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RZR 170 2009
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 (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
Conversion Table
7
Standard Torque Specifications
8
Sae Tap / Drill Sizes
9
Metric Tap / Drill Sizes
9
Glossary of Terms
10
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
Pre-Ride / Daily Inspection
20
Frame, Nuts, Bolts, and Fasteners
20
Shift Cable Inspection / Adjustment
20
Shift Cable Replacement
21
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
Engine Oil Level
30
Engine Oil Change
30
Engine Crankcase Ventilation System Inspection
31
Engine/Transmission Mount Locations
31
Compression / Leakdown Test
32
Intake Valve Clearance Adjustment
32
Exhaust Valve Clearance Adjustment
32
Exhaust - Spark Arrestor
33
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
Brake Fluid Inspection
42
Brake Pad / Disc Inspection
43
Brake Hose and Fitting Inspection
43
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
Starter Drive Gear Removal and Inspection
70
Flywheel Removal / Inspection
71
Crankshaft One Way Gear / Drive Sprocket Removal and Inspection
72
Starter Drive One-Way Clutch Removal and Inspection
73
Balance Shaft Sprocket Removal and Inspection
73
Oil Pump Removal / Drive Chain Inspection
74
Crankcase Disassembly
76
Crankcase Separation and Cam Chain Removal
76
Crankshaft Removal
76
Crankshaft / Cam Chain / Sprocket Inspection
77
Crankcase / Bearing Inspection
77
Crankcase Oil Strainer Inspection
77
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
Steering Shaft Removal / Installation
118
Steering Shaft Installation
118
Steering Gearbox Removal / Installation
119
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
Driven Clutch Removal, Disassembly, Inspection
155
Driven Clutch Assembly
157
Driven Clutch Installation
157
Transmission Service
158
Transmission Disassembly and Inspection
158
Input Shaft Removal / Inspection
161
Transmission Main Shaft Assembly View
162
Transmission Assembly
163
Output Gear Pinion Depth Adjustment
165
Output Shaft Housing Disassembly / Assembly
166
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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