Polaris RZR 170 2009, R09VA17AA Service Manual
GENERAL INFORMATION
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CHAPTER 1
GENERAL INFORMATION
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: 2009 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
1
1.1
GENERAL INFORMATION
}
Machine Model Number Identification
}
}
Model Year
Designation
Basic Chassis
Designation
Engine Designation
Emissions &
Model Option
R 0 9 V A 1 7 A D
}
4 X A V A 1 7 A * 9 P 0 0 0 0 0 0
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Description
Vehicle Identifier
Check Digit
Model
Year
Body Style
Plant No.
Individual Serial No.
* This could be either
a number or a letter
Powertrain
Emissions
ENGINE SERIAL NUMBER
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MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
S35C.................................................................................................Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start
VIN Identification
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.
1.2
Unit Serial Number (VIN) and Emissions Decal Locations
A
B
C
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GENERAL INFORMATION
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.
1
The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.
1.3
GENERAL INFORMATION
P/N 0453013
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VEHICLE INFORMATION
Publication Numbers
Model Model No. Owner’s Manual PN Parts Manual PN
2009 RANGER RZR 170 R09VA17AA
NOTE: When orderi ng se rvice part s 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
Painted Part Color Description Polaris Number
Frame / Bumpers / Racks Gloss Black P-067
Plastic - Hood / Dash / Fenders Indy Red P-293
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.
9922131
9922569 (produced after 2/10/2009)
(produced before 2/10/2009)
9922132
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools
maybe 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/
.
1.4
GENERAL SPECIFICATIONS
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MODEL: 2009 RANGER RZR 170
MODEL NUMBER: R09VA17AA
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
(Includes people, cargo, accessories)
300 lbs. / 81.7 kg
GENERAL INFORMATION
1
1.5
GENERAL INFORMATION
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MODEL: 2009 RANGER RZR 170
MODEL NUMBER: R09VA17AA
ENGINE MODEL: S35C
Engine
Platform
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
Oil Capacity 37 oz.. / 1.1 liters
Exhaust System Single Headpipe / Single Silencer
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
Alternator Max Output 80 Watts @ 3000 RPM
Lights: Main Headlights
Tail / Brake 5 Watts / 21 Watts
Starting System Electric Start
Ignition System CDI
Ignition Timing Non-Adjustable
Spark plug / Gap
Battery
Fuses Main: 20 Amp
Single Cylinder, Air/Oil Cooled
4-Stroke
Above 32° F
Polaris ‘YOUTH’ oil
Below 32° F ( 0° C
20W-40 oil
Fuel System
2.5 gal. (9.5 liters)
87 Octane (minimum)
Electrical
2 - Single Beam
Daytime Running Lamps (DRL)
NGK CR6HSA
.024-.028 in. (0.6-0.7 mm)
GTX12-BS / Low Maintenence
12 Amp Hr. / 12 Volt
( 0° C )
)
Drivetrain
Transmission Type Polaris Automatic CVT
Shift Type In Line Shift - H / N / R
Transmission Oil Requirements
Main Gearcase
Drive Belt 0454497
Drive Chain - Type / # Links
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
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
Tire Air Pressure - Front / Rear 3 psi (20.7 kPa)
Brake - Front / Rear
Brake Fluid DOT 4
JETTING CHART
Altitude
0-3048
Meters
(Feet)
CLUTCH CHART
Meters
(Feet)
***15 gram weights are optional and are not a High Altitude
(H.A.) Warranty item.
(0-10000)
Above 3048
(Above 10,000)
Altitude Shift W e ight
0-3048
(0-10,000)
Above 3048
(Above 10,000)
Below 40 F
Below 5
Polaris AGL
23.7 oz. (700 ml)
520 / 30
Cam Adjustable
(Factory Setting - Softest)
110mm
Foot Actuated - 4 Wheel
Hydraulic Disc
Ambient Temperature
Above +40
C
102 100
100
6 @ 17 grams
*** 6 @ 15 grams
Above +5
98
#3 needle clip position
PN 0454619
F
C
1.6
MISC. SPECIFICATIONS AND CHARTS
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Conversion Table
GENERAL INFORMATION
1
°C to °F:
9/5
(°C + 32) = °F °F to °C:
5/9
(°F - 32) = °C
1.7
GENERAL INFORMATION
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Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.8
GENERAL INFORMATION
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SAE Tap / Drill Sizes
Decimal Equivalents
1
Metric Tap / Drill Sizes
1.9
GENERAL INFORMATION
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Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm).
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Rollers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close
and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in t he
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm²: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in²: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating posit ion of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mi
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft .
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
le/miles.
1.10
MAINTENANCE
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CHAPTER 2
MAINTENANCE
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
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
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MAINTENANCE
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ELECTRICAL AND IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.30
TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE FLUID INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.2
MAINTENANCE
WARNING
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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 ar e 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 operatio ns .
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 ind icate 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 th e cau se or se e you r dea ler.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance :
2
= 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.
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.
2.3
MAINTENANCE
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Pre-Ride - 25 Hour Maintenance Interval
Periodic Maintenance Chart
Maintenance Interval
Item
Steering - Daily -
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 -
Engine Oil Level - Daily -
E
Fuel Level - Daily -
Air Filter (main element) - Daily - Inspect; clean often, replace as needed
E
CVT Housing - Weekly -
Brake Pad Wear 10 H 1 M 100 (160) Inspect regularly
Idle Speed 10 H 1 M 100 (160) Check; adjust as needed
Choke 10 H 1 M 100 (160) Check for proper operation
E
Engine Oil Change
(Break-In Period)
Transmission Oil
(Break-In Period)
Drive Chain
(Break-In Period)
Valve Clearance 10 H 1 M 100 (160)
E
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Transmission Oil 25 H 12 M 250 (400) Inspect level; change yearly
(whichever comes first)
Hours Calendar Miles (KM)
10 H 1 M 100 (160)
10 H 1 M 100 (160)
10 H 1 M 100 (160)
Remarks
Check each day before driving the vehicle.
Make adjustments as needed. See the PreRide Checklist in the Owner’s Manual.
Open CVT drain as needed, check often if
operating in wet conditions
Perform a break-in oil change after t he first
10 hours of operation
Perform break-in oil change after the first
10 hours of operation
Adjust and lubricate after the fi rst 10 hours
of operation
Check clearance after the first 10 hours of
operation; Adjust to specification if
required
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.
2.4
MAINTENANCE
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30 - 100 Hour Maintenance Interval
Periodic Maintenance Chart
Maintenance Interval
Item
Oil Change 30 H 6 M 300 (480) Lubricate all grease fittings, pivots, & cables
Oil Pre-Filter Screen 30 H 6 M 300 (480)
General Lubrication 50 H 3 M 500 (800) Lubricate all grease fittings, pivots, & cables
Valve Clearance 50 H - 500 (800)
E
Carburetor Float Bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage
Throttle Cable /
E
ETC Switch
Choke Cable 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary
E
Carburetor Air Intake
E
Ducts / Flange
Shift Cables 50 H 6 M 500 (800) Inspect; lubricate; adjust
Brake Pad Wear 50 H 6 M 500 (800) Inspect; replace as needed
Drive Belt 50 H - 500 (800) Inspect; replace as needed
Fuel System 100 H 12 M 600 (1000)
E
Fuel Filter 100 H 12 M 600 (1000) Replace yearly
E
Engine Mounts 100 H 12 M 600 (1000) Inspect
Exhaust Emissions /
E
Muffler / Pipe
Ignition Timing 100 H 12 M 600 (1000) Inspect
E
Sp ark Plug 100 H 12 M 600 (1000)
E
Wiring 100 H 12 M 600 (1000)
C V T C l u t c h e s / D r i v e B e l t
(Drive and Driven)
Wheel / Axle Bearings 100 H 12 M 600 (1000) Inspect; replace as needed
Sp ark Arrestor 100 H 12 M 600 (1000) Clean
Toe Adjustment - --
Idle Speed - --Adjust as needed
(whichever comes first)
Hours Calendar Miles (KM)
Clean filter at every oil change; clean annually
if operated less than 10 hours
Check clearance; adjust to specification if
required; perform break-in adjustment after the
first 10 hours of operation
50 H 6 M 500 (800) Inspec t; ad jus t; lub ric ate ; re pla ce if nece ss ar y
50 H 6 M 500 (800) Inspect for proper sealing / air leaks
Check for leaks at tank cap, lines, fuel valve,
filter, carburetor, replace lines every two years
100 H 12 M 600 (1000)
100 H - 600 (1000) Inspect;clean; replace worn parts
Inspect secondary air system filter and
exhaust - clean as required
Clean; check condition; adjust gap;
replace as needed
Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to
water, mud, etc.
Inspect periodically; adjust when parts are
replaced
Remarks
2
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.
2.5
MAINTENANCE
Grease Steering Pivots
Grease A-arm Pivots
Inspect Brake Pads
Inspect / Clean Air Filter
Inspect Brake Pads
Clean / Lubricate Chain
Inspect Exhaust
Daytime Running
Lamps
Trail / Brake Lamp
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MAINTENANCE REFERENCES / SERVICE LOCATIONS
Front and Rear View
2.6
RH and LH Side Views
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MAINTENANCE
2
2.7
MAINTENANCE
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LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service Products
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876248
2872175
2873602
2873603
2873604
2871653
2872276
2871654
2870465 Oil Pump for 1 Gallon Jug
2871312 Grease Gun Kit
2871322
Polaris YOUTH Synthetic 0W-40 4-Cycle
Engine Oil (Quart)
Polaris Semi - Synthetic 20W-40 4-Cycle
Engine Oil (Quart)
Gearcase / Transmission Lubricants
AGL - Synthetic ATV Gearcase Lubricant
(1 Qt.) (12 Count)
AGL - Synthetic ATV Gearcase Lubricant
(1 Gal.) (4 Count)
AGL - Synthetic ATV Gearcase Lubricant
(2.5 Gal.) (2 Count)
ATV Angle Drive Fluid
(8 oz.) (12 Count)
ATV Angle Drive Fluid
(2.5 Gal) (2 Count)
Premium Demand Drive Fluid LT
(1 Qt.) (12 Count)
Grease / Specialized Lubricants
Premium All Season Grease
(3 oz. cartridge) (24 Count)
NOTE: Each item can be purchased separately at
your local Polaris dealer.
Part No. Description
Additives / Sealants / Thread Locking Agent s / Misc.
2870585 Loctite™ Primer N, Aerosol, 25 g
2871956
2871949
2871950
2871951
2870587
2871326
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2871957
2871958
2872189 DOT 4 Brake Fluid (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
Loctite™ Thread Sealant 565
(50 ml.) (6 Count)
Loctite™ Threadlock 242
(50 ml.) (10 Count)
Loctite™ Threadlock 242
(6 ml.) (12 Count)
Loctite™ Threadlock 262
(50 ml.) (10 Count)
Loctite™ 518 Gasket Eliminator / Flange
Sealant (50 ml.) (10 Count)
Premium Carbon Clean
(12 oz.) (12 Count)
Black RTV Silicone Sealer
(3 oz. tube) (12 Count)
Black RTV Silicone Sealer
(11 oz. cartridge) (12 Count)
2871423
2871460 Starter Drive Grease (12 Count)
2871329 Dielectric Grease (Nyogel™)
2872348
Premium All Season Grease
(14 oz. cartridge) (10 Count)
Chain Lubricant, Aerosol
(16 oz.) (12 Count)
2.8
MAINTENANCE
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MAINTENANCE REFERENCES
Item Ref. Rec. Lube / Fluid Method Frequency*
Change after 10 hrs, and then
Polaris YOUTH 40W Engine
Engine Oil Page 2.7
Brake Fluid Page 2.7 DOT 4 (PN 2872189)
Transmission Page 2.7
Front A -Arm and
Steering Pivot
Bushings
* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
Page 2.6
Oil or 20-W40 Synthetic.
(Ambient air temperatures
apply- see page 2.19)
AGL Synthetic Gearcase
Lubricant (PN 2873602)
Polaris Premium All Season
Grease (PN 2871423)
Add oil to proper level on
dipstick.
Fill reservoir between MAX
and MIN lines.
Add lube to bottom of fill
plug threads. 24 oz. (710 ml)
Locate grease fittings and
grease with grease gun.
every 50 hours, 6 months or
100 hours thereafter; Change
more often in extremely dirty
conditions, or short trip cold
weather operation.
Fill as required. Change
brake fluid every 2 years.
Change annually***
Semi-annually**
2
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
2.9
MAINTENANCE
Shift Cable
Mount
Dust Boot
Clevis Pin
Shift Cables
Lower
Jam Nut
Upper
Jam Nut
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GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel tank - fill to proper level
• All brakes - check operation and adjustment
• Throttle - check for free operation and closing
• Running lights/Taillight/Brakelight - also check
operation of all indicator lights and switches
• Ignition switch - check for proper function
• Wheels - check for tightness of wheel nuts and axle
nuts; check to be sure axle nuts are secured by cotter
pins
• Air cleaner element - check for dirt; clean or replace
1. Locate the shift cable in the rear wheel well area.
2. Inspect shift cable, clevis pin, pivot bushings, and dust
boot. Replace if worn or damaged.
3. If adjustment is required, loosen the lower jam nut and pull
the cable out of the mount to move the upper jam nut.
Frame, Nuts, Bolts, and Fasteners
Periodically inspect the torque of all fasteners in accordance
with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Shift Cable Inspection / Adjustment
Shift cable adjustment may be necessary if symptoms include:
• Steering - check for free operation noting any unusual
looseness in any area
• Loose parts - visually inspect vehicle for any damaged
or loose nuts, bolts or fasteners
• Check all front and rear suspension components for
wear or damage.
• Ratcheting noise on deceleration
• Inability to engage into a gear
• Excessive gear clash (noise)
• Gear selector moving out of desired range
4. Adjust the shift cables so there is an equal amount of lever
travel when shifting past the Neutral detent into HIGH (H)
and REVERSE (R).
5. Thread the upper jam nuts as required to obtain proper cable
adjustment without binding.
NOTE: This procedure may require a few attempts to
obtain the proper adjustment.
6. Once the proper adjustment is obtained, tighten the lower
jam nut against the mount.
7. Start engine and shift through all gears to ensure the shift
cable is properly adjusted. If transmission still ratchets
after cable adjustment, verify the idle RPM is set correctly,
otherwise the transmission may require service.
2.10
MAINTENANCE
Lower
Jam Nut
Upper
Jam Nut
Lower
Jam Nut
Upper
Jam Nut
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Shift Cable Replacement
Shift cable replacement may be necessary if symptoms include:
• Inability to engage into a gear
• Inability to adjust cables for proper operation
• Gear selector moving out of desired range
1. Locate the shift cables in the rear wheel well area.
2. Loosen the lower and upper jam nuts and remove the
cables.
8. Raise the vehicle and support it with jackstands in order to
access the underside to remove the cables.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
reassembly.
9. Install new cables and adjust for proper operation and lever
travel without binding.
IMPORTANT: Do not allow cables to hang below
vehicle frame.
10. Once installed, lower the vehicle. Start engine and shift
through all gears to ensure the shift cables are properly
adjusted. If transmission still ratchets after cable
adjustment, verify the idle RPM is set correctly, otherwise
the transmission may require service.
11. Reassemble the console cover, seats and shift knob as
outlined in Chapter 5.
2
3. Inspect shift cable arm. Replace if worn or damaged.
4. Remove the shift knob to prepare for seat panel removal.
Refer to Chapter 5.
5. Refer to Chapter 5 for console cover removal in order to
access the shift cable mount on the lever assembly.
6. Loosen the lower and upper jam nuts and remove the
cables.
7. Inspect shift lever assembly. Replace parts as required if
worn or damaged.
2.11
MAINTENANCE
Air Box Access
Secure Clips
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FUEL SYSTEM AND AIR INTAKE
Air Filter Service
It is recommended that the air filter be inspected as part of
pre-ride inspection. If riding in extremely dusty conditions,
apply a small amount of grease to the seal under the air box cap.
In extremely dusty conditions, air filter cleaning will be required
more often.
The filter should be serviced using the following procedure.
Removal
1. The air box is located on the upper frame by the rear LH
wheel. Access the air box by removing the panel located at
the top of the rear cab (under rear basket, if installed).
4. Inspect the air filter element for tears or damage.
NOTE: Filter is washable. Do not discard.
5. Wash the filter in warm soapy water and allow it to air dry.
6. Apply air filter oil (commercially available) to the filter,
following the directions on the label.
NOTE: If unable to clean the filter, replace it.
NOTE: Service the filter more frequently if vehicle is
operated in wet conditions, dusty conditions or at
high throttle openings for extended periods.
Installation
1. Verify the air box and support screen are thoroughly clean.
2. Install a clean, pre-oiled foam filter over the filter support.
NOTE: Apply a small amount of general purpose
grease to the sealing edge of the air box cap seal
before installing.
3. Install air box cap and secure with clips.
2. Unlatch the clips and remove the air box cap. Inspect the
seal. It should adhere tightly to the cover and seal all the
way around.
3. Remove air filter and the filter support screen.
4. Reattach the access panel and tighten the fasteners
sufficiently.
2.12
MAINTENANCE
CHOKE CABLE FREEPLA Y
Increase
Decrease
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Choke Cable Adjustment
V erify free play of 3/16” (4.76 mm) and smooth operation of the
choke cable at the dash.
Adjustments to the freeplay can be made by loosening the choke
cable bracket at the carburetor and moving the cable in or out to
gain the desired freeplay.
If smooth choke operation is not obtainable, inspect choke cable
for kinks or sharp bends in routing.
Choke Cable Replacement
The choke cable is replaced as an assembly.
1. Engine is off. Place the vehicle in neutral and apply the
parking brake.
2. Remove the cable end from the carburetor.
3. Remove the retaining screws and pull the choke assembly
out at the dash.
2
4. Raise the vehicle and support it with jackstands in order to
access the underside.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
reassembly.
5. Pull the cable out from under the dash and the underside of
the vehicle.
6. Route the new cable from front-to-back, through the
retainers at the bottom of the frame, following the routing
noted during disassembly. Place cable ties at the
appropriate locations.
IMPORTANT: Do not allow cable to hang below
vehicle frame.
7. Reinstall the choke assembly into the dash. Hand-tighten
fasteners sufficiently, using care not to over-tighten.
8. Reinstall the choke cable onto the carburetor.
9. Adjust cable to desired freeplay.
If smooth choke operation is not obtain able, inspect for kinks,
sharp bends in the routing or a linkage obstruction.
2.13
MAINTENANCE
Idle Speed
Screw
Increase
Decrease
IDLE SPEED
CAUTION
Increase
Decrease
PILOT AIR
SCREW
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Idle Speed Adjustment
1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the slide adjustment screw in
(clockwise) to increase or out (counterclockwise) to
decrease RPM. (Refer to illustration).
Pilot Air Screw Adjustment
The pilot air screw is calibrated at the factory to
meet EPA / CARB regulations for air quality
standards. Cleaning of the pilot circuit must be
performed by a certified repair shop to ensure
air quality standards are not exceeded.
1. Using a portable tachometer, start the engine and verify
the idle speed is set to specification. Always check throttle
cable freeplay after adjusting idle speed and adjust if
necessary.
2. Using ‘D’-shaped screwdriver Special Tool PA-47361
adjust the pilot air screw setting, turn the screw clockwise
until engine idle RPM begins to decrease. Stop turning at
this point and note the screw setting.
Idle Speed
1700 ± 100
NOTE: Always check throttle cable freeplay after
adjusting the idle speed and readjust if necessary.
Pilot Air Screw Base Setting:
2.25 turns out (initial)
Special Tool:
PA-47361
3. Slowly turn mixture screw counterclockwise until idle
speed returns to Idle RPM. Continue turning
counterclockwise until idle RPM begins to drop. Stop
turning at this point and note the screw setting
4. Center the mixture screw between points in Step 2 and 3.
5. Readjust idle speed if not within specification.
2.14
MAINTENANCE
WARNING
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Vent Lines
1. Check fuel tank, crankcase, carburetor and transmission
vent lines for signs of wear, deterioration, damage or
leakage. Replace every two years.
2. Verify vent lines are routed properly and secured with
cable ties.
Fuel System
Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors or in
a well ventilated area.
Do not smoke or allow open flames or sparks in
or near the area where refueling is performed or
where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and
can result loss of consciousness or death
in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.
Fuel Filter
The fuel filter should be replaced in accordance with the
“Periodic Maintenance Chart” or whenever sediment is visible
in the filter.
Fuel Filter Location - Located in-line between fuel pump
and carburetor inlet.
To service the fuel filter:
1. Shut off fuel supply at fuel valve.
2. Remove line clamps at both ends of the filter.
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines.
5. Turn fuel valve to ‘ON’.
6. Start engine and inspect for leaks.
2
2.15
MAINTENANCE
Turn knob to operate
the fuel valve
Drain Screw
Open
Close
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Fuel Valve Location
The fuel valve is located on the passenger side of the vehicle
below the gas cap. Always turn off the fuel when the vehicle is
not in use
Carburetor Draining
The carburetor float bowl should be drained before extended
periods of storage, or periodically to remove accumulated
moisture or sediment from the bowl.
Fuel Pump / Fuel Lines
NOTE: Thoroughly clean the exterior of all fuel
related components before servicing.
The RZR170 fuel pump is located in the right rear wheel well.
1. Check the fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
2. Be sure fuel line is routed properly.
IMPORTANT: Make sure line is not kinked or pinched.
3. Replace fuel lines every two years.
1. Turn fuel valve to the ‘OFF’ position.
2. Place a container beneath the bowl drain hose.
3. Loosen drain screw and allow fuel in the float bowl and fuel
line to drain completely.
4. Tighten drain screw.
5. Turn fuel valve to “ON” and check for fuel leaks.
6. Start engine and re–check for leaks.
2.16
NOTE: For all other information related to the fuel
System, refer to Chapter 4.
MAINTENANCE
Throttle Pedal
Jam Nut
Stop Screw
Decrease / Increase
SPEED
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Throttle Pedal Inspection
If the throttle pedal has excessive play due to cable stretch or
cable misadjustment, it will cause a delay in throttle response.
Also, the throttle may not open fully. If the throttle pedal has no
play, the throttle may be hard to control, and the idle speed may
be erratic.
Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust if necessary.
Throttle Stop Speed Control
Use the following procedure to control how far the throttle
opens.
IMPORTANT: This procedure should be performed
by consumers only when they determine that their
child is capable of handling the additional speed.
2
1. Loosen the jam nut.
2. Turn the screw clockwise to increase speed or counter-
clockwise to reduce speed.
3. Tighten the jam nut after adjusting.
2.17
MAINTENANCE
Throttle Cable
Adjuster
WARNING
Pivot Bearing
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Throttle Freeplay Adjustment
Inspection
1. Place the transmission in the Neutral (N) position.
2. Start the engine and warm it up thoroughly.
3. Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Freeplay should be 1/16”
- 1/8” (1.5 - 3 mm).
Adjustment
1. The throttle cable adjuster is located at the throttle pedal
housing, outside of the cab well.
Throttle Cable Replacement
Follow the factory cable routing as installed to
prevent cable pinching, binding or damage.
Do not allow cable to hang below vehicle frame.
Failure to install properly could result in loss of
vehicle control, resulting in severe injury or death.
1. Engine is off. Place the vehicle in neutral and apply the
parking brake.
2. Remove the foot pedal ETC cover screws and ONE leftside housing mounting screw.
2. Slide back the cable adjuster boot.
3. Using an open-end wrench, loosen the adjustment jam nut.
4. Using an open-end wrench, move the cable adjuster until
1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the
throttle pedal.
NOTE: While adjusting, lightly move the throttle
pedal in and out.
5. Re-tighten the jam nut.
6. Apply a small amount of grease to the inside of the boot and
slide it over the cable adjuster to its original position.
NOTE: Pivot bearing inside the housing is a slip-fit
and will require some light prying to separate the
housing. Use caution.
3. Remove the cable from the housing and the ball -end from
the throttle pedal arm.
2.18
MAINTENANCE
= T
= T
Pivot Bearing
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4. Remove the carburetor slide assembly from the carburetor
body and disconnect the throttle cable.
5. Raise the vehicle and support it with jack stands in order to
access the underside of the vehicle.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
reassembly.
6. Remove the panduit straps retaining the throttle cable to the
frame and brake line.
7. Pull the throttle cable out through the back of the vehicle
and discard the cable.
8. Route the new cable from back-to-front, through the
retainers at the bottom of the frame, following the routing
noted during disassembly.
12. Install the new cable onto the carburetor slide assembly and
install the slide into the carburetor. Hand-tighten the slide
cap sufficiently.
13. Place the throttle cable end into the foot pedal housing.
14. Place a new gasket on the housing and install the cover.
Torque the retaining screws to specification.
2
9. Fasten the cable with cable ties at the same locations they
were previously removed.
10. Continue to route the cable towards the front of the vehicle
using the brake line routing as a general guide.
ETC Throttle Housing Screws:
8.5-10 ft. lbs. (11.5-13.5 Nm)
Throttle Pedal Mounting Screws:
16-20 ft. lbs. (21-27 Nm)
15. Start the engine and allow it to warm up.
16. Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Freeplay should be 1/16" 1/8" (1.5 - 3 mm).
• If freeplay is correct, proceed to step 21.
• If adjustment is required, refer to “Throttle Freeplay
Adjustment” procedure.
17. After reassembly and adjustment, field test vehicle to
ensure proper throttle operation.
11. Use cable ties to retain the throttle cable, using the sam e
locations they were previously removed.
NOTE: Be sure to route the throttle cable inside the
retainers.
2.19
MAINTENANCE
Dipstick
Full
Add Oil
{
Safe Range
CAUTION
Drain Plug
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ENGINE
Engine Oil Level
Maintain the oil level within the safe range on the dipstick. Do
not overfill.
To check the oil level:
1. Position the vehicle on a level surface.
2. Remove the dipstick. Wipe it dry with a clean cloth.
Engine Oil Change
1. Position the vehicle on a level surface.
2. Clean area around the drain plug.
3. Run engine until warm.
4. Stop the engine.
Hot oil can cause serious burns to skin. Do not
allow hot oil to come in contact with skin.
5. Place a drain pan beneath the engine crankcase.
6. Remove the drain plug and pre-filter screen. Allow the oil
to drain completely.
3. Reinstall the dipstick completely.
4. Remove the dipstick and check the oil level.
NOTE: Rising oil level between checks in cool
weather driving, can indicate moisture collecting in
the oil reservoir. If the oil level is over the full mark,
change the oil.
5. Add the recommended oil as needed.
NOTE: Do not fill the over the normal oil operating
range. Filling over the normal operating range could
cause a mist of oil to enter the air box.
6. Reinstall the dipstick.
2.20
7. Wash the oil pre-filter screen with solvent to remove any
debris. Allow the screen to air dry.
8. Inspect the O-ring on drain plug, replace if needed.
NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks
or scratches.
9. Reassemble the pre-filter screen and spring to the pre-filter
plug.
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