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Polaris RANGER RZR 170 User manual

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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)
© Copyright 2012 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
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
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
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9923983 - 2012-2013 RZR 170 Service Manual
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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
© Copyright 2012 Polaris Sales Inc.
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
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9923983 - 2012-2013 RZR 170 Service Manual
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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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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
© Copyright 2012 Polaris Sales Inc.
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 acould
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
© Copyright 2012 Polaris Sales Inc.
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
/