Polaris RANGER RZR 170 User manual

2012-2013 RANGER RZR® 170

SERVICE MANUAL

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent

version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer



technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from

the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the

service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper

tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service

Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful.

Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask

Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual/Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,

2100 Hwy 55, Medina, MN 55340.

Publication Printed July 2012 (PN 9923983)

improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any

reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,

bystander or person(s) inspecting or servicing the vehicle.

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the

vehicle.

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Some Polaris factory publications can be downloaded from www.polaris.com, purchased from www.purepolaris.com

or by contacting the nearest Polaris dealer.

WARNING

CAUTION

1

GENERAL INFORMATION

2

MAINTENANCE

3

ENGINE / TRANSMISSION

4

FUEL SYSTEM

5

BODY / SUSPENSION / STEERING

6

BRAKES

7

CVT

8

ELECTRICAL

GENERAL INFORMATION

1.1

CHAPTER 1

GENERAL INFORMATION

1

9923983 - 2012-2013 RZR 170 Service Manual

MODEL NUMBER DESIGNATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

UNIT SERIAL NUMBER (VIN) AND EMISSIONS DECAL LOCATIONS . . . . . . . . . . . . .1.3

VEHICLE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL: 2012 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

MODEL: 2012 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

MODEL: 2013 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

MODEL: 2013 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

MISCELLANEOUS SPECIFICATIONS AND CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

1.2

GENERAL INFORMATION

9923983 - 2012-2013 RZR 170 Service Manual

MODEL NUMBER DESIGNATIONS

Model Number Designation

Example: R12VA17AA

VEHICLE IDENTIFICATION NUMBER

VIN Number Designation

Example: RF3VA17A6BT012516

Engine Designation Number

S35C-Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start

Engine Serial Number Location

Whenever corresponding about an engine, be sure to refer to the engine

model number and serial number. This information can be found on the

sticker applied to the clutch-side engine case.

GROUP

MODEL

YEAR

CHASSIS DRIVELINE ENGINE CATEGORY OPTION

1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit**

R= RANGER

12

13

V = RZR A = 2x4 Chain

Displacement in cc

(i.e. 17 = 170cc)

A = ORV A

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively

** = 9th digit will be used on color/featured versions of models (not including the base)

First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.

World Mfg. ID

Vehicle Descriptors Vehicle Identifiers

Chassis

Driveline

Engine Size

Engine Modifier

Category

Check Digit

Model Year *

Mfg. Location

Individual Serial No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

R F 3 V A 1 7 A 6 B T 0 1 2 5 1 6

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013

ENGINE SERIAL NUMBER

1.3

GENERAL INFORMATION

1

9923983 - 2012-2013 RZR 170 Service Manual

Unit Serial Number (VIN) and Emissions Decal Locations

The machine model information decal (A) and vehicle identification number (VIN) are important for identification. The

VIN number (B) is stamped on a portion of the front left frame rail close to the left front wheel.

The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.

A

B

C

1.4

GENERAL INFORMATION

9923983 - 2012-2013 RZR 170 Service Manual

VEHICLE INFORMATION

Publication Numbers

NOTE: When ordering service parts be sure to use the correct parts manual.

NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

www.purepolaris.com.

Paint Codes

Replacement Keys

Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut

to match the original. Should both keys become lost, ignition switch replacement is required.

Model Model No. Owner’s Manual PN Parts Manual PN

2012 RANGER RZR 170

R12VA17AA

R12VA17AC

9923583 9923584

2013 RANGER RZR 170

R13VA17AA

R13VA17AB

9923980 9923981

Painted Part Color Description Polaris Number

Frame / Bumpers / Racks Gloss Black P-067

Plastic - Hood / Dash / Fenders

Indy Red

White

P-293

P-133

P/N 0453013

1.5

GENERAL INFORMATION

1

9923983 - 2012-2013 RZR 170 Service Manual

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other

tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when

servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation,

by phone at 1-800-328-6657 or on-line at

http://polaris.spx.com/.

Select “SPX Website - Tools, diagnostics” from

the “Service and Warranty” drop down menu

1.6

GENERAL INFORMATION

9923983 - 2012-2013 RZR 170 Service Manual

GENERAL SPECIFICATIONS

MODEL: 2012 RANGER RZR 170

MODEL NUMBER: R12VA17AA / R12VA17AC

ENGINE MODEL: S35C

Category Dimension / Capacity

Length 85 in. / 216 cm

Width 48 in. / 122 cm

Height 55 in. / 139.7 cm

Wheel Base 65 in. / 165 cm

Ground Clearance 6 in. / 15.2 cm

Dry Weight 500 lbs. / 227 kg

Gross Vehicle Weight 840 lbs. / 381 kg

Maximum Weight

Capacity

300 lbs. / 81.7 kg

(Includes people, cargo, accessories)

1.7

GENERAL INFORMATION

1

9923983 - 2012-2013 RZR 170 Service Manual

MODEL: 2012 RANGER RZR 170

MODEL NUMBER: R12VA17AA / R12VA17AC

ENGINE MODEL: S35C

JETTING CHART

CLUTCH CHART

Engine

Platform

Single Cylinder, Air/Oil Cooled

4-Stroke

Engine Model Number S35C

Engine Displacement 169cc

Number of Cylinders 1

Bore & Stroke (mm) 61 x 57.8 mm

Compression Ratio 9.5:1

Compression Pressure 130-160 psi @ W.O.T.

Engine Idle Speed 1700 ± 100 RPM

Engine Max Operating RPM 8000 ± 200 RPM

Lubrication Wet Sump

Oil Requirements

Performance Synthetic (PS-4)

Extreme Duty Oil

Oil Capacity 37 oz. / 1.1 liters

Exhaust System

Single Headpipe / Single

Silencer

Fuel System

Carburetor Type Keihin

Pilot Jet 35

Main Jet 100

Air Screw 2 1/4 Turns Out (initial)

Jet Needle 2MKNN - #4 clip position

Fuel Delivery Fuel Pump

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

2.5 gal. (9.5 liters)

87 Octane (minimum)

Electrical

Alternator Max Output 80 Watts @ 3000 RPM

Lights: Main Headlights

2 - Single Beam

Daytime Running Lamps

(DRL)

Tail / Brake 5 Watts / 21 Watts

Starting System Electric Start

Ignition System CDI

Ignition Timing Non-Adjustable

Spark plug / Gap

NGK CR6HSA

.024-.028 in. (0.6-0.7 mm)

Battery

GTX12-BS / Low Maintenance

12 Amp Hr. / 12 Volt

Fuses Main: 20 Amp

Drivetrain

Transmission Type Polaris Automatic CVT

Shift Type In Line Shift - H / N / R

Transmission Oil

Requirements Main Gearcase

Polaris AGL

23.7 oz. (700 ml)

Drive Belt 0454497

Drive Chain - Type / # Links 520 / 30

Steering / Suspension

Front Suspension Single A-arm

Front Travel 5 in. / 12.7 cm

Rear Suspension Dual Shock Swingarm

Rear Travel 5 in. / 12.7 cm

Shock Preload Adjustment

Front / Rear

Cam Adjustable

(Factory Setting - Softest)

Toe Out 1/8-1/4 in. / 3-6.35 mm

Wheels / Brakes

Front Tire Size 19 x 7 - 8

Rear Tire Size 20 x 10 - 9

Bolt Pattern 110mm

Tire Air Pressure - Front / Rear 3 psi (20.7 kPa)

Brake - Front / Rear

Foot Actuated - 4 Wheel

Hydraulic Disc

Brake Fluid DOT 4

Altitude

Meters

(Feet)

Ambient Temperature

Below 40 F

Below 5

 C

Above +40 F

Above +5

 C

0-3000

(0-10000)

102 100

3000+

(10,000+)

100

98

#3 needle clip position

Altitude

Meters

(Feet)

Shift Weight

0-3000

(0-10,000)

6 @ 17 grams

3000+ (10,000+)

*** 6 @ 15 grams

PN 0454619

1.8

GENERAL INFORMATION

9923983 - 2012-2013 RZR 170 Service Manual

MODEL: 2013 RANGER RZR 170

MODEL NUMBER: R13VA17AA / R13VA17AB

ENGINE MODEL: S35C

Category Dimension / Capacity

Length 85 in. / 216 cm

Width 48 in. / 122 cm

Height 55 in. / 139.7 cm

Wheel Base 65 in. / 165 cm

Ground Clearance 6 in. / 15.2 cm

Dry Weight 500 lbs. / 227 kg

Gross Vehicle Weight 840 lbs. / 381 kg

Maximum Weight

Capacity

300 lbs. / 81.7 kg

(Includes people, cargo, accessories)

1.9

GENERAL INFORMATION

1

9923983 - 2012-2013 RZR 170 Service Manual

MODEL: 2013 RANGER RZR 170

MODEL NUMBER: R13VA17AA / R13VA17AB

ENGINE MODEL: S35C

JETTING CHART

CLUTCH CHART

Engine

Platform

Single Cylinder, Air/Oil Cooled

4-Stroke

Engine Model Number S35C

Engine Displacement 169cc

Number of Cylinders 1

Bore & Stroke (mm) 61 x 57.8 mm

Compression Ratio 9.5:1

Compression Pressure 130-160 psi @ W.O.T.

Engine Idle Speed 1700 ± 100 RPM

Engine Max Operating RPM 8000 ± 200 RPM

Lubrication Wet Sump

Oil Requirements

Performance Synthetic (PS-4)

Extreme Duty Oil

Oil Capacity 37 oz. / 1.1 liters

Exhaust System

Single Headpipe / Single

Silencer

Fuel System

Carburetor Type Keihin

Pilot Jet 35

Main Jet 100

Air Screw 2 1/4 Turns Out (initial)

Jet Needle 2MKNN - #4 clip position

Fuel Delivery Fuel Pump

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

2.5 gal. (9.5 liters)

87 Octane (minimum)

Electrical

Alternator Max Output 80 Watts @ 3000 RPM

Lights: Main Headlights

2 - Single Beam

Daytime Running Lamps

(DRL)

Tail / Brake 5 Watts / 21 Watts

Starting System Electric Start

Ignition System CDI

Ignition Timing Non-Adjustable

Spark plug / Gap

NGK CR6HSA

.024-.028 in. (0.6-0.7 mm)

Battery

GTX12-BS / Low Maintenance

12 Amp Hr. / 12 Volt

Fuses Main: 20 Amp

Drivetrain

Transmission Type Polaris Automatic CVT

Shift Type In Line Shift - H / N / R

Transmission Oil

Requirements Main Gearcase

Polaris AGL

23.7 oz. (700 ml)

Drive Belt 0454497

Drive Chain - Type / # Links 520 / 30

Steering / Suspension

Front Suspension Single A-arm

Front Travel 5 in. / 12.7 cm

Rear Suspension Dual Shock Swingarm

Rear Travel 5 in. / 12.7 cm

Shock Preload Adjustment

Front / Rear

Cam Adjustable

(Factory Setting - Softest)

Toe Out 1/8-1/4 in. / 3-6.35 mm

Wheels / Brakes

Front Tire Size 19 x 7 - 8

Rear Tire Size 20 x 10 - 9

Bolt Pattern 110mm

Tire Air Pressure - Front / Rear 3 psi (20.7 kPa)

Brake - Front / Rear

Foot Actuated - 4 Wheel

Hydraulic Disc

Brake Fluid DOT 4

Altitude

Meters

(Feet)

Ambient Temperature

-30 to -10° F

(-34 to -23° C)

-15 to 5° F

(-26 to -15° C)

0° F+

(-17° C+)

0-2400

(0-8000)

Main Jet = 102

Pilot Jet = 38

Clip Position = 4

Main Jet = 100

Pilot Jet = 38

Clip Position = 4

Main Jet = 100

Pilot Jet = 35

Clip Position = 4

2400+

(8000+)

Main Jet = 100

Pilot Jet = 38

Clip Position = 4

Main Jet = 98

Pilot Jet = 38

Clip Position = 4

Main Jet = 98

Pilot Jet = 35

Clip Position = 4

Shaded cell indicates factory setting.

Altitude

Meters

(Feet)

Shift Weight

0-3000

(0-10,000)

6 @ 17 grams

3000+ (10,000+)

6 @ 15 grams

PN 0454619

1.10

GENERAL INFORMATION

9923983 - 2012-2013 RZR 170 Service Manual

MISCELLANEOUS SPECIFICATIONS

AND CHARTS

Standard Bolt Torque Specification

Metric Bolt Torque Specification

Grade 2

Grade 5

Grade 8

Bolt Size

Grade 2

ft-lbs (Nm)

Grade 5

ft-lbs (Nm)

Grade 8

ft-lbs (Nm)

1/4-20 5 (7) 8 (11) 12 (16)

1/4-28 6 (8) 10 (14) 14 (19)

5/16-18 11 (15) 17 (23) 25 (35)

5/16-24 12 (16) 19 (26) 29 (40)

3/8-16 20 (27) 30 (40) 45 (62)

3/8-24 23 (32) 35 (48) 50 (69)

7/16-14 30 (40) 50 (69) 70 (97)

7/16-20 35 (48) 55 (76) 80 (110)

1/2-13 50 (69) 75 (104) 110 (152)

1/2-20 55 (76) 90 (124) 120 (166)

Bolt Size

GRADE

4.6 4.8 8.8/8.9 10.9 12.9

FT-LB/NM (DRY THREADS)

M3 .3/.5 .5/.7 1/1.3 1.5/2 1.5/2

M4 .8/1.1 1/1.5 2/3 3/4.5 4/5

M5 1.5/2.5 2/3 4.5/6 6.5/9 7.5/10

M6 3/4 4/5.5 7.5/10 11/15 13/18

M8 7/9.5 10/13 18/25 26/35 33/45

M10 14/19 18/25 37/50 55/75 63/85

M12 26/35 33/45 63/85 97/130 110/150

M14 37/50 55/75 103/140 151/205 177/240

M16 59/80 85/115 159/215 232/315 273/370

M18 81/110 118/160 225/305 321/435 376/510

1.11

GENERAL INFORMATION

1

9923983 - 2012-2013 RZR 170 Service Manual

Conversion Table

°C to °F:

9/5

(°C + 32) = °F

°F to °C:

5/9

(°F - 32) = °C

Unit of Measure Multiplied by Converts to

ft-lbs x 12 = in-lbs

in-lbs x .0833 = ft-lbs

ft-lbs x 1.356 = Nm

in-lbs x .0115 = kg-m

Nm x .7376 = ft-lbs

kg-m x 7.233 = ft-lbs

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

in. x 25.4 = mm

mm x .03937 = in.

in. x 2.54 = cm

mile (mi.) x 1.6 = km

km x .6214 = mile (mi.)

Ounces (oz.) x 28.35 = Grams (g)

Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)

Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)

Grams (g) x 0.035 = Ounces (oz.)

lb. x .454 = kg

kg x 2.2046 = lb.

Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)

Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)

Imperial pints (Imp pt.) x 0.568 = Liters (l)

Liters (l) x 1.76 = Imperial pints (Imp pt.)

Imperial quarts (Imp qt.) x 1.137 = Liters (l)

Liters (l) x 0.88 = Imperial quarts (Imp qt.)

Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)

US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)

US quarts (US qt.) x 0.946 = Liters (l)

Liters (l) x 1.057 = US quarts (US qt.)

US gallons (US gal) x 3.785 = Liters (l)

Liters (l) x 0.264 = US gallons (US gal)

Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)

Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)

Kilopascals (kPa) x 0.01 = Kilograms - force per square cm

Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

p(3.14)xR2x H (height) = Cylinder Volume

1.12

GENERAL INFORMATION

9923983 - 2012-2013 RZR 170 Service Manual

SAE Tap Drill Sizes

Metric Tap Drill Sizes

Decimal Equivalents

Thread Size / Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64

#1-64 53 1/2-20 29/64

#1-72 53 9/16-12 31/64

#2-56 51 9/16-18 33/64

#2-64 50 5/8-11 17/32

#3-48 5/64 5/8-18 37/64

#3-56 45 3/4-10 21/32

#4-40 43 3/4-16 11/16

#4-48 42 7/8-9 49/64

#5-40 38 7/8-14 13/16

#5-44 37 1-8 7/8

#6-32 36 1-12 59/64

#6-40 33 1 1/8-7 63/64

#8-32 29 1 1/8-12 1 3/64

#8-36 29 1 1/4-7 1 7/64

#10-24 24 1 1/4-12 1 11/64

#10-32 21 1 1/2-6 1 11/32

#12-24 17 1 1/2-12 1 27/64

#12-28 4.6mm 1 3/4-5 1 9/16

1/4-20 7 1 3/4-12 1 43/64

1/4-28 3 2-4 1/2 1 25/32

5/16-18 F 2-12 1 59/64

5/16-24 I 2 1/4-4 1/2 2 1/32

3/8-16 O 2 1/2-4 2 1/4

3/8-24 Q 2 3/4-4 2 1/2

7/16-14 U 3-4 2 3/4

7/16-20 25/64

Tap Size Drill Size

Decimal

Equivalent

Nearest

Fraction

3x.50 #39 0.0995 3/32

3x.60 3/32 0.0937 3/32

4x.70 #30 0.1285 1/8

4x.75 1/8 0.125 1/8

5x.80 #19 0.166 11/64

5x.90 #20 0.161 5/32

6x1.00 #9 0.196 13/64

7x1.00 16/64 0.234 15/64

8x1.00 J 0.277 9/32

8x1.25 17/64 0.265 17/64

9x1.00 5/16 0.3125 5/16

9x1.25 5/16 0.3125 5/16

10x1.25 11/32 0.3437 11/32

10x1.50 R 0.339 11/32

11x1.50 3/8 0.375 3/8

12x1.50 13/32 0.406 13/32

12x1.75 13/32 0.406 13/32

MAINTENANCE

2.1

CHAPTER 2

MAINTENANCE

2

9923983 - 2012-2013 RZR 170 Service Manual

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

30 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

MAINTENANCE REFERENCES / SERVICE LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 2.6

FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . .2.8

MAINTENANCE REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10

PRE-RIDE / DAILY INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

SHIFT CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

CHOKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

CHOKE CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

PILOT AIR SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

FUEL VALVE LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

FUEL PUMP / FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

THROTTLE STOP SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

THROTTLE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

ENGINE OIL CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

ENGINE CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . . . . . . . .2.21

ENGINE/TRANSMISSION MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

COMPRESSION / LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

INTAKE VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

EXHAUST VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

TRANSMISSION SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

TRANSMISSION OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

DRIVE CHAIN LUBRICATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

2.2

MAINTENANCE

9923983 - 2012-2013 RZR 170 Service Manual

ELECTRICAL AND IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.31

TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

BRAKE FLUID INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

PARKING BRAKE CABLE FREEPLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 2.34

PARKING BRAKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

2.3

MAINTENANCE

2

9923983 - 2012-2013 RZR 170 Service Manual

PERIODIC MAINTENANCE CHART

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.

NOTE: 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

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the

oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to

rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:



= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an

authorized Polaris dealer.



= SEVERE USE ITEM -- See Above

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with acould

result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

2.4

MAINTENANCE

9923983 - 2012-2013 RZR 170 Service Manual

Pre-Ride - 25 Hour Maintenance Interval

Periodic Maintenance Chart

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (KM)

Steering - Daily -

Check each day before driving the vehicle.

Make adjustments as needed. See the Pre-

Ride Checklist in the Owner’s Manual.

Front-Suspension - Daily -

Rear-Suspension - Daily -

Tires - Daily -

Brake Pedal Travel - Daily -

Brake Fluid Level - Daily -

Daytime Running Lights - Daily -

Drive Chain - Daily -

Brake Lamp / Tail Lamp - Daily -

Throttle - Daily -

Wheels / Fasteners - Daily -

Frame Fasteners - Daily -



E

Engine Oil Level - Daily -

Fuel Level - Daily -



E

Air Filter (main element) - Daily - Inspect; clean often, replace as needed

CVT Housing - Weekly -

Open CVT drain as needed, check often if

operating in wet conditions





Brake Pad Wear 10 H 1 M 100 (160) Inspect regularly

Idle Speed 10 H 1 M 100 (160) Check; adjust as needed



E

Choke 10 H 1 M 100 (160) Check for proper operation



Engine Oil Change

(Break-In Period)

10 H 1 M 100 (160)

Perform a break-in oil change after the first 10

hours of operation

Drive Chain

(Break-In Period)

10 H 1 M 100 (160)

Adjust and lubricate after the first 10 hours of

operation



E

Valve Clearance 10 H 1 M 100 (160)

Check clearance after the first 10 hours of

operation; Adjust to specification if required

Battery 25 H Monthly 250 (400) Check terminals; clean; test



Transmission Oil 25 H 12 M 250 (400) Inspect level; change yearly

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Polaris RANGER RZR 170 User manual

Polaris RANGER RZR 170 User manual

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