Polaris RZR 170 UTV Shop Manual 2012 – 2015 – PDF DOWNLOAD

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Polaris RZR 170 UTV Shop Manual 2012 – 2015

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POLARIS RZR 170 UTV SHOP MANUAL 2012 – 2015 – PDF DOWNLOAD:

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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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