Polaris RANGER RZR 170 Service Manual
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Polaris RANGER RZR 170 Service Manual

2012-2013
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2012-2013 RANGER RZR® 170
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures 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, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed July 2012 (PN 9923983)
© Copyright 2012 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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  • Page 1 Publication Printed July 2012 (PN 9923983) © Copyright 2012 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Some Polaris factory publications can be downloaded from www.polaris.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 3 GENERAL INFORMATION MAINTENANCE ENGINE / TRANSMISSION FUEL SYSTEM BODY / SUSPENSION / STEERING BRAKES ELECTRICAL...

  • Page 5: Table Of Contents

    MODEL: 2012 RANGER RZR 170 ........

  • Page 6: Model Number Designations

    Whenever corresponding about an engine, be sure to refer to the engine ENGINE SERIAL NUMBER model number and serial number. This information can be found on the sticker applied to the clutch-side engine case. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 7: Unit Serial Number (Vin) And Emissions Decal Locations

    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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 8: Vehicle Information

    White P-133 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 9923983 - 2012-2013 RZR 170 Service Manual...

  • Page 9: Special Tools

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted 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/.

  • Page 10: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2012 RANGER 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.
  • Page 11 GENERAL INFORMATION MODEL: 2012 RANGER RZR 170 Drivetrain Transmission Type Polaris Automatic CVT MODEL NUMBER: R12VA17AA / R12VA17AC Shift Type In Line Shift - H / N / R ENGINE MODEL: S35C Transmission Oil Polaris AGL Engine Requirements Main Gearcase 23.7 oz.

  • Page 12: Model: 2013 Ranger Rzr 170

    GENERAL INFORMATION MODEL: 2013 RANGER RZR 170 MODEL 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.

  • Page 13: Model: 2013 Ranger Rzr 170

    GENERAL INFORMATION MODEL: 2013 RANGER RZR 170 Drivetrain Transmission Type Polaris Automatic CVT MODEL NUMBER: R13VA17AA / R13VA17AB Shift Type In Line Shift - H / N / R ENGINE MODEL: S35C Transmission Oil Polaris AGL Engine Requirements Main Gearcase 23.7 oz.

  • Page 14: Miscellaneous Specifications And Charts

    33/45 14/19 18/25 37/50 55/75 63/85 26/35 33/45 63/85 97/130 110/150 37/50 55/75 103/140 151/205 177/240 59/80 85/115 159/215 232/315 273/370 81/110 118/160 225/305 321/435 376/510 1.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 15: Conversion Table

    98.1 = Kilopascals (kPa) p(3.14)xR2x H (height) = Cylinder Volume °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 1.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 16: Sae Tap Drill Sizes

    17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 0.339 11/32 11x1.50 0.375 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32 1.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 17: Maintenance

    LUBRICANTS / SERVICE PRODUCTS ........2.8 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... .2.8 MAINTENANCE REFERENCES .
  • Page 18 MAINTENANCE LOG ........... 2.36 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 19: Periodic Maintenance Chart

      = 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.

  • Page 20: Pre-Ride - 25 Hour Maintenance Interval

     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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 21: 30 - 100 Hour Maintenance Interval

     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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 22: Maintenance References / Service Locations

    Grease Steering Pivots Grease A-arm Pivots Inspect Brake Pads Tail / Brake Lamp Inspect Exhaust Inspect / Replace Air Filter Inspect Brake Pads Clean / Lubricate Chain 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 23: Rh And Lh Side Views

    MAINTENANCE RH and LH Side Views 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 24: Lubricants / Service Products

    Premium All Season Grease 2871423 (14 oz. cartridge) (10 Count) 2871460 Starter Drive Grease (12 Count) 2871329 Dielectric Grease (Nyogel™) Chain Lubricant, Aerosol 2872348 (16 oz.) (12 Count) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 25: Maintenance References

    * 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) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 26: General Vehicle Inspection And Maintenance

    NOTE: This procedure may require a few attempts to obtain the proper adjustment. 6. Once the proper adjustment is obtained, tighten the lower jam nut against the mount. 2.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 27: Shift Cable Replacement

    5. Refer to Chapter 5 for console cover removal in order as outlined in Chapter 5. to access the shift cable mount on the lever assembly. 2.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 28: Fuel System And Air Intake

    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. AIR FILTER 2.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 29: Choke Cable Adjustment

    2. Remove the cable end from the carburetor. If smooth choke operation is not obtainable, inspect for kinks, sharp bends in the routing or a linkage obstruction. 2.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 30: Idle Speed Adjustment

    2. 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. 2.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 31: Vent Lines

    Never drain the fuel when the engine is hot. 5. Turn fuel valve to ‘ON’. Severe burns may result. 6. Start engine and inspect for leaks. 2.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 32: Fuel Valve Location

    3. Replace fuel lines every two years. fuel line to drain completely. NOTE: For all other information related to the fuel System, refer to Chapter 4. Close Open Drain Screw 2.16 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 33: Throttle Pedal Inspection

    Decrease / Increase 1. Loosen the jam nut. 2. Turn the screw clockwise to increase speed or counter-clockwise to reduce speed. 3. Tighten the jam nut after adjusting. 2.17 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 34: Throttle Freeplay Adjustment

    4. Remove the carburetor slide assembly from the carburetor body and disconnect the throttle cable. 2.18 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 35 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. 2.19 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 36: Engine

    6. Reinstall the dipstick. crankcase should be clean and free of burrs, nicks or scratches. 9. Reassemble the pre-filter screen and spring to the pre-filter plug. 2.20 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 37: Engine Crankcase Ventilation System Inspection

    Periodically inspect engine/transmission upper and lower IMPORTANT: Over-filling engine crankcase will result mounts for cracks or damage. in oil entering the air box. Maintain the recommended oil level. 2.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 38: Compression / Leakdown Test

    6. Re-check the valve clearance. 7. Repeat adjustment procedure if necessary until clearance is correct with locknut secured. = In. / mm. Valve Clearance: .003” (.07 mm) 2.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 39: Exhaust - Spark Arrestor

    3. Inspect the screen for wear and damage. Replace if required. 4. Reinstall the arrestor and torque the fasteners to specification. Silencer Screen Retaining Arrestor Screws Spark Arrestor Fasteners: 7 ft-lbs (9.5 Nm) 2.23 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 40: Transmission

    (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 plug. 2.24 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 41: Final Drive / Wheel And Tire

    3. Place the wheel in the correct position on the wheel hub. Make sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 2.25 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 42: Tire Inspection

    3 psi (20.7 kPa) Tire Tread Depth Drive Chain Lubrication and Adjustment Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Periodic Maintenance Chart. Lubricate more often under severe use, such as in dirty or wet conditions.
  • Page 43 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. 2.27 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 44: Electrical And Ignition System

    4. Connect and tighten the red (positive) cable first. 5. Connect and tighten the black (negative) cable last. 6. Verify that cables are properly routed and reinstall the driver’s seat. 2.28 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 45: Battery Off Season Storage

    20 hrs less NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about Spark Plug Service once a month to make up for normal self-discharge. Battery tenders can be left connected during the 1.

  • Page 46: Engine To Frame Ground

    The ground cable runs from the engine starter motor to the ground terminal location under the driver’s seat. U-Joints Tie Rod Location Ground Gearbox Terminal Location 2.30 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 47: Steering Inspection / Tie Rod Ends And Hubs

    1/8” to 1/4” (.3 to .6 cm) wider than the measurement at the rear (B). = In. / mm. Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm) 2.31 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 48: Toe Adjustment

    Preload Special Tool: Shock Spanner Wrench 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 2.32 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 49: Brake System

    Brake Hose and Fitting Inspection Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 2.33 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 50: Parking Brake Cable Freeplay Adjustment

    5. After setting the correct amount of freeplay, tighten the in-line adjuster jam nut against adjuster. Inspect Freeplay Here Inline Adjuster Nut Jam Nut 2.34 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 51: Parking Brake Adjustment

    DOWN position), and that the vehicle will not move when the parking brake is applied (lever in the UP position). Hold Adjuster Bolt While Tightening Jam Nut 2.35 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 52: Maintenance Log

    MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2.36 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 53 OIL PUMP REMOVAL / DRIVE CHAIN INSPECTION ......3.31 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 54 GENERAL TROUBLESHOOTING ......... 3.51 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 55: Tools

    7-8 (9-11 Nm) Valve Adjuster Lock Nut 5mm 4-5 (5-7 Nm) Starter Motor 5-7 (7-9 Nm) Spark Plug 12mm 11 (15 Nm) Pulse Coil Screws 4-5 (5-7 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 56: Torque Patterns

    3 steps following the sequence outlined. Refer to the table for torque specifications. 6 mm Cylinder Base / Head and Rocker Assembly RH Crankcase - (Inside Stator Cover) RH Crankcase - Stator Cover 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 57: Engine Information

    ENGINE ENGINE INFORMATION Engine Exploded Views Cylinder Head Cylinder / Crankcase Crankshaft and Piston Valve Train 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 58: Engine Lubrication

    See text for oil control ring upper rail installation. Oversize Standard Piston Engine Model No. Available (mm) Identification ”IN” marking on ES35C top of piston toward intake 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 59: Engine Service Data

    Install new as a part of any crankshaft Cam Chain removal KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;  PTO: Power Take Off 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 60 Install new as a part of any crankshaft Cam Shaft Chain replacement KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 61: Oil Flow Diagram

    ENGINE Oil Flow Diagram 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 62: Engine Systems Service

    NOTE: Over-filling of crankcase will result in oil in the air box. Always keep oil volume at recommended level. 7-8 ft-lbs (9-11 Nm) To One-Way Valve To Air Box 7-8 ft-lbs (9-11 Nm) To Valve Cover To Crank Case 3.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 63: Emissions Secondary Air System

    7-8 ft-lbs (9-11 Nm) Air In 16 ft-lbs (22 Nm) To Intake (impulse) Air To Cylinder Head Exhaust Passage 7-8 ft-lbs (9-11 Nm) 7-8 ft-lbs (9-11 Nm) 3.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 64: Cooling Shroud Removal/Installation

    8. Install the upper and lower housings (C), making sure the snap-hooks are secure. Install the housing screws Cooling Shroud Exploded View MAG View PTO View A. Fan Shroud B. Air Horn Assembly C. Housing 3.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 65: Engine Removal

    Duty Oil, or API certified “SH” oil equivalent. • Use fuel with a minimum octane of 87 (R+M)/2 method. • Change break-in oil at 10 hours or 100 miles, whichever comes first. 3.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 66: Top-End Disassembly

    (A) for wear or damage. gasket surface, the cam lobes must be pointed downward and the rockers must have valve  clearance at this point. 3.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 67: Rocker Assembly

    NOTE: Always inspect camshaft lobes if rocker arms are worn or damaged. Inspect 3.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 68: Camshaft Removal

    4. If not removing the cylinder for other service, secure the cam chain with a wire to prevent it from falling into Lobe Height the crankcase. 3.16 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 69: Cylinder Head Removal

    Replace camshaft if damaged or if any part is worn reinforced areas or on thick parts of cylinder head excessively. casting to avoid damaging casting. 6. Remove cylinder head (A) and head gasket (B). 3.17 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 70: Cylinder Head Inspection

    (A). 3. Push valve out, keeping it in order for reassembly in the same guide. 3.18 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 71: Valve Inspection

    5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Replace if excessive wear is evident. Measure valve stem in several places 3.19 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 72: Valve Seat Reconditioning

    Wear eye protection when seat, check the pilot. Look for burrs, nicks, or performing cylinder head service. runout. If the pilot is bent it must be replaced. 3.20 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 73 • If too low use the 60 or 75 cutter to raise the seat. When contact area is centered on the valve face, measure seat width. 3.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 74: Cylinder Head Assembly

    3. Coat valve stem with molybdenum disulfide grease. repeat process for the other valve. 4. Install valve carefully with a rotating motion to avoid damaging valve seal. 3.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 75: Valve Sealing Test

    The valve seats should hold fluid with no leaking. 2. Remove chain guides and inspect for cracks, wear or damage. Replace assemblies as required. 3.23 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 76: Piston Removal

    1/2” Up From Bottom of a top and bottom steel rail and a center expander section. Remove the top rail first followed by the bottom rail and expander. 3.24 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 77: Cylinder Hone Selection / Honing Procedure

    Polaris 4 Cycle Lubricant to prevent the formation of surface rust. If cylinder wear or damage is excessive, it will be = In.

  • Page 78: Piston Ring Installed Gap

    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. 3.26 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 79: Bottom-End Disassembly

    2. Remove the fan hub by removing the flywheel nut, washer and pulling the hub from the crankshaft. Washer Flywheel Nut 3. Remove stator housing bolts and remove housing. 3.27 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 80: Flywheel Removal / Inspection

    7. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken. 8. Inspect the stator housing bearing. Replace if worn, rough or damaged. 3.28 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 81: Crankshaft One Way Gear / Drive Sprocket Removal/Inspection

    (A). PA-49935 3. Remove the starter drive one-way gear assembly (A) from the crankshaft. 4. Remove drive sprocket (D) and woodruff key from the crankshaft. 3.29 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 82: Starter Drive One-Way Clutch Removal And Inspection

    Replace component assembly. 3. Do not add specialized lubricants or greases to the bearing or one-way components, as this may cause undesirable operation. 3.30 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 83: Oil Pump Removal / Drive Chain Inspection

    4. Thoroughly clean all oil passages with clean solvent. 6. Inspect sprockets and gear teeth for wear or damage. 7. Inspect woodruff key for wear. 8. Replace any worn or damaged parts. 3.31 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 84 5. Install a new pump with the oil galley pointed down as shown. Install with the oil galley pointing down 6. Torque screws to specification. Oil Pump Screw: 4-5 ft-lbs (5-7 Nm) 3.32 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 85: Crankcase Disassembly

    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. 3.33 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 86: Crankshaft / Cam Chain / Sprocket Inspection

    2. Remove oil strainer and visually inspect for any damage or obstructions in screen. 4. Check oil passages to make sure they are clear. 3. Replace oil strainer if it fails visual inspection. 3.34 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 87: Engine Reassembly

    5. Press the mag and pto assembles together using a press. Verify the balance shaft is seated and both shafts turn freely once installed. 3.35 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 88: Chain Guide/Tensioner Installation

    5-6.5 ft-lbs (7-9 Nm) 7. Install the two mag side flange bolts and torque to specification. Crankcase Bolt Torque: 14 - 15 ft-lbs (19-21 Nm) Crankcase Sealant PN 2871557 3.36 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 89: Crankshaft, Balance Shaft And Starter Drive Gear Installation

    4. Using Slotted Nut Socket PA-47344, tighten the nut to Special Tool: the specified torque. PA-49935 Install Balance Shaft Slotted Nut: 43 ft-lbs(59 Nm) Special Tool: PA-47344 3.37 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 90: Oil Pump And Chain Installation

    Install with the oil galley pointing down Oil Pump Baffle Plate Screw: 5-7 ft-lbs (7-9 Nm) Oil Pump Cover Screw: 4-5 ft-lbs (5-7 Nm) 3.38 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 91: Piston Ring Installation

    Verify that the both directions to make sure the clips are properly ring gaps are 120 degrees apart from each other seated in the groove. before installation. 3.39 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 92: Cylinder Installation

    Place the cylinder on to the studs. 3. Loop the cam chain through the cylinder chain room and secure with mechanic’s wire. Seat the cylinder fully on the piston and support block. 3.40 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 93: Cylinder Head And Camshaft Installation

    3. Apply engine assembly 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. 3.41 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 94 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 and re-check marks/timing. 3.42 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 95 Method 1 - Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) Crankshaft Keyway ‘UP’ 3.43 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 96: Camshaft Timing Using Flywheel

    TDC on compression stroke (cam lobes facing downward) Single TDC Mark Aligned TDC Mark Rotation Cam Timing (View through timing inspection hole) Position crankshaft at TDC 3.44 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 97: Rocker Arm / Shaft Assembly

    2. Verify the cam is still in the TDC position before installing the rocker assembly onto the cylinder studs. Valve Cover/ Secondary Air Pipe Bolt: 7-8 ft-lbs (9-11 Nm) 3.45 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 98: Cam Chain Tensioner Installation

    Torque cap to specification. Valve Clearance: 4. Slowly rotate engine two to three revolutions and re- .003” (.07 mm) check cam timing once chain is tight. 3.46 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 99: Starter Drive Assembly

    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. 3.47 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 100: Stator Housing Installation

    5. Install the cooling shroud and tighten the fasteners sufficiently. Use care not to over-tighten. (#1, #2 RH case bolts) RH Crankcase - Stator Cover Stator Housing Bolt: 7-8 ft-lbs (9-11 Nm) 3.48 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 101: Exhaust System

    Chapter 2. Replace the Gasket Silencer Spark Arrestor 7-8 ft-lbs (9-11 Nm) 7-8 ft-lbs (9-11 Nm) 7-8 ft-lbs (9-11 Nm) 3.49 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 102: Troubleshooting

    • TRS switch limiting speed • Reverse speed limiter limiting speed • Carburetor vacuum slide sticking/diaphragm damaged • Incorrect ignition timing • Restricted exhaust system • Cam lobe worn 3.50 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 103 • Bent valve or stuck valve • Valve spring broken or weak • Valve not seating properly (bent or carbon accumulated on valve area) • Rocker arm sticking 3.51 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 104 ENGINE NOTES 3.52 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 105 POOR IDLE............4.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 106: Carburetion

    7-8 (9-11 Nm) Mount Bolt Fuel Tank Strap Bolts 17 (23 Nm) Crankcase Vent System Mount Bolts 7-8 (9-11 Nm) Secondary Air System Mount Bolts 7-8 (9-11 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 107: Carburetor Assembly

    FLOAT BOWL VENT NIPPLE FUEL INLET O-RINGS CHOKE LEVER / SPRING CHOKE CABLE SUPPORT ENGINE NEEDLE VALVE MAIN JET PILOT JET FLOAT / VALVE ASSEMBLY FLOAT BOWL BOWL DRAIN 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 108: Carburetor Service

    4. Inspect the drained fuel 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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 109: Carburetor Disassembly - Keihin

    5. Note the position of both the pilot mixture screw (J) and idle speed adjustment screw (K) and remove both from the carb body. 3. Remove the pilot jet (E). 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 110: Carburetor Cleaning

    IMPORTANT: Do not use wire or welding tip cleaners Needle as the orifice size may be altered. 5. Use low pressure air to dry carburetor body and all components. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 111: Float Height Adjustment

    Float Tongue 3. If adjustment is required, carefully bend the float tongue up or down to achieve the proper float height. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 112: Carburetor Assembly

    3. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. If not, inspect needle and seat and seat O-ring or gasket. Image for Reference Only 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 113: Fuel Tank

    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. Fuel Tank Strap Fastener Torque 17 ft-lbs (23 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 114: Fuel Tank Removal

    See Chapter 3. Remove the two tank straps by removing the four fasteners securing them to the frame. Front Strap Fasteners 4.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 115: Fuel Valve Service

    Chapter 2. When installing a new filter, verify the arrow points in the direction of the carburetor. Fuel Pump Pulse Line FILTER 4.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 116: Air Filter

    COVER GASKET INLET COVER AIR FILTER MESH SCREEN MID INTAKE TUBE INLET MOUNT AIR BOX AIR FILTER SPACER INTAKE TUBE OIL SEPARATOR HOSE NIPPLE SEDIMENT TRAP 4.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 117: Secondary Air Injection System

    The air injection filter housing houses a filter element and screen and should be cleaned as part of periodic SCREEN maintenance as outlined in Chapter 2. FILTER 4.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 118: Crankcase Ventilation System

    Never over-fill the oil level in the engine. Doing so may cause oil to accumulate inside the airbox. 4.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 119: Troubleshooting

    • 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 4.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 120 FUEL SYSTEM NOTES 4.16 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 121: Body / Suspension / Steering

    WHEELS ............. 5.32 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 122: General Information

    40 ft-lbs (55 Nm) Front / Rear Wheel Nuts 27 ft-lbs (37 Nm) Rear Axle Housing Bolts 72 ft-lbs (98 Nm) Rear Axle Clamp Bolts 36 ft-lbs (49 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 123: Body Removal

    Mounting Loops 4. Torque the front retaining nuts to specification. Passenger Seat Retaining Nuts: 10 ft-lbs (13.5 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 124: Front Bumper Removal / Installation

    4. Reverse this procedure to reinstall the front bumper. Tighten all fasteners securely. Body Component Fasteners: 16 in-lbs (1.8 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 125 6. Carefully remove the front cab frame from the vehicle. 7. Remove the (2) screws retaining the choke bracket. Cab Frame Fasteners: 20 ft-lbs (27 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 126: Rocker Panel Removal

    2. Remove the (6) screws retaining the rear bumper to the frame. Body Component Fasteners: 3. Reverse this procedure to reinstall the rear bumper. 16 in-lbs (1.8 Nm) Tighten all fasteners securely. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 127: Service Panel (Seat Shield) Removal

    3. Disengage the service panel from the sides of the rear cab and remove the panel from the vehicle. 4. Disconnect the battery leads and unhook the fuse holder from the console cover. Unhook Disconnect 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 128 Remove 7. Remove the shift knob cap. Remove the fastener and shift knob from the shift lever. Shift Knob 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 129: Key Switch / Indicator Light Replacement

    9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 130: Body Exploded View

    BODY / SUSPENSION / STEERING Body Exploded View 5.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 131: Cab Frame

    6. Torque all cab frame fasteners to specification. Cab Frame Fasteners: 20 ft-lbs (27 Nm) 7. Refer to the Owner’s Manual for the “Cab Nets and Storage Bag” installation procedure. 5.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 132: Main Frame

    BODY / SUSPENSION / STEERING MAIN FRAME Exploded View 36 ft-lbs (49 Nm) 36 ft-lbs (49 Nm) 17 ft-lbs (23 Nm) 5.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 133: Front A-Arms

    BODY / SUSPENSION / STEERING FRONT A-ARMS Exploded View 30 ft-lbs (41 Nm) 30 ft-lbs (41 Nm) 5.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 134 8. To reinstall, reverse steps 1-7. Torque fasteners to Retainer specification. A-arm to Spindle Castle Nut: 30 ft-lbs (41 Nm) Front Shock Mounting Bolt: 36 ft-lbs (49 Nm) Wheel Nuts: 27 ft-lbs (37 Nm) 5.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 135: Front Hub

    5. Remove the hub assembly from the spindle. Remove 3. Remove the cotter pin, castle nut and washers. Cotter Pin Washers 5.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 136: Hub Seal And Bearing Replacement

    4. Using an arbor press, install new bearings along with to specification. the spacer tube back into the hub. Brake Caliper Bolts: 18 ft-lbs (24 Nm) 5.16 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 137: Shocks

    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”). 5.17 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 138: Shock Replacement

    43 ft-lbs (58 Nm) 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”). 5.18 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 139: Rear Swing Arm

    84 in-lbs (22 Nm) (10 Nm) 72 ft-lbs (98 Nm) 36 ft-lbs (49 Nm) 72 ft-lbs (98 Nm) 16 ft-lbs (22 Nm) 72 ft-lbs (98 Nm) 5.19 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 140: Swing Arm Removal

    7. Remove the upper shock mounting bolts. Remove Remove 4. Loosen all (4) axle housing bolts. 5.20 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 141: Swing Arm Installation

    2. Line up the swing arm with the frame and install the through-bolts. Torque the swing arm bolts to Rear Axle Housing Bolts: specification. 72 ft-lbs (98 Nm) Swing Arm Mounting Bolts: 72 ft-lbs (98 Nm) 5.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 142: Rear Axle

    6. Remove the (2) fasteners retaining the LH axle 9. Remove the (2) axle retaining nuts and the (2) fasteners retaining the RH axle housing to the swing 5.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 143: Axle Housing Service

    Outer Nut: 72 ft-lbs (98 Nm) 3. Install the rear brake caliper and torque the mounting bolts to specification. Brake Caliper Bolts: 18 ft-lbs (24 Nm) 5.23 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 144: Axle Removal

    Rear Axle Housing Bolts: 72 ft-lbs (98 Nm) Axle Installation 1. Reverse the “Axle Removal” procedure. Axle Removal 1. Remove the axle housing fasteners (see “Axle Housing Removal”). 5.24 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 145 2. Torque the axle clamp bolts to specification. Axle Clamp Bolts: 36 ft-lbs (49 Nm) 3. Install the rear axle housing fasteners (see “Axle Housing Installation”). 5.25 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 146: Steering

    (15 Nm) 10 ft-lbs (13.5 Nm) 16-17 ft-lbs (22-23 Nm) 16-17 ft-lbs (22-23 Nm) 29-37 ft-lbs (39-50 Nm) 17 ft-lbs (23 Nm) 21 ft-lbs (28 Nm) 5.26 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 147: Steering Shaft Removal

    5. Install the upper pinch bolt and torque to specification. the steering pivot tube assembly to the frame. Steering Shaft Pinch Bolt: 29-37 ft-lbs (39-50 Nm) 5.27 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 148: Steering Gearbox Removal

    4. Carefully pry up on the tie rod plate and remove it from the steering gearbox. 5.28 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 149: Steering Gearbox Installation

    17 ft-lbs (23 Nm) 5. Install the front bumper if previously removed (see “Front Bumper Removal / Installation”). 6. Install the steering shaft (see “Steering Shaft Installation”). 5.29 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 150: Tie Rod

    BODY / SUSPENSION / STEERING TIE ROD Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View 5.30 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 151: Tie Rod Removal / Installation

    12-14 ft-lbs (17-19 Nm) Cotter Pin Tie Rod End Castle Nuts: 25 ft-lbs (34 Nm) NOTE: Refer to Chapter 2 “Maintenance” for the steering toe alignment procedure. 5.31 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 152: Wheels

    BODY / SUSPENSION / STEERING WHEELS Front Wheel Exploded View 5.32 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 153 Severe injury could occur if machine tips or falls. 5. Remove the wheel nuts and remove the wheel. 6. If removing the hub, take off the castle nut and washers(s). 5.33 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 154 If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. 5.34 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 155 PARKING BRAKE DRAGS OR INEFFECTIVE BRAKE......6.27 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 156 15 in-lb Hose Clamps Master Cylinder Reservoir 60 in-lb Hose Adaptor Clamp Parking Brake Adjuster Jam 12.0 16.0 Wheel Nuts, Front 27.0 37.0 Wheel Nuts, Rear 27.0 37.0 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 157: Brake System Service Notes

    If noise does not change when brake is applied check other sources. Inspect and repair as necessary Wrong pad for conditions Use only Pure Polaris replacement pads. Optional softer or harder pads may be available 9923983 - 2012-2013 RZR 170 Service Manual...

  • Page 158: Hydraulic Brake System - Overview Of Operation

    Do not fill it beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.

  • Page 159: Brake System - Mechanical Components

    BRAKE SYSTEM - MECHANICAL COMPONENTS Brake System - Mechanical Components 12 ft-lb (16 Nm) Brake Light Switch Spring Pedal Return Spring Parking Brake Cable Parking Brake Switch 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 160: Brake System - Hydraulic Components

    LH Front Caliper Adaptor Clamps 60 in-lbs. (6.8 Nm) Master Cylinder RH Front Caliper 1 (All Banjo Bolts) 52 in-lbs. (5.8 Nm) 60 in-lbs. (6.8 Nm) Rear Caliper 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 161: Brake Bleeding / Fluid Change

    Mity Vac™ (PN 2870975) CAUTION Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir at all times to prevent air from entering the master cylinder. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 162 Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir at all times to prevent air from entering the master cylinder. 11. Perform Steps 4-8 for the rear caliper. Open Close 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 163: Brake Pedal

    Pedal Travel 1 - 1 1/2 in. (25-37mm) Pedal Installation 1. Apply Polaris Premium All Season grease to pivot post and install pedal with bushings and sleeve. 2. Install washer and a new retaining E-clip. 3. Align pedal with master cylinder clevis and install pin.

  • Page 164: Parking Brake

    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 6.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 165: Parking Brake Cable Replacement

    4. Have an assistant help tip the vehicle toward the passenger side, or secure vehicle to a lift that allows access to the underside. 6.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 166 10. Connect caliper end of the cable. 11. Adjust parking brake and inspect cable freeplay. 2. Push 10. Remove cable from lever arm. 11. Pull cable out of holder on frame. 6.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 167: Front Brake Pads

    C-clamp or locking pliers with pads installed. Measure Thickness Front Brake Pad Thickness .300” ± .007” (7.6 mm ± .178 mm) Service Limit: .180” (4.6 mm) 6.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 168: Front Brake Pad Assembly / Caliper Installation

    7. Rotate wheel hub and verify the hub turns freely without brake drag. 8. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. 6.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 169: Front Brake Disc

    Replace disc if worn beyond service limit at any measurement point. Brake Disc Thickness Service Limit: .170" (4.32 mm) Brake Disc Thickness Variance Service Limit .002” (.051 mm) difference between measurements 6.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 170: Disc Replacement

    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. 6.16 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 171: Caliper Installation

    2. Place new sealing washers on each side of brake line banjo fitting and install banjo bolt. NOTE: If new brake pads are installed, brake burnishing is recommended. See “Brake Burnishing Procedure” on page 6.21. 6.17 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 172: Rear Brake Pad

    4. Remove caliper mounting bolts (A) and lift caliper off disc. NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 6.18 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 173: Rear Brake Pad Inspection

    Rotate pad and remove. Service Limit .180" (4.6 mm) 9. Inspect caliper piston seals for signs of brake fluid leakage. Replace caliper if leaking. 6.19 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 174: Rear Brake Pad Assembly / Caliper Installation

    Maintain at least 1/2 inch (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 7. Adjust parking brake. See “Parking Brake Cable Freeplay Adjustment” on page 6.10. 6.20 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 175: Brake Burnishing Procedure

    1. Visually inspect disc for scoring, scratches, or gouges. If any deep scratches are evident, replace Brake Disc Runout the disc . Service Limit .010” (.254 mm) 6.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 176: Rear Brake Disc Replacement

    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. 6.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 177: Rear Caliper Service

    Brake line with park brake cable. 4. Tie straps - secure brake line with throttle cable in areas (A). Secure with parking brake cable to frame in area (B). 6.23 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 178: Rear Brake Caliper Installation

    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-lbs. (16 Nm). 6.24 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 179: Master Cylinder

    4. Remove front and rear brake line banjo bolts (B). Immediately cover and seal ends of brake lines to prevent contamination. NOTE: Note brake line locations on master cylinder. 6.25 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 180: Installation

    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.

  • Page 181: Troubleshooting

    • Mechanical parts sticking (brake pedal, parking brake lever, etc.) • Caliper pistons sticking • Master cylinder piston sticking • Improper assembly of brake system components 6.27 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 182 BRAKES NOTES 6.28 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 183 OUTPUT SHAFT HOUSING DISASSEMBLY / ASSEMBLY .....7.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 184: Specifications / Tools

    14 (19 Nm) Transmission  6-8 (8-11 Nm) Cover Bolts Special Tools PART NUMBER TOOL DESCRIPTION PA-49959 Output Shaft Collar Nut Socket SPX Corp: 1-800-328-6657 or http://polaris.spx.com/ 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 185: Cvt System

    All CVT maintenance or repairs should be performed created, causing the rollers to push against the cam plate only by a certified Polaris Master Service Dealer (MSD) and force the moveable sheave toward the drive belt. This technician who has received the proper training and motion pinches the drive belt between the spinning understands the procedures outlined in this manual.

  • Page 186: Cvt System Drying

    CVT Air Duct System Air Outlet Duct 36 in-lb. (4.0 Nm) Air Inlet Duct Clamps 25 in-lb. (2.8 Nm) 36 in-lb. (4.0 Nm) Clamps 25 in-lb. (2.8 Nm) Boot Boot 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 187: Clutch (Cvt) Cover Removal / Inspection

    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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 188: Drive Belt Removal

    (mm) of spline is exposed. If less than 5/16 is exposed, remove clutch and sleeve and check assembly of components. 3. Remove drive clutch nut (A). Use a strap wrench to hold stationary sheave. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 189 FULL engagement of stationary sheave splines with shaft splines. 6. Hold stationary sheave with a strap wrench. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 190: Drive Clutch Service

    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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 191: Drive Clutch Assembly

    2. Use a strap wrench to hold drive hub and remove driven clutch retaining nut. 3. Pull outward on driven clutch and tap shaft with a soft Drive Hub I. D. Service Limit: 4.43” (112.5 mm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 192 Driven Compression Spring Length Service Limit: 2.74” (69.7mm) 8. Remove (3) rollers and pins (D). Inspect roller tracks (E) in moveable sheave. Refer to Fig. 2. 7.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 193: Driven Clutch Assembly

    5. Clean threads (E) to remove all oil, grease, or old locking agent then apply a few drops of Loctite 272. 7.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 194: Driven Clutch Installation

    4. Install drive hub and engage splines of drive hub to splines of transmission input shaft. 5. Install driven clutch nut. Tighten nut to specified torque. 7.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 195: Transmission Service

    7. Turn output shaft by hand to check for smooth rotation. Push on splined end and gear end of shaft. There 4. Remove angle drive inspection / oil fill cover. 7.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 196 13. Inspect gear teeth and bearing. If components are replaced, inspect output gear pinion depth and adjust with shims as required. See “Output Gear Pinion Depth Adjustment” on page 7.21 for procedure. 7.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 197 16. Push and release the spring loaded gear position switch plunger (F). Be sure it moves freely inward and 19. Remove shift fork. extends under spring pressure when released. 7.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 198 23. Pull main shaft from case with thrust washer on inside end. 27. Inspect mainshaft components. See “Transmission Main Shaft Assembly View” on page 7.18 7.16 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 199: Input Shaft Removal / Inspection

    Input Shaft Removal / Inspection 1. Remove bearing stop screw and washer (A). 2. Tap input shaft from CVT side to remove shaft with bearing. 87 in-lbs (9.8 Nm) 7.17 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 200: Transmission Main Shaft Assembly View

    Inspect needle sliding dog gear (F), snap ring retainer (G), splined bearing (M). washer (H), gear with needle bearing (I), and thrust washer (J). Fig. 3 7.18 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 201: Transmission Assembly

    Transmission Cover Screws: 6-8 ft-lbs (8-11 Nm) 4. Install and torque drain plug. Oil Drain Plug: 18 ft-lbs (24.5 Nm) 7.19 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 202 (G) pointing down. 9. After installation in the frame, adjust shift cables in the following manner: • Place gear selector in NEUTRAL 7.20 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 203: Output Gear Pinion Depth Adjustment

    - .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 and gears bottomed.  7.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 204: Output Shaft Housing Disassembly / Assembly

    7. Install new seal (D) in housing with spring side of seal facing pinion gear. 13. Install new O-ring (G) on housing after Step 12 is completed. 72ft-lbs (98Nm) 7.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 205 STARTER SYSTEM TESTING ......... . . 8.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 206: General Information

    (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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 207: Brake Pedal / Parking Brake Switches

    .5 ohms when the brake is lever is pulled, which signals the CDI to limit engine RPM. applied with slight pressure. 1. Locate the parking brake and brake pedal switches. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 208: Throttle Release Switch (Trs)

    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. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 209: Daytime Running Lights

    3. If continuity is good, perform stator resistance tests and related wiring for possible malfunction. using the resistance chart located in the wiring diagram. 4. Replace Generator / Stator if resistance is not within specification. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 210: Tail Light

    “Neutral” or “Reverse” to verify light operation. 8. If the lights do not operate, check battery voltage at the light harness and check related wiring for possible malfunction. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 211: Transmission Switch

    2. First, shift the transmission into “neutral” and test for continuity between the DG/WH wire and ground. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 212: Removal

    • Flywheel loose or damaged • Excessive crankshaft runout on magneto. (RH) end should not exceed .005” • Faulty CDI module Indicator Switch Screw: 39-52 in-lbs (4.5-6 Nm) 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 213: Ignition System Testing

    If vehicle still has no spark, repeat troubleshooting steps. Pay close attention to condition of wires and connections. 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 214: Rpm Ignition Limiter Functions

    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 or stuck. 8.10 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 215: Rpm Limiter Specifications

    CDI output to the ignition coil. When finished, reconnect CDI output wire to ignition coil. Connect Meter Output Test Reading Leads To: BLK/YEL to CDI Output 180 DC Volts ± 20% Engine Ground 8.11 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 216: Charging System

    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. 8.12 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 217: Main Fuse / Fuse Holder Location

    NOTE: To check the charging system output further, start the engine and perform the same tests. Voltage should increase with increased RPM. Maximum Stator Output 6.5 Amps @ W.O.T. 8.13 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 218: Battery

    5. Charge the battery initially for 3 to 5 hours using Christie Charger (PA-37453) or a charger with an output capable of 1/10th the battery’s amp-hour rating. 8.14 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 219: Battery Removal

    Coat the cranking voltage drops below 9.5 volts during the test, terminals with dielectric grease or petroleum jelly. replace the battery. 8.15 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 220: Battery Charging Procedure

    Conductance OLTAGE CTION HARGE testing is more accurate than voltage, specific gravity, or Charge load testing. FULL None Authorized Polaris dealers/distributors are required to use 100% 12.8-13.0 None Required the conductance analyzer when testing 12V Polaris batteries. Slight 12.5-12.8...

  • Page 221: Starter System

    Check the parts manual for replacement part information. 1. Disconnect the negative battery cable and starter motor harness. Remove the (2) bolts from the starter and pull it from the engine. 8.17 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 222: Starter Brush Inspection / Replacement

    4. Be sure that the terminal bolt insulation washer is properly seated in the housing and the tab on the brush plate engages the notch in the brush plate housing. 8.18 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 223: Armature Test

    (.3 cm) above armature coil laminates. Rotate armature 360°. If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced. 8.19 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 224: Starter System Troubleshooting

    Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 8.20 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

  • Page 225: Starter System Testing

    Check the function of the foot Replace foot brake brake switch. pedal switch. Is there continuity between the DG/ YEL and BROWN wires when the foot brake pedal is pressed? 8.21 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 226 ELECTRICAL NOTES 8.22 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 227 Cam Chain Tensioner, Inspection ... . . 3.14 Daytime Running Lamps, Replacement ..8.5 IX.1 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 228 Hand Brake, ......2.35 6.10 Hand Brake, Assembly View ....6.5 IX.2 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 229 Specification, Tensioner Blade Bolt Torque ..3.36 Specification, Tie Rod Jam Nut Torque ..5.31 IX.3 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.
  • Page 230 5.34 Wheel, Removal ..... 2.25 5.33 IX.4 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc.

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