slack is removed from each cable and tighten cable adjusters securely C...

Page 203: ...n by applying light pressure to the center of the output shaft Measure the gap with a feeler gauge and record 5 The specified pinion depth is 012 016 inch 0 3mm 0 4mm from the bottomed position Therefore you will need to install a shim pack with a thickness of 012 016 inch 0 3mm 0 4mm plus the gap measured in Step 4 Example Gap between housing and case is 020 inch 0 50 mm with no shims installed a...

Page 204: ... with spring side of seal facing pinion gear 8 Apply grease to shaft oil seal then carefully slide shaft assembly through seal and into housing until bottomed in bearing bore 9 Install bearing E over splined end of shaft and push into housing until seated 10 Install collar nut hand tight 11 Temporarily install housing to transmission case with all 3 screws A and fully tighten collar nut to specifi...

Page 205: ...MITER FUNCTIONS 8 10 RPM LIMITER SPECIFICATIONS 8 11 IGNITION COIL TEST 8 11 CDI OUTPUT TEST USING PEAK READING ADAPTOR 8 11 PULSER COIL OUTPUT RESISTANCE TESTS 8 11 CHARGING SYSTEM 8 12 CHARGING SYSTEM TESTING 8 12 MAIN FUSE FUSE HOLDER LOCATION 8 13 VOLTAGE REGULATOR RECTIFIER 8 13 STATOR ALTERNATOR TESTS 8 13 BATTERY 8 14 BATTERY MAINTENANCE SERVICE NOTES 8 14 NEW BATTERY ACTIVATION 8 14 BATTER...

Page 206: ...e obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is acceptable for use when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply SWITCHES AND CON...

Page 207: ...ake switch is closed when the parking brake lever is pulled which signals the CDI to limit engine RPM 1 Locate the parking brake and brake pedal switches 2 Disconnect wire harness from each switch and connect an ohmmeter across the two switch wires The reading should be infinite 3 Apply either the brake pedal or parking brake and check for continuity between switch contacts Replace switch if there...

Page 208: ...le is being operated the spring loaded throttle arm will return back and depress the micro switch limiting engine rpm The TRS switch and throttle arm are located in a sealed throttle pedal assembly Switch or throttle cable replacement requires removing the assembly cover Always replace the cover gasket with a new one during assembly TRS Switch Adjustment 1 Slide the boot off the throttle cable adj...

Page 209: ...o the running lights There should be continuity between the YELLOW wire at the light connector and the YELLOW wire at the Generator Stator 3 If continuity is good perform stator resistance tests using the resistance chart located in the wiring diagram 4 Replace Generator Stator if resistance is not within specification DRL Lamp Replacement If the daytime running lights do not operate lamp replacem...

Page 210: ... 4 Reinstall the lens cover INDICATOR LAMPS Indicator Lamp Replacement 1 The indicator lamps are located on the dash 2 Disconnect the indicator light wire connections from the harness 3 Remove the nut from the backside of the indicator lamp 4 Remove the lamp 5 Install new lamp s into the dash and secure with retaining nut 6 Apply dielectric grease to the wire connections of the new lamp 7 Turn ign...

Page 211: ... 1 With the switch installed use an ohmmeter to test continuity between the switch leads and engine ground 2 First shift the transmission into neutral and test for continuity between the DG WH wire and ground 3 Then shift the transmission into reverse and test for continuity between the DB wire and ground In both tests you should have continuity to ground ...

Page 212: ...t includes a stator pulser coil CDI Box ignition coil and related wiring connectors Timing is non adjustable on this ignition system Ignition System Troubleshooting No Spark Weak or Intermittent Spark No 12 volt power on brown BN wire at CDI box or no CDI box ground path from the black white BK WH wire Spark plug gap incorrect Fouled spark plug Faulty spark plug cap or poor connection to high tens...

Page 213: ...ED circuit at key switch Battery voltage on BROWN wire at key switch at ON position Replace key switch Check wiring between switch and CDI Check 15A fuse and battery NO YES NO YES NO Disconnect 4 wire plug from CDI Check the BLACK wire for continuity to ground YES Continuity Check wiring NO Disconnect DG wire from ignition coil Check for continuity between plug and key switch in ON position YES Co...

Page 214: ...y 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 The CDI box can also receive a ground path from the TRS switch causing the CDI box to retard timing and limit RPM if the throttle cable becomes slack o...

Page 215: ... the CDI box Install the Peak Reading Adaptor PV 39991 to your meter and connect one meter lead to the dark blue black wire DB YEL and the other to engine ground Set meter to read DC Volts Crank engine and verify pulser coil output If readings are within specifications test the resistance value of the pulser coil When finished reconnect the 4 wire connector to CDI box Model Max RPM Ignition Timing...

Page 216: ...ct the alternator wires Note Red wire must be connected to harness Battery voltage must be present on red wire terminal on harness side of voltage regulator connector Is it If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or terminal board replace the voltage regulator Yes No Yes Yes Remove the battery and properly...

Page 217: ...e performed using a multimeter to determine the condition of the stator TEST 1 Measure resistance value of each stator leg 1 Measure the resistance value of the stator legs Use the following chart as a reference when testing TEST 2 Measure AC voltage output of each stator leg Test at cranking rpm with a voltmeter set to read AC volts 1 Turn over the engine with the starter motor 2 First measure fr...

Page 218: ...ack seals releasing electrolyte into the battery Allow the pack to drain for 20 minutes periodically tapping the sides to release any air lock or bubbles that may be present 4 Properly dispose of the battery electrolyte pack Let battery set with the vent cap strip off for 30 minutes to allow full absorption of the electrolyte After 30 minutes install the battery seal strip onto the battery 5 Charg...

Page 219: ... charging See Load Test NOTE Batteries should be kept at or near a full charge as possible If the battery is stored or used in a partially charged condition crystal sulfation will form on the plates reducing the efficiency and service life of the battery Battery Load Test A battery may indicate a full charge condition in the battery voltage test and the specific gravity test but still may not have...

Page 220: ...stics of a sealed battery overcharging decreases the volume of electrolyte The longer the overcharge time the greater the drop in electrolyte and subsequently starting power Water cannot be added to a sealed battery If a sealed battery is overcharged it will have to self discharge before it can be used Overcharging can also warp plates making future charging difficult Watch charging times carefull...

Page 221: ...t condition Starter Motor Service The starter motor is a complete service part If it is determined that the starter motor has failed replace as needed See the parts manual for the correct part number Although the starter motor is not serviceable it can be disassembled tested and cleaned Starter Disassembly NOTE Use only electrical contact cleaner to clean starter motor parts Other solvents may lea...

Page 222: ... 3 ohms or less Measure the resistance between the cable terminal and brush housing Make sure the brush is not touching the case The reading should be infinite no reading 2 Remove the brush plate and brushes Measure the brush length and replace if worn past the service limit 3 Inspect the surface of the commutator for wear or discoloration See Armature Test 4 Be sure that the terminal bolt insulat...

Page 223: ...gnet casing 2 Inspect and replace the O rings if damaged 3 Install case sealing O ring Make sure O ring is in good condition and not twisted on the case Lubricate the ends of the armature shaft and oil seal with a light film of grease and install housing 4 Install brush housing onto the armature pushing back brushes while installing armature shaft 5 Reinstall starter motor housing screws and washe...

Page 224: ... Faulty ignition switch Do other systems function Faulty starter solenoid or starter motor Engine problem seized or binding Can engine be rotated easily with recoil starter Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test below Engine problem seized or binding Can engine be rotated easily with recoil starter...

Page 225: ... read DC voltage and connect meter leads between the DG YEL and DG RED wires Turn the key switch to the START position and push in the brake pedal Is battery voltage present Connect meter leads to RED lug to starter motor and engine ground and retest Is battery voltage present Check battery condition RED battery connections at relay and 15A fuse Condition Good Check the key switch for proper funct...

Page 227: ...liper Front 6 16 Caliper Rear 6 23 Cam Chain Tensioner Inspection 3 14 Cam Chain Tensioner Installation 3 46 Camshaft Inspection 3 16 Camshaft Removal 3 16 Camshaft Timing Method 1 3 41 Camshaft Timing Method 2 3 44 Carburetion System 4 2 Carburetion Carburetor Assembly 4 3 Carburetor Service 4 4 Carburetor Assembly 4 8 Carburetor Cleaning 4 6 Carburetor Disassembly Keihin 4 5 Carburetor Draining ...

Page 228: ... 4 10 Fuel Valve Location 2 16 Fuel Valve Service 4 11 Fuse Location 8 13 G General Specifications Brakes 6 2 Ground Engine 2 30 H Hand Brake 2 35 6 10 Hand Brake Assembly View 6 5 I Idle Speed Adjustment 2 14 Ignition Coil Testing 8 11 Ignition System 8 8 Ignition System Troubleshooting 8 8 Ignition System Testing 8 9 Indicator Lamp Replacement 8 6 Indicator Light Replacement 5 9 Inspection Drive...

Page 229: ... Type 2 20 Specification Flywheel Nut Torque 3 47 Specification Idle Speed 2 14 Specification Oil Filter Torque 2 21 Specification Oil Pump Baffle Plate Screw Torque 3 38 Specification Oil Pump Gear Nut Torque 3 38 Specification Oil Pump Screw Torque 3 38 Specification Piston Ring Installed Gap 3 26 Specification Shock Mounting Torque 5 18 Specification Starter Idle Gear Bolt Torque 7 5 7 6 7 8 Sp...

Page 230: ...lation 8 8 Transmission Switch Removal 8 8 Transmission Switch Testing 8 7 Transmission Disassembly 7 13 Transmission Inspection 7 13 Transmission Output Shaft Shimming Procedure 7 21 Transmission Reassembly 7 19 Troubleshooting Brake Noise 6 3 Troubleshooting Brake System 6 27 Troubleshooting Carburetion 4 15 Troubleshooting Engine 3 50 Troubleshooting Spark Plug Fouling 3 50 TRS Operation 8 4 TR...

Page 231: ...2012 2013 RZR 170 ...

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