Polaris RZR 170 (2009) - Workshop Manual - Wiring Diagram

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

- English Workshop Manual, Wiring Diagram and Owners Manual to Polaris RZR 170.

CONTENTS:

WORKSHOP 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