Polaris RZR 170 2009 Manuals

Manuals and User Guides for Polaris RZR 170 2009. We have 1 Polaris RZR 170 2009 manual available for free PDF download: Service Manual

Polaris RZR 170 2009 Service Manual

Polaris RZR 170 2009 Service Manual (187 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 8.52 MB

Table of Contents

General Information Chapter

1
- Table of Contents
  1
- Chapter 1
  2
- Engine Designation Number
  2
- Engine Serial Number Location
  2
- Model Identification
  2
- Model Information
  2
- Vin Identification
  2
- Unit Serial Number (Vin) and Emissions Decal Locations
  3
- Special Tools
  4
- Vehicle Information
  4
  - Publication Numbers
    4
  - Paint Codes
    4
  - Replacement Keys
    4
- General Specifications
  5
  - Model: 2009 Ranger Rzr 170
    5
- Misc. Specifications and Charts
  7
Maintenance Chapter 2 Maintenance 2

11
- Chapter 2
  13
- Maintenance Chart Key
  13
- Periodic Maintenance Chart
  13
- Periodic Maintenance Overview
  13
- Pre-Ride - 25 Hour Maintenance Interval
  14
- 30 - 100 Hour Maintenance Interval
  15
- Maintenance References / Service Locations
  16
  - Front and Rear View
    16
  - Rh and Lh Side Views
    17
- Lubricants / Service Products
  18
- Maintenance References
  19
- General Vehicle Inspection and Maintenance
  20
- Fuel System and Air Intake
  22
  - Air Filter Service
    22
  - Choke Cable Adjustment
    23
  - Choke Cable Replacement
    23
  - Idle Speed Adjustment
    24
  - Pilot Air Screw Adjustment
    24
  - Vent Lines
    25
  - Fuel System
    25
  - Fuel Filter
    25
  - Fuel Valve Location
    26
  - Carburetor Draining
    26
  - Fuel Pump / Fuel Lines
    26
  - Throttle Pedal Inspection
    27
  - Throttle Stop Speed Control
    27
  - Throttle Freeplay Adjustment
    28
  - Throttle Cable Replacement
    28
- Engine
  30
- Transmission
  34
  - Transmission Specification Chart
    34
  - Transmission Oil Change
    34
- Final Drive / Wheel and Tire
  35
  - Wheel, Hub, and Spindle Torque Table
    35
  - Wheel Removal
    35
  - Wheel Installation
    35
  - Tire Inspection
    36
  - Tire Pressure
    36
  - Drive Chain Lubrication and Adjustment
    36
- Electrical and Ignition System
  37
  - Battery Maintenance
    37
  - Battery Removal
    38
  - Battery Installation
    38
  - Battery off Season Storage
    38
  - Battery Charging (Maintenance Free)
    38
  - Spark Plug Service
    39
  - Engine to Frame Ground
    39
- Steering
  40
  - Steering Inspection
    40
  - Steering Wheel Freeplay
    40
  - Steering Inspection / Tie Rod Ends and Hubs
    40
  - Toe Alignment Inspection
    41
  - Toe Adjustment
    41
- Brake System
  42
- Suspension
  42
  - Spring Preload Adjustment
    42
- Maintenance Log
  44
Engine

45
- Chapter 3 Special Tools
  47
- Tools
  47
- Torque Specifications
  47
  - Engine Torque Specifications
    47
  - Torque Patterns
    47
- Engine Information
  48
  - Engine Exploded Views
    48
  - Engine Lubrication
    49
  - Piston Identification
    49
  - Accessible Components
    49
  - Engine Service Data
    50
  - Oil Flow Diagram
    52
- Engine Systems Service
  53
  - Breather / Oil Separator
    53
  - Emissions Secondary Air System
    54
  - Cooling Shroud Removal/Installation
    55
  - Engine Removal
    56
  - Engine Installation Notes
    56
- Top-End Disassembly
  57
  - Engine Removal/Installation
    57
  - Finding Top Dead Center (Tdc)
    57
  - Cam Chain Tensioner Inspection
    57
  - Rocker Assembly Disassembly and Inspection
    58
  - Camshaft Removal
    59
  - Camshaft Inspection
    59
  - Cylinder Head Removal
    60
  - Cylinder Head Inspection
    61
  - Cylinder Head Warp Inspection
    61
  - Combustion Chamber Inspection
    61
  - Cylinder Head Disassembly
    61
  - Valve Inspection
    62
  - Valve Seat Reconditioning
    63
  - Cylinder Head Assembly
    65
  - Valve Sealing Test
    66
  - Cylinder Removal
    66
  - Cam Chain Follower / Tensioner Guide Removal
    66
  - Piston Removal
    67
  - Cylinder Inspection
    67
  - Cylinder Hone Selection / Honing Procedure
    68
  - Honing to Deglaze
    68
  - Piston Inspection
    68
  - Piston Ring Installed Gap
    69
- Bottom-End Disassembly
  70
- Crankcase Disassembly
  76
- Engine Reassembly
  78
  - Bearing / Seal Installation
    78
  - Crankcase Reassembly
    78
  - Chain Guide/Tensioner Installation
    79
  - Crankshaft, Balance Shaft and Starter Drive Gear Installation
    79
  - Oil Pump and Chain Installation
    80
  - Piston Ring Installation
    81
  - Piston Installation
    82
  - Cylinder Installation
    83
  - Cylinder Head and Camshaft Installation
    83
  - Camshaft Timing
    84
  - Rocker Arm / Shaft Assembly
    88
  - Rocker Assembly Installation
    88
  - Cam Chain Tensioner Installation
    89
  - Intake Valve Clearance Adjustment
    89
  - Exhaust Valve Clearance Adjustment
    89
  - Starter Drive Assembly
    90
  - Flywheel Installation
    90
  - Stator Installation
    90
  - Stator Housing Installation
    91
  - Exhaust System
    92
- Troubleshooting
  93
  - Spark Plug Fouling
    93
  - General Troubleshooting
    93
Body / Suspension / Steering Chapter 5 Body / Suspension / Steering

95
- Body Removal
  96
  - Seat Removal
    96
  - Seat Installation
    97
  - Front Bumper Removal / Installation
    97
  - Front Cab Removal / Installation
    97
  - Rocker Panel Removal
    99
  - Rear Bumper Removal / Installation
    99
  - Rear Cab Removal
    99
  - Service Panel (Seat Shield) Removal
    100
  - Console Cover Removal
    100
  - Key Switch / Indicator Light Replacement
    101
  - Decal Replacement
    102
  - Body Exploded View
    103
- Chapter 5
  96
- General Information
  96
- Special Tools
  96
- Torque Specifications
  96
- Cab Frame
  104
  - Exploded View
    104
  - Cab Frame Assembly
    104
- Main Frame
  105
  - Exploded View
    105
- Front A-Arms
  106
  - Exploded View
    106
  - A-Arm Replacement
    107
- Front Hub
  108
  - Hub Removal
    108
  - Hub Seal and Bearing Replacement
    108
  - Hub Installation
    109
- Shocks
  110
  - Shock Exploded View
    110
  - Shock Removal / Replacement / Installation
    110
- Rear Swing Arm
  111
  - Exploded View
    111
  - Swing Arm Removal
    112
  - Swing Arm Installation
    113
- Rear Axle
  114
  - Axle Housing Removal
    114
  - Axle Housing Service
    115
  - Axle Housing Installation
    115
  - Axle Removal / Installation
    116
- Steering
  117
- Tie Rod
  120
  - Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View
    120
  - Tie Rod Removal / Installation
    121
- Wheels
  122
  - Front Wheel Exploded View
    122
  - Rear Wheel Exploded View
    122
  - Wheel Removal / Installation
    123
Brakes Chapter 6 Brakes

125
- Chapter 6
  126
- General Specifications
  126
- Special Tools
  126
- Torque Specifications
  126
- Brake Noise Troubleshooting
  127
- Brake System Service Notes
  127
- Hydraulic Brake System - Overview of Operation
  128
- Brake System - Hydraulic Components
  129
- Brake Bleeding / Fluid Change
  130
- Brake Pedal
  131
  - Brake Pedal Removal
    131
  - Pedal Installation
    131
  - Brake Pedal Inspection / Adjustment
    132
- Parking Brake
  132
  - Parking Brake Adjustment
    132
  - Parking Brake Cable Replacement
    133
- Front Brake Pads
  135
  - Front Pad Removal
    135
  - Pad Inspection
    135
  - Front Brake Pad Assembly / Caliper Installation
    136
- Front Brake Disc
  137
  - Disc Inspection
    137
  - Disc Replacement
    137
- Front Caliper
  138
  - Front Caliper Removal
    138
  - Caliper Installation
    138
- Rear Brake Pad
  139
  - Rear Brake Pad Removal
    139
  - Rear Brake Pad Inspection
    140
  - Rear Brake Pad Assembly / Caliper Installation
    141
  - Brake Burnishing Procedure
    142
- Rear Brake Disc
  142
  - Disc Inspection
    142
  - Rear Brake Disc Replacement
    142
- Rear Caliper Service
  143
  - Rear Caliper Removal
    143
  - Rear Brake Caliper Installation
    144
- Master Cylinder
  145
  - Removal
    145
  - Installation
    145
- Troubleshooting
  146
  - Brakes Squeal / Poor Brake Performance
    146
  - Pedal Vibration
    146
  - Caliper Overheats (Brakes Drag)
    146
  - Brakes Lock
    146
Cvt / Transmission Chapter 7 Cvt / Transmission

147
- Chapter 7
  148
- Special Tools
  148
- Specifications / Tools
  148
- Torque Specifications
  148
- Cvt System
  149
  - Cvt Maintenance / Inspection
    149
  - Drive Clutch Operation
    149
  - Driven Clutch Operation
    149
  - Cvt System Drying
    150
  - Cvt Overheating / Water Ingestion Diagnostics
    150
  - Clutch (Cvt) Cover Removal / Inspection
    151
  - Clutch (Cvt) Cover Installation
    151
  - Drive Belt Removal
    152
  - Drive Belt Inspection
    152
  - Drive Belt Installation
    152
- Drive Clutch Service
  153
  - Drive Clutch Removal, Disassembly and Inspection
    153
  - Drive Clutch Assembly
    154
- Driven Clutch Service
  155
- Transmission Service
  158
Electrical Chapter 8 Electrical

167
- Chapter 8
  168
- Electrical System Service Notes
  168
- General Information
  168
- Special Tools
  168
- Switches and Controls
  168
  - Key Switch
    168
  - Brake Pedal / Parking Brake Switches
    169
  - Electronic Throttle Control (Etc)
    170
  - Etc Operation
    170
  - Etc Switch Adjustment
    170
- Daytime Running Lights
  171
- Drl" Lamp Replacement
  171
- Drl" Test
  171
- Indicator Lamps
  172
  - Indicator Lamp Replacement
    172
- Tail Light
  172
  - Tail Light Lamp Replacement
    172
- Transmission Switch
  173
  - Transmission Switch - Circuit Breakout
    173
  - Testing
    173
  - Removal
    174
  - Installation
    174
- Ignition System
  174
  - Overview
    174
  - Ignition System Troubleshooting
    174
  - Ignition System Testing
    175
  - Rpm Ignition Limiter Functions
    176
  - Rpm Limiter Specifications
    177
  - Ignition Coil Test
    177
  - CDI Output Test Using Peak Reading Adaptor
    177
  - Pulser Coil Output / Resistance Tests
    177
- Charging System
  178
  - Charging System Testing
    178
  - Main Fuse / Fuse Holder Location
    179
  - Voltage Regulator / Rectifier
    179
  - Stator / Alternator Tests
    179
- Battery
  180
  - Battery Load Test
    181
  - Battery Cleaning
    181
- Starter System
  182
  - Starter Relay
    182
  - Battery Storage
    182
  - Starter Motor Service
    183
  - Starter Disassembly
    183
  - Starter Brush Inspection / Replacement
    184
  - Armature Test
    184
  - Starter Reassembly
    185
  - Voltage Drop Test
    185
  - Starter System Troubleshooting
    185
  - Starter System Testing
    186

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