Polaris RZR 170 (2009) - Workshop Manual - Wiring Schematics - User Manual

POLARIS RZR 170 (2009) - REPAIR, SERVICE, WORKSHOP MANUAL - OWNERS

- English Workshop Manual, Wiring Schematics and User Manual to Polaris RZR 170.



INDEX:


SERVICE MANUAL:

9922134 CH 01

- TABLE OF CONTENTS
- MODEL INFORMATION
- Model Identification
- Engine Designation Number
- VIN Identification
- Engine Serial Number Location
- Unit Serial Number (VIN) and Emissions Decal Locations
- VEHICLE INFORMATION
- Publication Numbers
- Paint Codes
- Replacement Keys
- SPECIAL TOOLS
- GENERAL SPECIFICATIONS
- MODEL: 2009 RANGER RZR 170
- MODEL: 2009 RANGER RZR 170
- MISC. SPECIFICATIONS AND CHARTS
- Conversion Table
- Standard Torque Specifications
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

- Glossary of Terms

9922134 CH 02

- TABLE OF CONTENTS
- PERIODIC MAINTENANCE CHART
- Periodic Maintenance Overview
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 30 - 100 Hour Maintenance Interval
- MAINTENANCE REFERENCES / SERVICE LOCATIONS
- Front and Rear View
- RH and LH Side Views
- LUBRICANTS / SERVICE PRODUCTS
- Polaris Lubricants, Maintenance and Service Products
- MAINTENANCE REFERENCES
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, and Fasteners
- Shift Cable Inspection / Adjustment
- Shift Cable Replacement
- FUEL SYSTEM AND AIR INTAKE
- Air Filter Service
- Choke Cable Adjustment
- Choke Cable Replacement
- Idle Speed Adjustment
- Pilot Air Screw Adjustment
- Vent Lines
- Fuel System
- Fuel Filter
- Fuel Valve Location
- Carburetor Draining
- Fuel Pump / Fuel Lines
- Throttle Pedal Inspection
- Throttle Stop Speed Control
- Throttle Freeplay Adjustment
- Throttle Cable Replacement
- ENGINE
- Engine Oil Level
- Engine Oil Change
- Engine Crankcase Ventilation System Inspection
- Engine/Transmission Mount Locations
- Compression / Leakdown Test
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Exhaust - Spark Arrestor
- TRANSMISSION
- Transmission Specification Chart
- Transmission Oil Change
- FINAL DRIVE / WHEEL AND TIRE
- Wheel, Hub, and Spindle Torque Table
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure
- Drive Chain Lubrication and Adjustment
- ELECTRICAL AND IGNITION SYSTEM
- Battery Maintenance
- Battery Removal
- Battery Installation
- Battery Off Season Storage
- Battery Charging (Maintenance Free)
- Spark Plug Service
- Engine To Frame Ground
- STEERING
- Steering Inspection
- Steering Wheel Freeplay
- Steering Inspection / Tie Rod Ends and Hubs
- Toe Alignment Inspection
- Toe Adjustment
- SUSPENSION
- Spring Preload Adjustment
- BRAKE SYSTEM
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- Brake Hose and Fitting Inspection
- MAINTENANCE LOG

9922134 CH 03

- TABLE OF CONTENTS
- TOOLS
- Special Tools
- TORQUE SPECIFICATIONS
- Engine Torque Specifications
- Torque Patterns
- ENGINE INFORMATION
- Engine Exploded Views
- Engine Lubrication
- Piston Identification
- Accessible Components
- Engine Service Data
- Engine Service Data
- Oil Flow Diagram
- ENGINE SYSTEMS SERVICE
- Breather / Oil Separator
- Emissions Secondary Air System
- Cooling Shroud Removal/Installation
- Engine Removal
- Engine Installation Notes
- TOP-END DISASSEMBLY
- Engine Removal/Installation
- Finding Top Dead Center (TDC)
- Cam Chain Tensioner Inspection
- Rocker Assembly Disassembly and Inspection
- Camshaft Removal
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp Inspection
- Combustion Chamber Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Removal
- Cam Chain Follower / Tensioner Guide Removal
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection / Honing Procedure
- Honing to Deglaze
- Piston Inspection
- Piston Ring Installed Gap
- BOTTOM-END DISASSEMBLY
- Starter Drive Gear Removal and Inspection
- Flywheel Removal / Inspection
- Crankshaft One Way Gear / Drive Sprocket Removal and Inspection
- Starter Drive One-way Clutch Removal and Inspection
- Balance Shaft Sprocket Removal and Inspection
- Oil Pump Removal / Drive Chain Inspection
- CRANKCASE DISASSEMBLY
- Crankcase Separation and Cam Chain Removal
- Crankshaft Removal
- Crankshaft / Cam Chain / Sprocket Inspection
- Crankcase / Bearing Inspection
- Crankcase Oil Strainer Inspection
- ENGINE REASSEMBLY
- Bearing / Seal Installation
- Crankcase Reassembly
- Chain Guide/Tensioner Installation
- Crankshaft, Balance Shaft and Starter Drive Gear Installation
- Oil Pump and Chain Installation
- Piston Ring Installation
- Piston Installation
- Cylinder Installation
- Cylinder Head and Camshaft Installation
- Camshaft Timing
- Rocker Arm / Shaft Assembly
- Rocker Assembly Installation
- Cam Chain Tensioner Installation
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Starter Drive Assembly
- Flywheel Installation
- Stator Installation
- Stator Housing Installation
- Exhaust System
- TROUBLESHOOTING
- Spark Plug Fouling
- General Troubleshooting

9922134 CH 05

- TABLE OF CONTENTS
- GENERAL INFORMATION
- Special Tools
- Torque Specifications
- BODY REMOVAL
- Seat Removal
- Seat Installation
- Front Bumper Removal / Installation
- Front Cab Removal / Installation
- Rocker Panel Removal
- Rear Bumper Removal / Installation
- Rear Cab Removal
- Service Panel (Seat Shield) Removal
- Console Cover Removal
- Key Switch / Indicator Light Replacement
- Decal Replacement
- Body Exploded View
- CAB FRAME
- Exploded View
- Cab Frame Assembly
- MAIN FRAME
- Exploded View
- FRONT A-ARMS
- Exploded View
- A-arm Replacement
- FRONT HUB
- Hub Removal
- Hub Seal and Bearing Replacement
- Hub Installation
- SHOCKS
- Shock Exploded View
- Shock Removal
- Shock Replacement
- Shock Installation
- REAR SWING ARM
- Exploded View
- Swing Arm Removal
- Swing Arm Installation
- REAR AXLE
- Axle Housing Removal
- Axle Housing Service
- Axle Housing Installation
- Axle Removal
- Axle Installation
- STEERING
- Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View
- Steering Shaft Removal
- Steering Shaft Installation
- Steering Gearbox Removal
- Steering Gearbox Installation
- TIE ROD
- Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View
- Tie Rod Removal / Installation
- WHEELS
- Front Wheel Exploded View
- Rear Wheel Exploded View
- Wheel Removal
- Wheel Installation

9922134 CH 06

- TABLE OF CONTENTS
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION
- BRAKE SYSTEM - MECHANICAL COMPONENTS
- Brake System - Mechanical Components
- BRAKE SYSTEM - HYDRAULIC COMPONENTS
- BRAKE BLEEDING / FLUID CHANGE
- BRAKE PEDAL
- Brake Pedal Removal
- Pedal Installation
- Brake Pedal Inspection / Adjustment
- PARKING BRAKE
- Parking Brake Adjustment
- Parking Brake Cable Replacement
- FRONT BRAKE PADS
- Front Pad Removal
- Pad Inspection
- Front Brake Pad Assembly / Caliper Installation
- FRONT BRAKE DISC
- Disc Inspection
- Disc Replacement
- FRONT CALIPER
- Front Caliper Removal
- Caliper Installation
- REAR BRAKE PAD
- Rear Brake Pad Removal
- Rear Brake Pad Inspection
- Rear Brake Pad Assembly / Caliper Installation
- Brake Burnishing Procedure
- REAR BRAKE DISC
- Disc Inspection
- Rear Brake Disc Replacement
- REAR CALIPER SERVICE
- Rear Caliper Removal
- Rear Brake Caliper Installation
- MASTER CYLINDER
- Removal
- Installation
- TROUBLESHOOTING
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
- Parking Brake Drags or Ineffective Brake

9922134 CH 07

- TABLE OF CONTENTS
- SPECIFICATIONS / TOOLS
- Torque Specifications
- Special Tools
- CVT SYSTEM
- CVT Maintenance / Inspection
- Drive Clutch Operation
- Driven Clutch Operation
- CVT System Drying
- CVT Overheating / Water Ingestion Diagnostics
- Clutch (CVT) Cover Removal / Inspection
- Clutch (CVT) Cover Installation
- Drive Belt Removal
- Drive Belt Inspection
- Drive Belt Installation
- DRIVE CLUTCH SERVICE
- Drive Clutch Removal, Disassembly and Inspection
- Drive Clutch Assembly
- DRIVEN CLUTCH SERVICE
- Driven Clutch Removal, Disassembly, Inspection
- Driven Clutch Assembly
- Driven Clutch Installation
- TRANSMISSION SERVICE
- Transmission Disassembly and Inspection
- Input Shaft Removal / Inspection
- Transmission Main Shaft Assembly View
- Transmission Assembly

- Output Gear Pinion Depth Adjustment
- Output Shaft Housing Disassembly / Assembly

9922134 CH 08

- TABLE OF CONTENTS
- GENERAL INFORMATION
- Special Tools
- Electrical System Service Notes
- SWITCHES AND CONTROLS
- Key Switch
- Brake Pedal / Parking Brake Switches
- Electronic Throttle Control (ETC)
- ETC Operation
- ETC Switch Adjustment
- DAYTIME RUNNING LIGHTS
- “DRL” Test
- “DRL” Lamp Replacement
- TAIL LIGHT
- Tail Light Lamp Replacement
- INDICATOR LAMPS
- Indicator Lamp Replacement
- TRANSMISSION SWITCH
- Transmission Switch - Circuit Breakout
- Testing
- Removal
- Installation
- IGNITION SYSTEM
- Overview
- Ignition System Troubleshooting
- Ignition System Testing
- RPM Ignition Limiter Functions
- RPM Limiter Specifications
- Ignition Coil Test
- CDI Output Test Using Peak Reading Adaptor
- Pulser Coil Output / Resistance Tests
- CHARGING SYSTEM
- Charging System Testing
- Main Fuse / Fuse Holder Location
- Voltage Regulator / Rectifier
- Stator / Alternator Tests
- BATTERY
- Battery Maintenance Service Notes
- New Battery Activation
- Battery Removal
- Battery Cleaning
- Battery Installation
- Battery Voltage Test
- Battery Load Test
- Battery Charging Procedure
- Battery Storage
- STARTER SYSTEM
- Starter Relay
- Starter Motor Service
- Starter Disassembly
- Starter Brush Inspection / Replacement
- Armature Test
- Starter Reassembly
- Voltage Drop Test
- Starter System Troubleshooting
- Starter System Testing

9922134 WIRE DIAGRAM




OWNER'S MANUAL:


WELCOME
 
- Dear Parents
- Dear Young Operators

TABLE OF CONTENTS

INTRODUCTION

- Vehicle Identification Numbers

SAFETY

- Equipment Modifications
- Safe Riding Gear
- Safety Warnings
- Safety Labels and Locations

FEATURES AND CONTROLS

- Component Locations
- Seats
- Steering Wheel
- Passenger Hand Hold
- Seat Belts
- Cab Nets/Side Guards
- Fuel Cap
- Fuel Valve
- Ignition Switch
- Choke
- Gear Selector
- Parking Brake
- Brake Pedal
- Throttle Pedal
- Speed Control System

OPERATION

- Vehicle Break-in Period
- Pre-Ride Inspection
- Safe Operation Practices
- Starting the Engine
- Stopping the Engine
- Braking
- Parking the Vehicle
- New Operator Driving Procedures
- Driving with a Passenger
- Driving on Slippery Surfaces
- Driving Uphill
- Driving on a Sidehill
- Driving Downhill
- Driving Through Water
- Driving Over Obstacles
- Driving in Reverse
- Parking on an Incline

EMISSION CONTROL SYSTEMS

- Noise Emission Control System
- Operation on Public Lands in the U.S.A.
- Crankcase Emission Control System
- Exhaust Emission Control System
- Electromagnetic Interference

MAINTENANCE

- Periodic Maintenance Chart
- Lubrication Recommendations
- Engine Oil
- Transmission (Main Gearcase)
- Drive Chain Lubrication
- Drive Chain Slack
- Drive Chain Slack Adjustment
- Parking Brake Adjustment
- Spark Plugs
- Constant Variable Transmission (CVT) System
- Filter Systems
- Spark Arrestor
- Throttle System
- Carburetor
- Carburetor/Engine Idle Rpm Adjustment
- Brakes
- Steering Wheel Inspection
- Shock Spring Adjustment
- Toe Alignment
- Tires
- Front Wheel Hub Tightening
- Wheel Nut Torque Specifications
- Lights
- Vehicle Immersion
- Battery
- Cleaning and Storage
- Transporting the Vehicle

SPECIFICATIONS

POLARIS PRODUCTS

TROUBLESHOOTING

DECLARATION OF CONFORMITY

WARRANTY

MAINTENANCE LOG

INDEX