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GENERAL INFORMATION

CHAPTER 1 GENERAL INFORMATION

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MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MODEL: 2009 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

1.1


GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service.

Model Year Designation

} } }

}

Machine Model Number Identification R 09 VA 17 AD Emissions & Model Option Basic Chassis Designation

Engine Designation

Engine Designation Number S35C ................................................................................................. Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start

VIN Identification World Mfg. ID

Vehicle Identifier

Vehicle Description

}

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A V A 1 7 A * 9 P 0 0 0 0 0 0

Body Style

Engine

Model Year

Individual Serial No.

Emissions Plant No. Powertrain Check Digit

* This could be either a number or a letter

Engine Serial Number Location Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the clutch-side engine case.

ENGINE SERIAL NUMBER

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

A

B The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.

C

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1


GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers Model

Model No.

Owner’s Manual PN

Parts Manual PN

2009 RANGER RZR 170

R09VA17AA

9922131 (produced before 2/10/2009) 9922569 (produced after 2/10/2009)

9922132

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.

Paint Codes Painted Part

Color Description

Polaris Number

Frame / Bumpers / Racks

Gloss Black

P-067

Plastic - Hood / Dash / Fenders

Indy Red

P-293

Replacement Keys Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the original. Should both keys become lost, ignition switch replacement is required.

P/N 0453013

SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe 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/.

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GENERAL INFORMATION GENERAL SPECIFICATIONS

1

MODEL: 2009 RANGER RZR 170 MODEL NUMBER: R09VA17AA ENGINE MODEL: S35C Category

Dimension / Capacity

Length

85 in. / 216 cm

Width

48 in. / 122 cm

Height

55 in. / 139.7 cm

Wheel Base

65 in. / 165 cm

Ground Clearance

6 in. / 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)

1.5


GENERAL INFORMATION MODEL: 2009 RANGER RZR 170

Drivetrain

MODEL NUMBER: R09VA17AA ENGINE MODEL: S35C Engine

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

Platform

Single Cylinder, Air/Oil Cooled 4-Stroke

Engine Model Number

S35C

Engine Displacement

169cc

Number of Cylinders

1

Bore & Stroke (mm)

61 x 57.8 mm

Front Travel

5 in. / 12.7 cm

Compression Ratio

9.5:1

Rear Suspension

Dual Shock Swingarm

Compression Pressure

130-160 psi @ W.O.T.

Rear Travel

5 in. / 12.7 cm

Engine Idle Speed

1700 ± 100 RPM

Engine Max Operating RPM

8000 ± 200 RPM

Shock Preload Adjustment Front / Rear

Cam Adjustable (Factory Setting - Softest)

Lubrication

Wet Sump

Toe Out

1/8-1/4 in. / 3-6.35 mm

Steering / Suspension Front Suspension

Wheels / Brakes

Above 32° F ( 0° C ) Polaris ‘YOUTH’ oil Oil Requirements

Below 32° F ( 0° C ) 20W-40 oil

Oil Capacity

37 oz.. / 1.1 liters

Exhaust System

Single Headpipe / Single Silencer Fuel System

Carburetor Type

Keihin

Pilot Jet

35

Main Jet

100

Air Screw

2 1/4 Turns Out (initial)

Front Tire Size

19 x 7 - 8

Rear Tire Size

20 x 10 - 9

Bolt Pattern

110mm

Tire Air Pressure - Front / Rear

3 psi (20.7 kPa)

Brake - Front / Rear

Foot Actuated - 4 Wheel Hydraulic Disc

Brake Fluid

DOT 4

JETTING CHART Ambient Temperature Below 40 F Below 5 C

Above +40 F Above +5 C

0-3048 (0-10000)

102

100

Above 3048 (Above 10,000)

100

Altitude Jet Needle

2MKNN - #4 clip position

Fuel Delivery

Fuel Pump

Fuel Filters

See Chapter 4

Fuel Capacity / Requirement

2.5 gal. (9.5 liters) 87 Octane (minimum)

Single A-arm

Meters (Feet)

98 #3 needle clip position

Electrical Alternator Max Output

80 Watts @ 3000 RPM

Lights: Main Headlights

2 - Single Beam Daytime Running Lamps (DRL)

Tail / Brake

5 Watts / 21 Watts

Starting System

Electric Start

1.6

Ignition System

CDI

Ignition Timing

Non-Adjustable

Spark plug / Gap

NGK CR6HSA .024-.028 in. (0.6-0.7 mm)

Battery

GTX12-BS / Low Maintenence 12 Amp Hr. / 12 Volt

Fuses

Main: 20 Amp

CLUTCH CHART Altitude Meters (Feet)

Shift Weight

0-3048 (0-10,000)

6 @ 17 grams

Above 3048 (Above 10,000)

*** 6 @ 15 grams PN 0454619

***15 gram weights are optional and are not a High Altitude (H.A.) Warranty item.


GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS

1

Conversion Table

°C to °F: 9/5(°C + 32) = °F

°F to °C: 5/9(°F - 32) = °C

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

1.8


GENERAL INFORMATION SAE Tap / Drill Sizes

Decimal Equivalents

1

Metric Tap / Drill Sizes

1.9


GENERAL INFORMATION Glossary of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Rollers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. DCV: Direct current voltage CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm²: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in²: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

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MAINTENANCE

CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 30 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2

MAINTENANCE REFERENCES / SERVICE LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 2.6 FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 SHIFT CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 CHOKE 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 ENGINE OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 ENGINE CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . 2.21 ENGINE/TRANSMISSION MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 COMPRESSION / LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 TRANSMISSION SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 TRANSMISSION OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 DRIVE CHAIN LUBRICATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.1


MAINTENANCE ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.30 TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

2.2


MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and 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 begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance:

= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer. = SEVERE USE ITEM -- See Above E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING Improperly performing the procedures marked with acould result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

2.3

2


MAINTENANCE Pre-Ride - 25 Hour Maintenance Interval Periodic Maintenance Chart Maintenance Interval (whichever comes first)

Item

Remarks

Hours

Calendar

Miles (KM)

 Steering

-

Daily

-

 Front-Suspension  Rear-Suspension

-

Daily

-

-

Daily

-

-

Daily

-

-

Daily

-

Brake Fluid Level

-

Daily

-

Daytime Running Lights

-

Daily

-

Drive Chain

-

Daily

-

Brake Lamp / Tail Lamp

-

Daily

-

Throttle

-

Daily

-

Wheels / Fasteners

-

Daily

-

Frame Fasteners

-

Daily

-

-

Daily

-

-

Daily

-

-

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

1M

100 (160)

Inspect regularly

10 H

1M

100 (160)

Check; adjust as needed

10 H

1M

100 (160)

Check for proper operation

10 H

1M

100 (160)

Perform a break-in oil change after the first 10 hours of operation

10 H

1M

100 (160)

Perform break-in oil change after the first 10 hours of operation

 (Break-In Period)

10 H

1M

100 (160)

Adjust and lubricate after the first 10 hours of operation

 Valve Clearance E

10 H

1M

100 (160)

Check clearance after the first 10 hours of operation; Adjust to specification if required

25 H

Monthly

250 (400)

Check terminals; clean; test

25 H

12 M

250 (400)

Inspect level; change yearly

Tires

 Brake Pedal Travel

 Engine Oil Level E

Fuel Level

 Air Filter (main element) E

Idle Speed  Choke E Engine Oil Change

 (Break-In Period)

Transmission Oil

 (Break-In Period) Drive Chain

Battery

 Transmission Oil

Check each day before driving the vehicle. Make adjustments as needed. See the PreRide Checklist in the Owner’s Manual.

Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.4


MAINTENANCE 30 - 100 Hour Maintenance Interval Periodic Maintenance Chart Maintenance Interval (whichever comes first)

Item

Remarks

Hours

Calendar

Miles (KM)

 Oil Change

30 H

6M

300 (480)

Lubricate all grease fittings, pivots, & cables

 Oil Pre-Filter Screen

30 H

6M

300 (480)

Clean filter at every oil change; clean annually if operated less than 10 hours

 General Lubrication

50 H

3M

500 (800)

Lubricate all grease fittings, pivots, & cables

 Valve Clearance E

50 H

-

500 (800)

Check clearance; adjust to specification if required; perform break-in adjustment after the first 10 hours of operation

50 H

6M

500 (800)

Drain bowl periodically and prior to storage

 Throttle Cable / E ETC Switch

50 H

6M

500 (800)

Inspect; adjust; lubricate; replace if necessary

 Choke Cable E

50 H

6M

500 (800)

Inspect; adjust; lubricate; replace if necessary

Carburetor Air Intake Ducts / Flange

50 H

6M

500 (800)

Inspect for proper sealing / air leaks

Shift Cables

50 H

6M

500 (800)

Inspect; lubricate; adjust

 Brake Pad Wear

50 H

6M

500 (800)

Inspect; replace as needed

 Drive Belt

50 H

-

500 (800)

Inspect; replace as needed

 Fuel System E

100 H

12 M

600 (1000)

Check for leaks at tank cap, lines, fuel valve, filter, carburetor, replace lines every two years

 Fuel Filter E

100 H

12 M

600 (1000)

Replace yearly

 Engine Mounts

100 H

12 M

600 (1000)

Inspect

 Exhaust Emissions / E Muffler / Pipe

100 H

12 M

600 (1000)

Inspect secondary air system filter and exhaust - clean as required

 Ignition Timing E

100 H

12 M

600 (1000)

Inspect

 Spark Plug

100 H

12 M

600 (1000)

Clean; check condition; adjust gap; replace as needed

 Wiring

100 H

12 M

600 (1000)

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

100 H

-

600 (1000)

Inspect;clean; replace worn parts

100 H

12 M

600 (1000)

Inspect; replace as needed

100 H

12 M

600 (1000)

Clean

 Toe Adjustment

-

-

-

Inspect periodically; adjust when parts are replaced

Idle Speed

-

-

-

Adjust as needed

Carburetor Float Bowl

E

E

CVT Clutches / Drive Belt (Drive and Driven)

 Wheel / Axle Bearings Spark Arrestor

 Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.5

2


MAINTENANCE MAINTENANCE REFERENCES / SERVICE LOCATIONS Front and Rear View

Daytime Running Lamps Grease Steering Pivots

Grease A-arm Pivots

Inspect Brake Pads

Trail / Brake Lamp

Inspect Exhaust

Inspect / Clean Air Filter

Clean / Lubricate Chain

2.6

Inspect Brake Pads


MAINTENANCE RH and LH Side Views

2

2.7


MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products

NOTE: Each item can be purchased separately at your local Polaris dealer. Part No.

Description

Additives / Sealants / Thread Locking Agents / Misc. Part No.

Description

2870585

Loctite™ Primer N, Aerosol, 25 g

2871956

Loctite™ Thread Sealant 565 (50 ml.) (6 Count)

Engine Lubricant 2870791

Fogging Oil (12 oz. Aerosol)

2876248

Polaris YOUTH Synthetic 0W-40 4-Cycle Engine Oil (Quart)

2871949

Loctite™ Threadlock 242 (50 ml.) (10 Count)

2872175

Polaris Semi - Synthetic 20W-40 4-Cycle Engine Oil (Quart)

2871950

Loctite™ Threadlock 242 (6 ml.) (12 Count)

2871951

Loctite™ Threadlock 262 (50 ml.) (10 Count)

2870587

Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) (10 Count)

2871326

Premium Carbon Clean (12 oz.) (12 Count)

2870652

Fuel Stabilizer (16 oz.) (12 Count)

Gearcase / Transmission Lubricants 2873602 2873603

AGL - Synthetic ATV Gearcase Lubricant (1 Qt.) (12 Count) AGL - Synthetic ATV Gearcase Lubricant (1 Gal.) (4 Count)

2873604

AGL - Synthetic ATV Gearcase Lubricant (2.5 Gal.) (2 Count)

2871653

ATV Angle Drive Fluid (8 oz.) (12 Count)

2871957

Black RTV Silicone Sealer (3 oz. tube) (12 Count)

2872276

ATV Angle Drive Fluid (2.5 Gal) (2 Count)

2871958

Black RTV Silicone Sealer (11 oz. cartridge) (12 Count)

2871654

Premium Demand Drive Fluid LT (1 Qt.) (12 Count)

2872189

DOT 4 Brake Fluid (12 Count)

2871557

Crankcase Sealant, 3-Bond 1215 (5oz.)

2870465

Oil Pump for 1 Gallon Jug

2872893

Engine Degreaser (12oz.) (12 Count)

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, Aerosol (16 oz.) (12 Count)

2.8

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.


MAINTENANCE MAINTENANCE REFERENCES Item

Ref.

Rec. Lube / Fluid

Method

Frequency* 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.

Engine Oil

Page 2.7

Polaris YOUTH 40W Engine Oil or 20-W40 Synthetic. Add oil to proper level on (Ambient air temperatures dipstick. apply- see page 2.19)

Brake Fluid

Page 2.7

DOT 4 (PN 2872189)

Fill reservoir between MAX Fill as required. Change and MIN lines. brake fluid every 2 years.

Transmission

Page 2.7

AGL Synthetic Gearcase Lubricant (PN 2873602)

Add lube to bottom of fill Change annually*** plug threads. 24 oz. (710 ml)

Front A -Arm and Steering Pivot Bushings

Page 2.6

Polaris Premium All Season Locate grease fittings and Grease (PN 2871423) grease with grease gun.

Semi-annually**

* More often under severe use, such as operated in water or under severe loads. **Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

2.9

2


MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE

1.

Locate the shift cable in the rear wheel well area.

Shift Cables

Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

Dust Boot

• Tires - check condition and pressures

Shift Cable Mount

• Fuel tank - fill to proper level • All brakes - check operation and adjustment

Clevis Pin

• Throttle - check for free operation and closing • Running lights/Taillight/Brakelight - also check operation of all indicator lights and switches

2.

Inspect shift cable, clevis pin, pivot bushings, and dust boot. Replace if worn or damaged.

3.

If adjustment is required, loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut.

• Ignition switch - check for proper function • Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

Upper Jam Nut

• Air cleaner element - check for dirt; clean or replace • Steering - check for free operation noting any unusual looseness in any area • Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners • Check all front and rear suspension components for wear or damage.

Lower Jam Nut

Frame, Nuts, Bolts, and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins 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:

4.

Adjust the shift cables so there is an equal amount of lever travel when shifting past the Neutral detent into HIGH (H) and REVERSE (R).

5.

Thread the upper jam nuts as required to obtain proper cable adjustment without binding.

• Ratcheting noise on deceleration

NOTE: This procedure may require a few attempts to obtain the proper adjustment.

• Inability to engage into a gear

6.

Once the proper adjustment is obtained, tighten the lower jam nut against the mount.

7.

Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, verify the idle RPM is set correctly, otherwise the transmission may require service.

• Excessive gear clash (noise) • Gear selector moving out of desired range

2.10


MAINTENANCE Shift Cable Replacement

8.

• Inability to engage into a gear

Raise the vehicle and support it with jackstands in order to access the underside to remove the cables. IMPORTANT: Document location of cable ties and routing prior to removal. This is important for reassembly.

• Inability to adjust cables for proper operation

9.

Shift cable replacement may be necessary if symptoms include:

• Gear selector moving out of desired range 1.

Locate the shift cables in the rear wheel well area.

2.

Loosen the lower and upper jam nuts and remove the cables. Upper Jam Nut

Install new cables and adjust for proper operation and lever travel without binding. IMPORTANT: Do not allow cables to hang below vehicle frame. 10. Once installed, lower the vehicle. Start engine and shift through all gears to ensure the shift cables are properly adjusted. If transmission still ratchets after cable adjustment, verify the idle RPM is set correctly, otherwise the transmission may require service. 11. Reassemble the console cover, seats and shift knob as outlined in Chapter 5.

Lower Jam Nut 3.

Inspect shift cable arm. Replace if worn or damaged.

4.

Remove the shift knob to prepare for seat panel removal. Refer to Chapter 5.

5.

Refer to Chapter 5 for 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.

Upper Jam Nut

Lower Jam Nut 7.

Inspect shift lever assembly. Replace parts as required if worn or damaged.

2.11

2


MAINTENANCE FUEL SYSTEM AND AIR INTAKE

4.

Inspect the air filter element for tears or damage.

NOTE: Filter is washable. Do not discard.

Air Filter Service It is recommended that the air filter be inspected as part of pre-ride inspection. If riding in extremely dusty conditions, apply a small amount of grease to the seal under the air box cap. In extremely dusty conditions, air filter cleaning will be required more often. The filter should be serviced using the following procedure.

5.

Wash the filter in warm soapy water and allow it to air dry.

6.

Apply air filter oil (commercially available) to the filter, following the directions on the label.

NOTE: If unable to clean the filter, replace it. NOTE: Service the filter more frequently if vehicle is operated in wet conditions, dusty conditions or at high throttle openings for extended periods.

Removal Installation 1.

The air box is located on the upper frame by the rear LH wheel. Access the air box by removing the panel located at the top of the rear cab (under rear basket, if installed).

Air Box Access

1.

Verify the air box and support screen are thoroughly clean.

2.

Install a clean, pre-oiled foam filter over the filter support.

NOTE: Apply a small amount of general purpose grease to the sealing edge of the air box cap seal before installing. 3.

2.

Install air box cap and secure with clips.

Unlatch the clips and remove the air box cap. Inspect the seal. It should adhere tightly to the cover and seal all the way around.

Secure Clips 4.

3.

Remove air filter and the filter support screen.

2.12

Reattach the access panel and tighten the fasteners sufficiently.


MAINTENANCE Choke Cable Adjustment

3.

Remove the retaining screws and pull the choke assembly out at the dash.

Verify free play of 3/16� (4.76 mm) and smooth operation of the choke cable at the dash. Decrease

2 Increase

CHOKE CABLE FREEPLAY 4.

Raise the vehicle and support it with jackstands in order to access the underside. IMPORTANT: Document location of cable ties and routing prior to removal. This is important for reassembly. Adjustments to the freeplay can be made by loosening the choke cable bracket at the carburetor and moving the cable in or out to gain the desired freeplay.

5.

Pull the cable out from under the dash and the underside of the vehicle.

6.

Route the new cable from front-to-back, through the retainers at the bottom of the frame, following the routing noted during disassembly. Place cable ties at the appropriate locations.

If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing.

Choke Cable Replacement The choke cable is replaced as an assembly. 1. 2.

Engine is off. Place the vehicle in neutral and apply the parking brake. Remove the cable end from the carburetor.

IMPORTANT: Do not allow cable to hang below vehicle frame. 7. 8. 9.

Reinstall the choke assembly into the dash. Hand-tighten fasteners sufficiently, using care not to over-tighten. Reinstall the choke cable onto the carburetor. Adjust cable to desired freeplay.

If smooth choke operation is not obtainable, inspect for kinks, sharp bends in the routing or a linkage obstruction.

2.13


MAINTENANCE Idle Speed Adjustment

Pilot Air Screw Adjustment

1.

Start engine and warm it up thoroughly.

2.

Adjust idle speed by turning the slide adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer to illustration).

Idle Speed Screw

CAUTION The pilot air screw is calibrated at the factory to meet EPA / CARB regulations for air quality standards. Cleaning of the pilot circuit must be performed by a certified repair shop to ensure air quality standards are not exceeded. 1.

IDLE SPEED Decrease

2.

Using a portable tachometer, start the engine and verify the idle speed is set to specification. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. Using ‘D’-shaped screwdriver Special Tool PA-47361 adjust 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.

Increase

PILOT AIR SCREW

Idle Speed 1700 ± 100

Increase

Decrease NOTE: Always check throttle cable freeplay after adjusting the idle speed and readjust if necessary.

Pilot Air Screw Base Setting: 2.25 turns out (initial) Special Tool: PA-47361

2.14

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 2 and 3.

5.

Readjust idle speed if not within specification.


MAINTENANCE Vent Lines

Fuel Filter

1.

Check fuel tank, crankcase, carburetor and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

The fuel filter should be replaced in accordance with the “Periodic Maintenance Chart” or whenever sediment is visible in the filter.

2.

Verify vent lines are routed properly and secured with cable ties.

Fuel Filter Location - Located in-line between fuel pump and carburetor inlet.

Fuel System 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 not overfill the tank. Do not fill the tank neck. If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time. Never drain the fuel when the engine is hot. Severe burns may result.

To service the fuel filter: 1.

Shut off fuel supply at fuel valve.

2.

Remove line clamps at both ends of the filter.

3.

Remove fuel lines from filter.

4.

Install new filter and clamps onto fuel lines.

5.

Turn fuel valve to ‘ON’.

6.

Start engine and inspect for leaks.

2.15

2


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2009 Polaris Ranger RAZR 170 Service Repair Manual  
2009 Polaris Ranger RAZR 170 Service Repair Manual  
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