Polaris RZR 170 UTV Shop Manual 2012 – 2015
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Polaris RZR 170 UTV Shop Manual 2012 – 2015
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.
Periodic Maintenance Overview:
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.
- Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour.
- Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
TABLE OF CONTENTS:
Polaris RZR 170 UTV Shop Manual 2012 – 2015
KEYWORD SEARCH....................................................................... 0 GENERAL INFORMATION ................................................................. 5 MODEL Number Designations........................................................ 6 Model Number Designation..................................................... 6 Vehicle Identification Number.................................................... 6 VIN Number Designation....................................................... 6 Engine Designation Number.................................................... 6 Engine Serial Number Location................................................ 6 Unit Serial Number (VIN) and Emissions Decal Locations....................... 7 VEHICLE INFORMATION.............................................................. 8 Publication Numbers.......................................................... 8 Paint Codes.................................................................. 8 Replacement Keys............................................................. 8 SPECIAL TOOLS.................................................................... 9 GENERAL SPECIFICATIONS........................................................... 10 MODEL: 2012 RANGER RZR 170................................................... 10 MODEL: 2012 RANGER RZR 170................................................... 11 MODEL: 2013 RANGER RZR 170................................................... 12 MODEL: 2013 RANGER RZR 170................................................... 13 MISCELLANEOUS SPECIFICATIONS AND CHARTS.......................................... 14 Standard Bolt Torque Specification........................................... 14 Metric Bolt Torque Specification............................................. 14 Conversion Table............................................................. 15 SAE Tap Drill Sizes.......................................................... 16 Metric Tap Drill Sizes....................................................... 16 Decimal Equivalents.......................................................... 16 MAINTENANCE ......................................................................... 17 PERIODIC MAINTENANCE CHART....................................................... 19 Periodic Maintenance Overview................................................ 19 Maintenance Chart Key........................................................ 19 Pre-Ride - 25 Hour Maintenance Interval...................................... 20 30 - 100 Hour Maintenance Interval........................................... 21 MAINTENANCE REFERENCES / SERVICE LOCATIONS....................................... 22 Front and Rear View.......................................................... 22 RH and LH Side Views......................................................... 23 LUBRICANTS / SERVICE PRODUCTS.................................................... 24 Polaris Lubricants, Maintenance and Service Products......................... 24 MAINTENANCE REFERENCES........................................................... 25 GENERAL VEHICLE INSPECTION AND MAINTENANCE....................................... 26 Pre-Ride / Daily Inspection.................................................. 26 Frame, Nuts, Bolts, and Fasteners............................................ 26 Shift Cable Inspection / Adjustment.......................................... 26 Shift Cable Replacement...................................................... 27 FUEL SYSTEM AND AIR INTAKE....................................................... 28 Air Filter Service........................................................... 28 Choke Cable Adjustment....................................................... 29 Choke Cable Replacement...................................................... 29 Idle Speed Adjustment........................................................ 30 Pilot Air Screw Adjustment................................................... 30 Vent Lines................................................................... 31 Fuel System.................................................................. 31 Fuel Filter.................................................................. 31 Fuel Valve Location.......................................................... 32 Carburetor Draining.......................................................... 32 Fuel Pump / Fuel Lines....................................................... 32 Throttle Pedal Inspection.................................................... 33 Throttle Stop Speed Control.................................................. 33 Throttle Freeplay Adjustment................................................. 34 Throttle Cable Replacement................................................... 34 ENGINE........................................................................... 36 Engine Oil Level............................................................. 36 Engine Oil Change ........................................................... 36 Engine Crankcase Ventilation System Inspection............................... 37 Engine/Transmission Mount Locations.......................................... 37 Compression / Leakdown Test.................................................. 38 Intake Valve Clearance Adjustment............................................ 38 Exhaust Valve Clearance Adjustment........................................... 38 Exhaust - Spark Arrestor..................................................... 39 TRANSMISSION..................................................................... 40 Transmission Specification Chart............................................. 40 Transmission Oil Change...................................................... 40 FINAL DRIVE / WHEEL AND TIRE..................................................... 41 Wheel, Hub, and Spindle Torque Table......................................... 41 Wheel Removal................................................................ 41 Wheel Installation........................................................... 41 Tire Inspection.............................................................. 42 Tire Pressure................................................................ 42 Drive Chain Lubrication and Adjustment....................................... 42 ELECTRICAL AND IGNITION SYSTEM................................................... 44 Battery Maintenance.......................................................... 44 Battery Removal.............................................................. 44 Battery Installation......................................................... 44 Battery Off Season Storage................................................... 45 Battery Charging (Maintenance Free).......................................... 45 Spark Plug Service........................................................... 45 Engine To Frame Ground....................................................... 46 STEERING......................................................................... 46 Steering Inspection.......................................................... 46 Steering Wheel Freeplay...................................................... 46 Steering Inspection / Tie Rod Ends and Hubs ................................. 47 Toe Alignment Inspection..................................................... 47 Toe Adjustment............................................................... 48 SUSPENSION....................................................................... 48 Spring Preload Adjustment.................................................... 48 BRAKE SYSTEM..................................................................... 49 Brake Fluid Inspection....................................................... 49 Brake Pad / Disc Inspection.................................................. 49 Brake Hose and Fitting Inspection............................................ 49 Parking Brake Cable Freeplay Adjustment...................................... 50 Parking Brake Adjustment..................................................... 51 MAINTENANCE LOG.................................................................. 52 ENGINE .............................................................................. 53 TOOLS............................................................................ 55 Special Tools................................................................ 55 TORQUE SPECIFICATIONS............................................................ 55 Engine Torque Specifications................................................. 55 Torque Patterns.............................................................. 56 ENGINE INFORMATION............................................................... 57 Engine Exploded Views........................................................ 57 Engine Lubrication........................................................... 58 Piston Identification........................................................ 58 Accessible Components........................................................ 58 Engine Service Data.......................................................... 59 Engine Service Data.......................................................... 60 Oil Flow Diagram............................................................. 61 ENGINE SYSTEMS SERVICE........................................................... 62 Breather / Oil Separator..................................................... 62 Emissions Secondary Air System............................................... 63 Cooling Shroud Removal/Installation.......................................... 64 Engine Removal............................................................... 65 Engine Installation Notes.................................................... 65 TOP-END DISASSEMBLY.............................................................. 66 Engine Removal/Installation.................................................. 66 Finding Top Dead Center (TDC)................................................ 66 Cam Chain Tensioner Inspection............................................... 66 Rocker Assembly Disassembly and Inspection................................... 67 Camshaft Removal............................................................. 68 Camshaft Inspection.......................................................... 68 Cylinder Head Removal........................................................ 69 Cylinder Head Inspection..................................................... 70 Cylinder Head Warp Inspection................................................ 70 Combustion Chamber Inspection................................................ 70 Cylinder Head Disassembly.................................................... 70 Valve Inspection............................................................. 71 Valve Seat Reconditioning.................................................... 72 Cylinder Head Assembly....................................................... 74 Valve Sealing Test........................................................... 75 Cylinder Removal............................................................. 75 Cam Chain Follower / Tensioner Guide Removal................................. 75 Piston Removal............................................................... 76 Cylinder Inspection.......................................................... 76 Cylinder Hone Selection / Honing Procedure................................... 77 Honing to Deglaze............................................................ 77 Piston Inspection............................................................ 77 Piston Ring Installed Gap.................................................... 78 BOTTOM-END DISASSEMBLY........................................................... 79 Starter Drive Gear Removal and Inspection.................................... 79 Flywheel Removal / Inspection................................................ 80 Crankshaft One Way Gear / Drive Sprocket Removal and Inspection.............. 81 Starter Drive One-way Clutch Removal and Inspection.......................... 82 Balance Shaft Sprocket Removal and Inspection................................ 82 Oil Pump Removal / Drive Chain Inspection.................................... 83 CRANKCASE DISASSEMBLY............................................................ 85 Crankcase Separation and Cam Chain Removal................................... 85 Crankshaft Removal........................................................... 85 Crankshaft / Cam Chain / Sprocket Inspection................................. 86 Crankcase / Bearing Inspection............................................... 86 Crankcase Oil Strainer Inspection............................................ 86 ENGINE REASSEMBLY................................................................ 87 Bearing / Seal Installation.................................................. 87 Crankcase Reassembly......................................................... 87 Chain Guide/Tensioner Installation........................................... 88 Crankshaft, Balance Shaft and Starter Drive Gear Installation................ 89 Oil Pump and Chain Installation.............................................. 90 Piston Ring Installation..................................................... 91 Piston Installation.......................................................... 91 Cylinder Installation........................................................ 92 Cylinder Head and Camshaft Installation...................................... 93 Camshaft Timing.............................................................. 93 Rocker Arm / Shaft Assembly.................................................. 97 Rocker Assembly Installation................................................. 97 Cam Chain Tensioner Installation............................................. 98 Intake Valve Clearance Adjustment............................................ 98 Exhaust Valve Clearance Adjustment........................................... 98 Starter Drive Assembly....................................................... 99 Flywheel Installation........................................................ 99 Stator Installation.......................................................... 99 Stator Housing Installation..................................................100 Exhaust System...............................................................101 TROUBLESHOOTING..................................................................102 Spark Plug Fouling ..........................................................102 General Troubleshooting......................................................102 FUEL SYSTEM .........................................................................105 Carburetion......................................................................106 Special Tools................................................................106 Carburetor Function..........................................................106 Torque Specifications........................................................106 Carburetor Assembly..........................................................107 Carburetor Service...............................................................108 Carburetor Float Bowl Draining...............................................108 Carburetor Removal...........................................................108 Carburetor Disassembly - Keihin..............................................109 Carburetor Cleaning..........................................................110 Carburetor Inspection........................................................110 Float Height Adjustment......................................................111 Carburetor Assembly..........................................................112 Needle and Seat Leak Test....................................................112 Fuel Tank........................................................................113 Assembly View................................................................113 Fuel Tank Removal............................................................114 Fuel Valve Service...........................................................115 Fuel Filter..................................................................115 Fuel Pump Assembly...........................................................115 Air Filter.......................................................................116 Assembly View................................................................116 Secondary Air Injection System...............................................117 Crankcase Ventilation System.................................................118 Troubleshooting..................................................................119 Fuel Starvation / Lean Mixture...............................................119 Rich Mixture.................................................................119 Poor Idle....................................................................119 BODY / SUSPENSION / STEERING ........................................................121 GENERAL INFORMATION..............................................................122 Special Tools................................................................122 Torque Specifications........................................................122 BODY REMOVAL.....................................................................123 Seat Removal.................................................................123 Seat Installation............................................................123 Front Bumper Removal / Installation..........................................124 Front Cab Removal / Installation.............................................124 Rocker Panel Removal.........................................................126 Rear Bumper Removal / Installation...........................................126 Rear Cab Removal.............................................................126 Service Panel (Seat Shield) Removal..........................................127 Console Cover Removal........................................................127 Key Switch / Indicator Light Replacement.....................................129 Decal Replacement............................................................129 Body Exploded View...........................................................130 CAB FRAME........................................................................131 Exploded View................................................................131 Cab Frame Assembly...........................................................131 MAIN FRAME.......................................................................132 Exploded View................................................................132 FRONT A-ARMS.....................................................................133 Exploded View................................................................133 A-arm Replacement............................................................134 FRONT HUB........................................................................135 Hub Removal..................................................................135 Hub Seal and Bearing Replacement.............................................136 Hub Installation.............................................................136 SHOCKS...........................................................................137 Shock Exploded View..........................................................137 Shock Removal................................................................137 Shock Replacement............................................................138 Shock Installation...........................................................138 Rear Swing Arm...................................................................139 Exploded View................................................................139 Swing Arm Removal............................................................140 Swing Arm Installation.......................................................141 Rear Axle........................................................................142 Axle Housing Removal.........................................................142 Axle Housing Service.........................................................143 Axle Housing Installation....................................................143 Axle Removal.................................................................144 Axle Installation............................................................144 STEERING.........................................................................146 Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View....146 Steering Shaft Removal.......................................................147 Steering Shaft Installation..................................................147 Steering Gearbox Removal.....................................................148 Steering Gearbox Installation................................................149 Tie Rod..........................................................................150 Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View..............150 Tie Rod Removal / Installation...............................................151 WHEELs...........................................................................152 Front Wheel Exploded View....................................................152 Rear Wheel Exploded View.....................................................153 Wheel Removal................................................................153 Wheel Installation...........................................................154 BRAKES ..............................................................................155 GENERAL SPECIFICATIONS...........................................................156 TORQUE SPECIFICATIONS............................................................156 SPECIAL TOOLS....................................................................156 BRAKE SYSTEM SERVICE NOTES.......................................................157 BRAKE NOISE TROUBLESHOOTING......................................................157 HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION...................................158 BRAKE SYSTEM - MECHANICAL COMPONENTS.............................................159 Brake System - Mechanical Components.........................................159 BRAKE SYSTEM - HYDRAULIC COMPONENTS..............................................160 BRAKE BLEEDING / FLUID CHANGE....................................................161 BRAKE PEDAL......................................................................163 Brake Pedal Removal..........................................................163 Pedal Installation...........................................................163 Brake Pedal Inspection / Adjustment..........................................163 PARKING BRAKE....................................................................164 Parking Brake Cable Freeplay Adjustment......................................164 Parking Brake Adjustment.....................................................164 Parking Brake Cable Replacement..............................................165 FRONT BRAKE PADS.................................................................167 Front Pad Removal............................................................167 Pad Inspection...............................................................167 Front Brake Pad Assembly / Caliper Installation..............................168 FRONT BRAKE DISC.................................................................169 Disc Inspection..............................................................169 Disc Replacement.............................................................170 FRONT CALIPER....................................................................170 Front Caliper Removal .......................................................170 Caliper Installation.........................................................171 REAR BRAKE PAD...................................................................172 Rear Brake Pad Removal.......................................................172 Rear Brake Pad Inspection....................................................173 Rear Brake Pad Assembly / Caliper Installation...............................174 Brake Burnishing Procedure...................................................175 REAR BRAKE DISC..................................................................175 Disc Inspection..............................................................175 Rear Brake Disc Replacement..................................................176 REAR CALIPER SERVICE.............................................................177 Rear Caliper Removal.........................................................177 Rear Brake Caliper Installation..............................................178 MASTER CYLINDER..................................................................179 Removal......................................................................179 Installation.................................................................180 TROUBLESHOOTING..................................................................181 Brakes Squeal / Poor Brake Performance.......................................181 Pedal Vibration..............................................................181 Caliper Overheats (Brakes Drag)..............................................181 Brakes Lock..................................................................181 Parking Brake Drags or Ineffective Brake.....................................181 CVT / TRANSMISSION ..................................................................183 SPECIFICATIONS / TOOLS...........................................................184 Torque Specifications........................................................184 Special Tools................................................................184 CVT SYSTEM.......................................................................185 CVT Maintenance / Inspection.................................................185 Drive Clutch Operation.......................................................185 Driven Clutch Operation......................................................185 CVT System Drying............................................................186 CVT Overheating / Water Ingestion Diagnostics................................186 Clutch (CVT) Cover Removal / Inspection......................................187 Clutch (CVT) Cover Installation..............................................187 Drive Belt Removal...........................................................188 Drive Belt Inspection........................................................188 Drive Belt Installation......................................................188 Drive Clutch Service.............................................................190 Drive Clutch Removal, Disassembly and Inspection.............................190 Drive Clutch Assembly........................................................191 Driven Clutch Service............................................................191 Driven Clutch Removal, Disassembly, Inspection...............................191 Driven Clutch Assembly.......................................................193 Driven Clutch Installation...................................................194 TRANSMISSION SERVICE.............................................................195 Transmission Disassembly and Inspection......................................195 Input Shaft Removal / Inspection.............................................199 Transmission Main Shaft Assembly View........................................200 Transmission Assembly .......................................................201 Output Gear Pinion Depth Adjustment..........................................203 Output Shaft Housing Disassembly / Assembly..................................204 ELECTRICAL ..........................................................................205 GENERAL INFORMATION..............................................................206 Special Tools................................................................206 Electrical System Service Notes..............................................206 SWITCHES AND CONTROLS............................................................206 Key Switch...................................................................206 Brake Pedal / Parking Brake Switches.........................................207 Throttle Release Switch (TRS)................................................208 TRS Operation................................................................208 TRS Switch Adjustment........................................................208 DAYTIME RUNNING LIGHTS...........................................................209 “DRL” Test...................................................................209 “DRL” Lamp Replacement.......................................................209 TAIL LIGHT.......................................................................210 Tail Light Lamp Replacement..................................................210 INDICATOR LAMPS..................................................................210 Indicator Lamp Replacement...................................................210 TRANSMISSION SWITCH..............................................................211 Transmission Switch - Circuit Breakout.......................................211 Testing......................................................................211 Removal......................................................................212 Installation.................................................................212 IGNITION SYSTEM..................................................................212 Overview.....................................................................212 Ignition System Troubleshooting..............................................212 Ignition System Testing......................................................213 RPM Ignition Limiter Functions...............................................214 RPM Limiter Specifications...................................................215 Ignition Coil Test...........................................................215 CDI Output Test Using Peak Reading Adaptor...................................215 Pulser Coil Output / Resistance Tests .......................................215 CHARGING SYSTEM..................................................................216 Charging System Testing......................................................216 Main Fuse / Fuse Holder Location.............................................217 Voltage Regulator / Rectifier................................................217 Stator / Alternator Tests....................................................217 BATTERY..........................................................................218 Battery Maintenance Service Notes............................................218 New Battery Activation.......................................................218 Battery Removal..............................................................219 Battery Cleaning.............................................................219 Battery Installation.........................................................219 Battery Voltage Test.........................................................219 Battery Load Test............................................................219 Battery Charging Procedure...................................................220 Battery Storage..............................................................220 STARTER SYSTEM...................................................................221 Starter Relay................................................................221 Starter Motor Service........................................................221 Starter Disassembly..........................................................221 Starter Brush Inspection / Replacement.......................................222 Armature Test................................................................223 Starter Reassembly...........................................................223 Voltage Drop Test............................................................223 Starter System Troubleshooting...............................................224 Starter System Testing ......................................................225 INDEX ...............................................................................227 WIRING DIAGRAM ......................................................................231
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