Polaris RANGER RZR 170 Service 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 publica tion. Due to constant improvements in the design and quality of production component s, some minor discrep ancies may result between t he actual vehicle and the inf ormation 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.

Page 2

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

WARNING

CAUTION

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, Re gist er ed Trademark of Textron Some Polaris factory publications can be do wnloaded from www.polaris.com, purchased from www.purepolaris.com

or by contacting the nearest Polaris dealer.

Page 3

GENERAL INFORMATION

MAINTENANCE

ENGINE / TRANSMISSION

FUEL SYSTEM

BODY / SUSPENSION / STEERING

BRAKES

CVT

ELECTRICAL

Page 4

Page 5

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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Page 6

GENERAL INFORMATION

ENGINE SERIAL NUMBER

MODEL NUMBER DESIGNATIONS

Model Number Designation

Example: R12VA17AA

GROUP

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

R= RANGER

* = 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.

MODEL

YEAR

12 13

CHASSIS DRIVELINE ENGINE CATEGORY OPTION

V = RZR A = 2x4 Chain

Displacement in cc

(i.e. 17 = 170cc)

A = ORV A

VEHICLE IDENTIFICATION NUMBER

VIN Number Designation

Example: RF3VA17A6BT012516

Vehicle Descriptors Vehicle Identifiers

World Mfg. ID

Chassis

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

Driveline

Engine Size

Engine Modifier

Category

Check Digit

Model Y ear *

Mfg. Location

Individual Serial No.

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

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.

1.2

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Unit Serial Number (VIN) and Emissions Decal Locations

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.

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

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GENERAL INFORMATION

P/N 0453013

VEHICLE INFORMATION

Publication Numbers

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

2012 RANGER RZR 170

2013 RANGER RZR 170

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.

R12VA17AA R12VA17AC

R13VA17AA R13VA17AB

9923583 9923584

9923980 9923981

Paint Codes

Painted Part Color Description Polaris Number

Frame / Bumpers / Racks Gloss Black P-067

Plastic - Hood / Dash / Fenders

Indy Red

White

P-293 P-133

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.

1.4

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GENERAL INFORMATION

Select “SPX Website - Tools, diagnostics” from

the “Service and Warranty” drop down menu

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/.

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GENERAL INFORMATION

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

(Includes people, cargo, accessories)

300 lbs. / 81.7 kg

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GENERAL INFORMATION

MODEL: 2012 RANGER RZR 170

MODEL NUMBER: R12VA17AA / R12VA17AC 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

Carburetor Type Keihin

Pilot Jet 35

Main Jet 100

Air Screw 2 1/4 Turns Out (init i al )

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

Performance Synthetic (PS-4)

Extreme Duty Oil

Single Headpipe / Single

Fuel System

Electrical

Daytime Running Lamps

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

GTX12-BS / Low Maintenance

Silencer

2.5 gal. (9.5 liters)

87 Octane (minimum)

2 - Single Beam

(DRL)

NGK CR6HSA

12 Amp Hr. / 12 Volt

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 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

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

Brake Fluid DOT 4

(Factory Setting - Softest)

Polaris AGL

23.7 oz. (700 ml)

Cam Adjustable

Foot Actuated - 4 Wheel

Hydraulic Disc

JETTING CHART

Altitude

Meters

(Feet)

0-3000

(0-10000)

3000+

(10,000+)

Ambient Temperature

Below 40 F

Below 5

 C

102 100

100

Above +40 F

Above +5

#3 needle clip position

 C

CLUTCH CHART

Altitude Meters (Feet)

0-3000

(0-10,000)

3000+ (10,000+)

Shift Weight

6 @ 17 grams

*** 6 @ 15 grams

PN 0454619

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GENERAL INFORMATION

MODEL: 2013 RANGER RZR 170

MODEL NUMBER: R13VA17AA / R13VA17AB ENGINE MODEL: S35C

Category Dimension / Capacity

Capacity

(Includes people, cargo, accessories)

300 lbs. / 81.7 kg

1.8

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GENERAL INFORMATION

MODEL: 2013 RANGER RZR 170

MODEL NUMBER: R13VA17AA / R13VA17AB 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

Carburetor Type Keihin

Pilot Jet 35

Main Jet 100

Air Screw 2 1/4 Turns Out (init i al )

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

Performance Synthetic (PS-4)

Extreme Duty Oil

Single Headpipe / Single

Fuel System

Electrical

Daytime Running Lamps

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

GTX12-BS / Low Maintenance

Silencer

2.5 gal. (9.5 liters)

87 Octane (minimum)

2 - Single Beam

(DRL)

NGK CR6HSA

12 Amp Hr. / 12 Volt

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 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

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

Brake Fluid DOT 4

(Factory Setting - Softest)

Polaris AGL

23.7 oz. (700 ml)

Cam Adjustable

Foot Actuated - 4 Wheel

Hydraulic Disc

JETTING CHART

Altitude

Meters

(Feet)

0-2400 (0-8000)

2400+ (8000+)

-30 to -10° F

(-34 to -23° C)

Main Jet = 102

Pilot Jet = 38

Clip Position = 4

Main Jet = 100

Pilot Jet = 38

Clip Position = 4

Shaded cell indicates factory setting.

Ambient Temperature

-15 to 5° F

(-26 to -15° C)

Main Jet = 100

Pilot Jet = 38

Clip Position = 4

Main Jet = 98

Pilot Jet = 38

Clip Position = 4

0° F+

(-17° C+)

Main Jet = 100

Pilot Jet = 35

Main Jet = 98

Pilot Jet = 35

CLUTCH CHART

Altitude

Meters

(Feet)

0-3000 (0-10,000)

3000+ (10,000+)

Shift Weight

6 @ 17 grams 6 @ 15 grams

PN 0454619

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GENERAL INFORMATION

Grade 2

Grade 5

Grade 8

MISCELLANEOUS SPECIFICATIONS AND CHARTS

Standard Bolt Torque Specification

Bolt Size

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)

Grade 2

ft-lbs (Nm)

Grade 5

ft-lbs (Nm)

Grade 8

ft-lbs (Nm)

Metric Bolt Torque Specification

GRADE

Bolt Size

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

4.6 4.8 8.8/8.9 10.9 12.9

1.10

FT-LB/NM (DRY THREADS)

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Conversion Table

GENERAL INFORMATION

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

°C to °F: °F to °C:

9/5

(°C + 32) = °F

5/9

(°F - 32) = °C

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GENERAL INFORMATION

SAE Tap Drill Sizes

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

Decimal Equivalents

Metric Ta p Drill Sizes

Tap Size Drill Size

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

1.12

Decimal

Equivalent

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Nearest

Fraction

Page 17

MAINTENANCE

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

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

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MAINTENANCE

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

2.2

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MAINTENANCE

WARNING

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 operatio ns.

Maintenance intervals in the following chart are based upon average ridi ng 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 determin e 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 :



= 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 acould result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

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MAINTENANCE

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 - D aily -

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 -

Fuel Level - Daily -

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

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

Engine Oil Change

(Break-In Period)

Drive Chain

(Break-In Period)

Valve Clearance 10 H 1 M 100 (160)

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)

Remarks

Check each day before driving the vehicle.

Make adjustments as needed. See the Pre-

Ride 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 the first 10

hours of operation

Adjust and lubricate after the first 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

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MAINTENANCE

30 - 100 Hour Maintenance Interval

Periodic Maintenance Chart

Maintenance Interval

Item





Carburetor Air Intake Ducts







C V T C l u t c h e s / D r i v e B e l t



 Wheel / Axle Bearings 100 H 12 M 600 (1000) Inspect; replace as needed

 Toe Adjustment - - -

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)

Carburetor Float Bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage

Throttle Cable /

TRS Switch

Choke Cable 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary

/ 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)

Fuel Filter 100 H 12 M 600 (1000) Repl ace yearly

Engine Mounts 100 H 12 M 600 (1000) Inspect

Exhaust Emissions /

Muffler / Pipe

Ignition Timing 100 H 12 M 600 (1000) Inspect

Spark Plug 100 H 12 M 600 (1000)

Wiring 100 H 12 M 600 (1000)

(Drive and Driven)

Spark Arrestor 100 H 12 M 600 (1000) Clean

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) Inspect; adjust; lubricate; replace if necessary

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; check condition; adjust gap;

Inspect for wear, routing, security; apply

dielectric grease to connectors subjected to

Inspect periodically; adjust when parts are

Remarks

- clean as required

replace as needed

water, mud, etc.

replaced

 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.

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MAINTENANCE

Grease Steering Pivots

Grease A-arm Pivots

Inspect Brake Pads

Inspect / Replace Air Filter

Inspect Brake Pads

Clean / Lubricate Chain

Inspect Exhaust

Daytime Running

Lamps

Tail / Brake Lamp

MAINTENANCE REFERENCES / SERVICE LOCATIONS

Front and Rear View

2.6

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Page 23

RH and LH Side Views

MAINTENANCE

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2.7

Page 24

MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2878920

2878922

2878919

2878068

2878069

2873604

2871653

2872276

2871654

Performance Synthetic (PS-4) Extreme

Duty Oil (Quart)

Performance Synthetic (PS-4) Extreme

Duty Oil (2 Quart)

Performance Synthetic (PS-4) Extreme

Duty Oil (Gallon)

Gearcase / Transmission Lubricants

AGL Plus - Synthetic ATV Gearcase

Lubricant (1 Qt.) (12 Count)

AGL Plus - Synthetic ATV Gearcase

Lubricant (1 Gal.) (4 Count)

AGL - Synthetic A TV Gear case Lubrican t

(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)

NOTE: Each item can be purchased separately at your local Polaris dealer.

Part No. Description Additives / Sealants / Thread Locking Agents / 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)

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)

2870465 Oil Pump for 1 Gallon Jug

Grease / Specialized Lubricants

2871312 Grease Gun Kit 2871322

2871423 2871460 Starter Drive Grease (12 Count)

2871329 Dielectric Grease (Nyogel™) 2872348

2.8

Premium All Season Grease

(3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Chain Lubricant, Aerosol

(16 oz.) (12 Count)

9923983 - 2012-2013 RZR 170 Service Manual

NOTE: The number count indicated next to each part number in the table above indicates the number of units that are shipped with each order.

Page 25

MAINTENANCE REFERENCES

Item Ref. Rec. Lube / Fluid Method Frequency*

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.

Page 2.6

Performance Synthetic

(PS-4) Extreme Duty Oil

AGL Plus 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.

MAINTENANCE

Change after 10 hrs, and

then 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**

**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

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MAINTENANCE

Shift Cable

Mount

Dust Boot

Clevis Pin

Shift Cables

Lower

Jam Nut

Upper

Jam Nut

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

• 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.

1. Locate the shift cable in the rear wheel well area.

2. Inspect shift cable, clevis pin, pivot bushing s, 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:

• 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. There are adjusters on the cables:

• If adjustment cannot be obtained, the adjusters on

the trans case should be set to center, and the adjusters on the cables should be used to set the adjustment

• The adjusters on the trans case can be used again

for subsequent adjustments

NOTE: This procedure may require a few attempts to obtain the proper adjustment.

2.10

6. Once the proper adjustment is obtained, tighten the lower jam nut against the mount.

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MAINTENANCE

Lower

Jam Nut

Upper

Jam Nut

Lower

Jam Nut

Upper

Jam Nut

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.

Shift Cable Replacement

Shift cable replacement may be necessary if symptoms include:

• Inability to engage 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.

6. Loosen the lower and upper jam nuts and remo ve the cables.

7. Inspect shift lever assembly. Replace parts as required if worn or damaged.

8. Raise the vehicle and support it with jack stands in order to access the underside to remove the cables.

IMPORTANT: It is important for reassembly to document location of cable ties and routing prior to removal.

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 .

9. Install new cables and adjust for proper oper ation and lever travel without binding.

IMPORTANT: Do not allow cables to hang below vehicle frame.

10. After installation, lower the vehicle, and then st art the 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.

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MAINTENANCE

ACCESS PANEL

AIR FILTER

APPLY LUBRICANT TO INNER LIP

FUEL SYSTEM AND AIR INTAKE

Air Filter Service

It is recommended that the air filter be inspected as p art 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.

NOTE: Service the filter more frequently if vehicle is operated in wet conditions, dusty conditions or at high throttle openings for extended periods.

1. Move or remove the storage bag. Remove the four (4) access cover fasteners, and then remove the access cover.

4. Clean the air box and remove any sediments/ contaminants.

5. Apply a small amount of commercially-available chassis lubricant to the inner lip seal of the new air filter. Install the filter and tighten the gear clamp.

6. Reinstall the air box cover and secure the spring clips.

7. Reinstall the access cover and storage bag.

2. Release the air box cover spring clips and remove the cover. Verify the cover seal is not damaged.

3. Loosen the air filter gear clamp and remove the filter. Discard the filter.

2.12

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MAINTENANCE

Increase

Decrease

Choke Cable Bracket

No Adjustment Past This Point

Choke Cable Adjustment

With the choke knob pushed in, verify the choke linkage is not engaged at the carburetor . Pull the choke knob out and verify there is 3/16" cable freeplay before the choke

linkage engages.

Free play adjustment is made by loosening the choke cable bracket at the carburetor and moving the cable barrel up or down in the bracket.

3. Remove the retaining screws and pull the choke assembly out at the dash.

4. Raise the vehicle and support it with jack stands in order to access the underside.

IMPORTANT: It is important for reassembly to document location of cable ties and routing prior to removal.

5. Pull the cable out from under the dash and the underside of the vehicle.

IMPORTANT: Do not adjust the cable barrel higher than flush with the bottom of the choke cable bracket.

After adjusting choke cable, pull choke knob out to full choke position. Verify knob does not pull out of cable. If knob pulls out of cable, decrease choke cable free play.

Choke Cable Replacement

The choke cable is replaced as an assembly.

1. With the engine off, place the vehicle in neutral and apply the parking brake.

2. Remove the cable end from the carburetor.

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. Handtighten fasteners sufficiently, using care not to overtighten.

8. Reinstall the choke cable onto the carburetor.

9. Adjust cable to desired freeplay.

If smooth choke operation is not obtainable, inspect for kinks, sharp bends in the routing or a linkage obstruction.

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MAINTENANCE

CAUTION

Idle Speed

Screw

Increase

Decrease

IDLE SPEED

Increase

Decrease

PILOT AIR

SCREW

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).

Stop turning at this point and note the screw setting.

Pilot Air Screw Base Setting:

2.25 turns out (initial)

Idle Speed 1700 ± 100

NOTE: Always check throttle cable freeplay after adjusting the idle speed and readjust if necessary.

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. Start the engine and verify (using a portable tachometer) the idle speed is set to specification. Always check throttle cable freepla y after adjusting idle speed, and adjust if necessary.

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 S tep 2 and

5. Readjust idle speed if not within specification.

2. Using ‘D’-shaped screwdriver S pecial Tool P A -47361 adjust the pilot air screw setting, turn the screw clockwise until engine idle RPM begins to decrease.

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MAINTENANCE

WARNING

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 servic e th e fuel filter :

1. Turn 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.

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MAINTENANCE

Turn knob to operate

the fuel valve

Drain Screw

Open

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.

4. Tighten drain screw.

5. Turn fuel valve to “ON” and check for fuel leaks.

6. Start engine and re–check for leaks.

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.

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.

1. Turn fuel valve to the ‘OFF’ position.

2. Place a container under the bowl drain hose.

3. Loosen drain screw and allow fuel in the float bowl and fuel line to drain completely.

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.

NOTE: For all other information related to the fuel System, refer to Chapter 4.

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MAINTENANCE

Throttle Pedal

Jam Nut Stop Screw

Decrease / Increase

SPEED

Throttle Pedal Inspection

If the throttle pedal has excessive play because of cable stretch or misadjustment, it will cause a delay in throttle response. In addition, 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.

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.

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MAINTENANCE

Throttle Cable

Adjuster

WARNING

Pivot Bearing

Throttle Freeplay Adjustment

Inspection

1. Place the transmission in the Neutral (N) position.

2. Star t 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. Turn engine off, then place the vehicle in neutral and apply the parking brake.

2. Remove the foot pedal TRS cover screws and ONE left-side 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 greas e 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.

4. Remove the carburetor slide assembly from the carburetor body and disconnect the throttle cable.

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MAINTENANCE

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Pivot Bearing

5. Raise the vehicle and support it with jack stands in order to access the underside of the vehicle.

IMPORTANT: It is important for reassembly to document location of cable ties and routing prior to removal.

6. Remove the panduit straps retaining the thr ottle 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.

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.

11. Use cable ties to retain the throttle cable, using the same locations they were previously removed.

TRS 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.

NOTE: Be sure to route the throttle cable inside the retainers.

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MAINTENANCE

Dipstick

Full

Add Oil

{

Safe Range

CAUTION

Drain Plug

ENGINE

Engine Oil Level

Maintain the oil level within the safe range on the dip stick. Do not overfill.

To check the oil level:

1. Position the vehicle on a level surface.

2. Remove the dipstick and 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 and a llow 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 over the normal oil operating range, because it could cause a mist of oil to enter the air box.

6. Reinstall the dipstick.

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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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MAINTENANCE

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10. Reinstall the drain plug, and torque to specification.

Crankcase Drain Plug:

18 ft-lbs (23 Nm)

11. Remove the dipstick. Add recommended oil making sure not to overfill.

Recommended Engine Oil:

Performance Synthetic (PS-4)

Extreme Duty Oil

Capacity:

37 oz. (1.1 ltr)

12. Reinstall the dipstick.

13. Start the en gine an d allow it to idle for a sh ort pe riod .

Engine Crankcase Ventilation System Inspection

The engine is equipped with a crankcase ventilation. Follow the breather hoses from the airbox to the engine and inspect the hoses for possible kinks or wear. The hoses are form-fitted for a proper fit.



14. Stop the engine and inspect for leaks.

15. Check the oil level. Add oil as needed to bring the level to the ‘Safe Range’ on the dipstick.

IMPORTANT: Over-filling engine crankcase will result in oil entering the air box. Maintain the recommended oil level.

NOTE: Make sure lines are not kinked or pinched.

Engine/Transmission Mount Locations

Periodically inspect engine/transmission upper and lower mounts for cracks or damage.

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MAINTENANCE

Compression tester adaptor threads

should not exceed spark plug threads.

1/2” (12.07mm)

= In. / mm.

Compression / Leakdown Test

IMPORTANT: Use of a compression tester adaptor that is too long WILL CAUSE DAMAGE to the cylinder head. The adaptor length should be no longer than the length of the spark plug threads (1/2” or 12.07mm) .

Cylinder Compression

Standard: 130 - 160 psi

Cylind er Le akage

Service Limit: 15%

Inspect if leakage exceeds 15%

Intake Valve Clearance Adjustment

1. Remove the valve cover and secondary air pipe assembly.

2. Verify cam lobes are pointed down.

3. Insert the correct thickness feeler gauge between end of intake valve stem and adjuster screw.

4. When clearance is correct, hold adjuster screw and tighten locknut securely.

5. Re-check the valve clearance.

6. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

Valve Clearance:

.003” (.07 mm)

Exhaust Valve Clearance Adjustment

1. Remove the valve cover and secondary air pipe assembly.

2. Verify cam lobes are pointed down.

3. Insert the correct thickness feeler gauge between end of exhaust valve stem and adjuster screw.

4. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge.

5. When clearance is correct, hold adjuster screw and tighten locknut securely.

6. Re-check the valve clearance.

7. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

Valve Clearance:

.003” (.07 mm)

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Exhaust - Spark Arrestor

WARNING

= T

Silencer

Retaining

Screws

Arrestor

Screen

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust syst em

becomes very hot. Serious burns could result from

contact with the exhaust components. Allow

components to cool sufficiently before proceeding.

Wear eye protection and gloves. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can

cause loss of consciousness or death in a very

short time.

To remove accumulated carbon, clean the spark arrestor at the interval recommended in the Periodic Maintenance Chart.

1. Remove the retaining screws and remove the arrestor from the end of the silencer.

MAINTENANCE

2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm.

3. Inspect the screen for we ar and d am a ge . Re pla ce if required.

4. Reinstall the arrestor and torque the fasteners to specification.

Spark Arrestor Fasteners:

7 ft-lbs (9.5 Nm)

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MAINTENANCE

Transmission Oil Fill/Check

TRANSMISSION

Transmission Specification Chart

GEARCASE LUBRICANT CAPACITY DRAIN PLUG TORQUE

Transmission

(Main Gearcase)

Transmission Oil Change

NOTE: It is important to follow the tran smissio n a nd gearcase maintenance intervals described in the Periodic Maintenance Chart.

AGL Plus - Synthetic

ATV Gearcase

Lubricant

23.7 oz. (700 ml) 18 ft-lbs ( 24 Nm) 30-45 in-lbs (3-5 Nm)

The fill plug is located on the side of the gearcase next to the shift lever bell crank. The fluid level should be maintained so it is even with the bottom of the fill plug hole.

Transmission Specifications

Specified Lubricant:

AGL Plus Synthetic Gearcase

Lubricant

(PN 2878068)

Approximate Capacity at Change:

23.7 oz. (700 ml)

FILL / LEVEL CHECK

LUG TORQUE

Fill / Level Plug Torque:

30-45 in-lbs (3-5 Nm)

Drain Plug Torque:

18 ft-lbs (24 Nm)

Transmission Oil Level Check:

• Be sure vehicle is positioned on a level surface when checking or changing fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

1. Position vehicle on a level surface.

2. Remove the fill plug.

3. Add the recommended fluid through the fill plug hole until it is even with the bottom of the check plug hole.

4. Reinstall the check/fill plug and torque to 30-45 in-lbs

(3-5 Nm) or tighten by hand sufficiently.

Transmission Oil Change:

1. Remove the level check plug (refer to “Lubricant Level Check”).

2. Place a drain pan under the main gea rcase drain plug.

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MAINTENANCE

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Steel Wheel

Aluminum Wheel

3. Remove the drain plug and allow to drain completely.

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring and torque to specification.

Transmission Drain Plug:

18 ft-lbs (24 Nm)

FINAL DRIVE / WHEEL AND TIRE

Wheel, Hub, and Spindle Torque Table

Item Nut Type Specification

Aluminum Wheels

Steel Wheels

Hub Retaining Nuts

(Front & Rear)

Lug Nut

(#1)

Flange Nut

(#2)

- 40 ft-lbs (54 Nm)

30 ft-lbs (41 Nm)

+1/4 turn

27 ft-lbs (37 Nm)

6. Add the recommended fluid through the fill plug hole. Maintain the fluid level even with the bottom of the fill plug hole when filling. Do not overfill.

7. Reinstall the fill plug.

8. Check for leaks.

9. Discard the used lubricant properly.

NOTE: Do not lubricate the stud or the lug nut.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in gear and stop the engine.

3. Loosen the wheel nuts slightly. If wheel hub removal is required, remove the cotter pin and loosen the hub nut slightly .

4. Elevate the appropriate side of the vehicle by placing a suitable jack and stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and washers.

Wheel Installation

1. Verify the transmission is in gear.

2. Install the wheel hub, washers, and hub nut, if previously removed.

3. Place the wheel in the correct position on the wheel hub. Make sure the valve stem is toward the outside and rotation arrows on the tire p oint toward forward

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rotation.

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MAINTENANCE

CAUTION

Wheel Nuts (4)

Hub Nut

Use a new

cotter pin

Note

Tire Rotation

Valve stem

facing outward

WARNING

CAUTION

Tread Depth 1/8" (3 mm)

4. Attach the wheel nuts and finger tighten them.

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section.

7. If hub nut was removed, install a new cotter pin after the hub nut has been tightened.

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

Operating a RANGER 170 with worn tires will increase the possibility of the vehicle skidding

easily with possible loss of control.

Worn tires can cause an accident.

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end

Tire Inspection

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect vehicle handling.

Tire Tread Depth

of nut seats properly into taper on wheel.

Always replace tires when the tread depth

measures 1/8", (.3 cm) or less.

Tire Pressure

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

Tire Pressure Inspection (Cold)

Front Rear

3 psi (20.7 kPa) 3 psi (20.7 kPa)

Drive Chain Lubrication and Adjustment

Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Periodic Maintenance Chart. Lubricate more often under severe use, such as in dirty or wet conditions.

IMPORTANT: Washing the drive chain with a high pressure washer or solvents can cause premature wear and chain failure. Do not use a high pressure washer or gasoline to clean the drive chai n. Operating the vehicle with improper rear drive chain deflection can result in severe damage to the transmission and

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MAINTENANCE

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drive components. Always make sure the chain adjusted within the stated specifications.

1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain.

2. Raise the rear of the vehicle and support securely under the mainframe. Allow the swing arm to hang at full shock extension without touching the ground. This establishes the tightest chain position.

3. Pull down on the chain tensioner to move it out of the way , then measure chain deflection. It shou ld have 1/ 4"-1/2" (6-12 mm) deflection.

7. Torque the chain adjuster locknuts. Hold the adjuster stud securely while tightening the nut to avoid breaking the stud.

Chain Adjuster Locknuts:

18 ft-lbs (25 Nm)

8. Torque the four rear housing mount bolts.

Rear Housing Mounting Bolts:

43 ft-lbs (60 Nm)

4. Loosen the four rear housing mount bolts ( two on each end of axle).

5. Loosen the chain adjuster locknuts.

6. Turn the chain adjusters evenly to achieve 1/4"-1/2" (6-12 mm) chain deflection.

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MAINTENANCE

WARNING

CAUTION

Battery

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one t ablespoon baking soda and one cup water . Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from

contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or

vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get

prompt medical attention.

Battery Removal

1. Remove or pull the driver’s seat forward to access the battery.

2. Disconnect the black (negative) battery cable.

3. Disconnect the red (positive) battery cable.

4. Remove the rubber strap and lift the battery out of th e vehicle.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed

space. Always shield eyes when

working near batteries.

KEEP OUT OF REACH OF CHILDREN.

NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent to 1/10 of the battery’s rated amp/hour capacity. Do not use the vehicle’s stator/alternator to charge a new battery.

To reduce the chance of sparks: Whenever

removing the battery, disconnect the black

(negative) cable first. When reinstalling the

battery, install the black (negative) cable last.

Battery Installation

IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure before installing the battery.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with rubber strap.

3. Coat the terminals with dielectric grease or petr oleum jelly.

4. Connect and tighten the red (positive) cable first.

5. Connect and tighten the black (negative) cable last.

2.28

6. Verify th at cables are properly routed and reinst all the driver’s seat.

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MAINTENANCE

WARNING

Inspect electrode for wear or buildup

Battery Off Season Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

Battery Charging (Maintenance Free)

The sealed battery is already filled with electrolyte and has been sealed at the factory. Never pry the sealing strip off or add any type of fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure the DC voltage at the battery terminals.

State of Charge

25% - 50%

0% - 25%

Voltage Action

11.5 - 12.0 VDC

11.5 VDC or less

Needs Charge

Needs Charge 20 hrs

Charge

Time

At least 13

hrs, verify

state of

charge

Spark Plug Service

1. Clean plug area so no dirt or debris can fall into the cylinder when the plug is removed.

A hot exhaust system and engine can cause serious

burns. Allow engine to cool or wear protective

gloves when removing the spark plug.

2. Remove the spark plug cap.

1. Check the battery voltage with a voltmeter or multimeter. The battery voltage should read 12.8 VDC or higher.

2. If the voltage is less than 12.8 volts, charge the battery at 1.2 amps or less until battery voltage is 12.8 VDC or greater.

NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for battery charging directions. When using a constant current charger, follow the guidelines in the following table:

State of Charge

100%

75% 100%

50% - 75%

Voltage Action

12.8 - 13.0 VDC

12.5 - 12.8 VDC

12.0 - 12.5 VDC

None, check

again in 3

months

May need

slight charge,

check again in

3 months

Needs Charge 5 - 11 hrs

Charge

Time

None

Required

3 - 6 hrs

3. Remove spark plug.

4. Inspect electrodes for wear or carbon buildup. Look for a sharp outer edge on the electrode, with no rounding or erosion.

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MAINTENANCE

Gap - .024-.028" (0.6-.07 mm)

Spark Plug Gap

Ground

Terminal Location

U-Joints

Gearbox

Tie Rod Location

5. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brus h or coated abrasive should not be used.

6. Measure gap with a wire gauge. Refer to specifications in the following illustration for proper spark plug type and gap. Adjust gap if necessary by carefully bending the side electrode.

7. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

8. Apply anti-seize compound to the spar k plug threads.

9. Install spark plug and torque to specification.

STEERING

Steering Inspection

The steering components should be checked pe riodically for loose fasteners, worn tie rod ends, ball joints, and damage. Also check that all cotter pins are in place. If cotter pins are removed, do not re–use, always use new cotter pins.

Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced, check front end alignment.

Steering Wheel Freeplay

Check the steering wheel for specified freeplay and operation.

1. Position the vehicle on level ground.

Recommended Spark Plug:

NGK CR6HSA

Spark Plug Torque:

11 ft-lbs (15 Nm)

Engine To Frame Ground

Inspect engine ground cable connection. Be sure it is clean and tight. The ground cable runs from the engine starter motor to the ground terminal location under the driver’s seat.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8”-1.0” (20-25 mm) of freeplay.

4. If there is excessive freeplay or the steering feels rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints

• Steering Gearbox

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MAINTENANCE

Check for Loose Wheel or Hub

= In. / mm.

Measurement “B”

Chalk Mark

Measurement “A”

Steering Inspection / Tie Rod Ends and Hubs

• To check for play in the tie rod end, grasp the steering tie rod and pull in all directions feeling for movement.

• Elevate front end of machine so front wheels ar e off the ground. Check for any looseness in front hub and wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

Toe Alignment Inspection

1. Place machine on a smooth level surface.

2. Set steering wheel in a straight ahead position and secure the steering wheel in this position.

3. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

• If abnormal movement is detected, inspect th e h ub and wheel assembly to determine the cause (possible loose wheel nuts or loose front hub components).

• Refer to Chapter 5 for front hub service procedures.

4. Measure the distance between the ma rks and r ecord the measurement. Call this measurement “A”.

5. Rotate the tires 180 by moving vehicle forward or backward. Position chalk marks facing rearward, even with the hub/axle center line.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” a nd “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8” to 1/4” (.3 to .6 cm) toe out. This means the measurement at th e front of the tire (A) is 1/8” to 1/4” (.3 to .6 cm) wider than the me asurement at the rear (B).

Wheel Toe-Out:

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

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MAINTENANCE

CAUTION

= T

WARNING

Increase

Preload

Decrease

Preload

Toe Adjustment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: Be sure steering wheel is straight ahead before determining which tie rod(s) need adjustment.

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both ends of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Toe Alignment Inspection.

• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

• After alignment is complete, torque jam nuts to specification. Keep tie rod parallel to the mounting surface.

SUSPENSION

Spring Preload Adjustment

The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and

serious injury or death. Always adjust all spring

preloads equally.

Suspension Spring Adjustment

1. Position the vehicle on a level surface and stop the engine.

2. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend.

NOTE: The tires should not be touching the ground.

3. To adjust the shock spring preload, rotate the adjustment cam clockwise to increase spring tension or counter-clockwise to decrease spring tension using the supplied spanner wrench.

Tie Rod Jam Nut:

12-14 ft-lbs (16-19 Nm)

2.32

Special Tool:

Shock Spanner Wrench

4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position.

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MAINTENANCE

Measure Pad Material

Service Limit:

.040" (1 mm)

Thickness

Measure Brake Disc Thickness

Service Limit:

.170" (4.32 mm)

Front

Disc

Rear

Disc

BRAKE SYSTEM

Brake Fluid Inspection

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years, anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be a ccessed through the left front wheel well.

1. Position the vehicle on a level surface with the engine off.

2. Place the transmission in gear and lock the parking brake.

3. View the brake fluid level in the reservoir. The level should be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches the MAX level line.

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds, then check for fluid leaks around the master cylinder and brake caliper fittings.

Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad wear surface for excessive wear.

3. Pads should be changed when the friction material is worn to .040” (1 mm).

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

6. The disc(s) should be replaced if thickness is less than .170” (4.32 mm).

Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

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MAINTENANCE

Inline Adjuster Nut

Jam Nut

Inspect Freeplay Here

Parking Brake Cable Freeplay Adjustment

Use the in-line adjuster to adjust the parking brake cable freeplay.

NOTE: Inspect the brake pads before adjusting parking brake adjuster.

1. Verify the parking brake lever is down.

2. Inspect the freeplay between the cable end and caliper bracket by pulling back on the cable.

3. Freeplay should be 1/16"-1/8" (1.5-3mm).

4. T o adjust the cable freeplay , loosen the in-line adjuster jam nut. Turn the adjuster nut outwards to decrease cable freeplay. Turn the adjuster inwards to increase cable freeplay.

5. After setting the correct amount of freeplay , tighten the in-line adjuster jam nut against adjuster.

2.34

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MAINTENANCE

Hold Adjuster Bolt While Tightening Jam Nut

Parking Brake Adjustment

NOTE: Inspect the brake pads before adjusting parking brake adjuster.

1. Place vehicle on a flat, level surface.

2. Shift transmission into Neutral.

3. Carefully lift rear tires off the ground with a stable platform jack, or set vehicle on stable jack stands.

4. Loosen jam nut (A) on parking brake ad justment bolt.

5. While rotating the rear wheels by hand, tighten the adjustment bolt (B) until significant brake drag is detected.

6. Back the adjustment bolt out 1/4 turn.

7. Hold adjustment bolt in place and tighten jam nut securely against lever arm.

8. Check parking brake lever movement. Verify the rear wheels rotate freely with the parking brake off (parking brake lever is in the DOWN position), and that the vehicle will not move when the parking brake is applied (lever in the UP position).

9. Verify the park brake lever stays in the UP position when brake is fully applied.

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MAINTENANCE

MAINTENANCE LOG

Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician

2.36

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CHAPTER 3

ENGINE

TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3

TORQUE PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4

ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

ENGINE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5

ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

PISTON IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6

ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .7

ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .8

OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

ENGINE SYSTEMS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

BREATHER / OIL SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

EMISSIONS SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

COOLING SHROUD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

TOP-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

ENGINE REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

FINDING TOP DEAD CENTER (TDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

ROCKER ASSEMBLY 

DISASSEMBLY AND INSPECTION3.15

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

CYLINDER HEAD DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

CYLINDER HEAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

CAM CHAIN FOLLOWER / TENSIONER GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . .3.23

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . .3.25

HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26

BOTTOM-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

STARTER DRIVE GEAR REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . .3.27

FLYWHEEL REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

CRANKSHAFT ONE WAY GEAR / DRIVE SPROCKET REMOVAL/INSPECTION . . .3.29

STARTER DRIVE ONE-WAY CLUTCH REMOVAL AND INSPECTION . . . . . . . . . . . .3.30

BALANCE SHAFT SPROCKET REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . .3.30

OIL PUMP REMOVAL / DRIVE CHAIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . .3.31

ENGINE

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ENGINE

CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33

CRANKCASE SEPARATION AND CAM CHAIN REMOVAL. . . . . . . . . . . . . . . . . . . . . 3.33

CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33

CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.34

CRANKCASE / BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34

CRANKCASE OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

BEARING / SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

CHAIN GUIDE/TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

CRANKSHAFT, BALANCE SHAFT AND STARTER DRIVE GEAR INSTALLATION . . 3.37

OIL PUMP AND CHAIN INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39

CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40

CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . .3.41

CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41

ROCKER ARM / SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

ROCKER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

CAM CHAIN TENSIONER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47

STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

STATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

STATOR HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49

EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51

SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51

GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51

3.2

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ENGINE

TOOLS

Special Tools

PART NUMBER TOOL DESCRIPTION 2870390 Piston Support Block PA-45153 Flywheel Puller

PA-49959

PA-47344

PA-49935

PA-49936

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/

Transmission Output Shaft Collar Tool

Balance Shaft Slotted Nut Socket

Crankshaft Slotted Nut Socket

Flywheel Puller Adaptor

(Use with PA-45153)

TORQUE SPECIFICATIONS

Engine Torque Specifications

TORQUE SPECIFICATIONS Fastener

Camshaft Chain Guide Pivot Bolt

Camshaft Chain Tensioner

Chain Tensioner Cap 6mm 5-7 (7-9 Nm) Carburetor Intake 6mm 7-8 (9-11 Nm) Cylinder/Head Nuts 10mm 18 (25 Nm) Cylinder Base Screws 6mm 5-7 (7-9 Nm) Crankcase (inner) 6mm 14-15 (19-21 Nm) Crankshaft Slotted Nut 14mm 43 (58 Nm) Balancer Shaft Nut 14mm 43 (58 Nm)

Thread Size

6mm 5-7 (7-9 Nm)

ES35C ft-lbs (Nm)

Exhaust Nuts 6mm 7-8 (9-11 Nm) Flywheel Nut 14mm 43 (58 Nm ) Cooling Fan 6mm 4-5 (5-7 Nm) Oil Drain Bolt 14mm 18 (25 Nm)

Oil Pump  Screws

Oil Pump Sprocket Nut 6mm 7-8 (9-11 Nm) Oil pump baffle plate 6mm 4-5 (5-7 Nm) Stator Assembly 6mm 7-8 (9-11 Nm) Stator Housing 6mm 7-8 (9-11 Nm) Valve Cover 6mm 7-8 (9-11 Nm) Valve Adjuster Lock Nut 5mm 4-5 (5-7 Nm) Starter Motor 6mm 5-7 (7-9 Nm) Spark Plug 12mm 11 (15 Nm)

6mm 4-5 (5-7 Nm)

Pulse Coil Screws 5mm 4-5 (5-7 Nm)

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ENGINE

6 mm

Cylinder Base / Head and Rocker Assembly

RH Crankcase - (Inside Stator Cover)

RH Crankcase - Stator Cover

Torque Patterns

Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined. Refer

to the table for torque specifications.

3.4

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ENGINE INFORMATION

Crankshaft

Cylinder /

and Piston

Cylinder Head

Crankcase

Valve Train

Engine Exploded Views

ENGINE

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ENGINE

Engine Lubrication

Oil Ty pe:**

Performance Synthetic (PS-4) Extreme Duty Oil

Capacity: Approximately 37 oz. (1.1 ltr.) Drain Plug (Engine Oil): 18 ft-lbs (23 Nm) Screen Fitting: 11 ft-lbs (15 Nm) Oil Pressure Specification: Not Applicable 



** For break-in period after engin e top end service, use Performance Synthetic (PS-4) Extreme Duty oil to ensure complete piston ring seating to cylinder wall. Change to above recommendation after 10 hours.

Piston Identification

The piston may or may not have an identification m ark for piston placement. If the piston has an identification mark, follow the directions for piston placement below. If the piston does not have an identification mark, the direction for placement of the piston does not matter.

Note the directional and identification marks when viewing the pistons from the top. The letters “IN” must always be toward the intake side of the engine. T he other numb ers are used for identification as to diameter, length and design. Four stroke engine rings are rectangular profile. Any numbers or letters on the rings (except oil control rings) must be positioned upward. See text for oil control ring upper rail installation.

Accessible Components

The following components can be serviced or removed with the engine installed in the frame:

• Flywheel

• Alternator/Stator

• Starter Motor/Starter Drive

• Oil pump / Chain

• Rocker Arms

• Carburetor

• Transmission Components

• Valves

• Cylinder Head

• Cylinder

• Piston/Rings

• Camshaft

The following components require engine removal for service:

• Cam Chain and Sprockets

• Crankshaft

• Crankshaft Main Bearings

• Crankcase/Bearings

• Balancer/Bearings

NOTE: Cam chain service requires crankshaft removal, as the chain is located on the pto side of the engine.

NOTE: Crankshaft components are not serviceable. Replace crankshaft as an assembly.

Engine Model No.

ES35C N/A

Oversize Available (mm)

3.6

Standard Piston Identification

”IN” marking on top of piston toward intake

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Engine Service Data

Cylinder Head / Valvetrain ES35C

ENGINE

Rocker Arm/Shaft

Camshaft Cam lobe height

Cylinder Head Surface warpage limit .002” (.05 mm) Valve Clearance

Valve Seat Angle Contacting width

Valve Stem diameter

Valve Guide Inner Diameter

Val ve S pring

Cam Chain

Rocker arm ID .3936 - .4007" (10.00 - 10.18 mm) Rocker shaft OD .3925 - .3931" (9.972 - 9.987 mm)

In Std .003" (.07 mm) Ex Std .003" (.07 mm)

Free Length Squareness

Std 1.1730" (29.795 mm) Limit 1.1574" (29.40 mm) Std 1.1637" (29.56 mm) Limit 1.1480" (29.16 mm)

Std .039" (1.0 mm) Limit .063" (1.6 mm) Std .039" (1.0 mm) Limit .063" (1.6 mm) In .1958 - .1960" (4.975 - 4.980 mm) Ex .1950 - .1956" (4.955 - 4.970 mm) Limit .1921" (4.9 mm) In .1968 - .1973" (5.0 - 5.012 mm) Ex .1968 - .1973" (5.0 - 5.012 mm) Limit .1980" (5.03 mm) Inner 1.275" (32.4 mm) Outer 1.385" (35.2 mm)

0.075” (1.9 mm) Install new as a part of any crankshaft

removal

KEY - Std : Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; 

PTO: Power Take Off

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ENGINE

Engine Service Data

Cylinder / Piston / Connecting Rod ES35C

Cylinder

Piston

Piston Pin

Surface warpage limit (mating with cylinder head)

Cylinder bore Std 2.4015 - 2.4019" (61 - 61.01 mm) Taper limit .002” (0.05 mm) Out of round limit .002” (0.05 mm)

Piston to cylinder clearance

Boring Limit Not Applicable

Std 2.4003 - 2.4011" (60.97 - 60.99 mm)

Outer diameter

Pin Bore - Inner Diameter .5906 - .5908" (15.002 - 15.008 mm) Pin outer diameter clearance in piston .00015 - .00047” (.004 - .012 mm)

Degree of fit

1st O.S. Not Applicable 2nd O.S. Not Applicable

Top ring

Std .00039 - .0015" (0.01 - 0.04 mm) Limit .0039" (0.1 mm)

Std .0059 - .013" (.15 - .35 mm) Limit .0196" (0.5 mm)

.002” (0.05 mm)

Piston Pin must be a push (by hand) fit at 68 F (20

 C)

Piston Ring Piston Ring Installed gap

Piston Ring

Connecting Rod

Crankshaft

Oil pump chain Install new as a part of any oil pump replacement

Cam Shaft Chain

Standard clearance -  piston ring to ring groove

Connecting rod small end ID .5903 - .5916” (15.01 - 15.028 mm) Connecting rod big end axial clearance Std .0039 - .011" (0.1 - 0.3 mm) Connecting rod big end radial

clearance Crankshaft end runout 0.0015" (0.04 mm)

Crankshaft end runout - limit 0.0039" (0.1 mm)

Second ring

Oil ring

Top ring

Second ring

Std .0059 - .013" (.15 - .35 mm) Limit .0196" (0.5mm) Std .0079 - .0314" (0.2 - 0.8 mm) Limit .059" (1.5 mm) Std .00078 - .0023" (0.02. - 06 mm) Limit .0035" (0.09 mm) Std .00078 - .0023" (0.02 - 0.06 mm) Limit .0035" (0.09 mm)

Std Not Applicable

Install new as a part of any crankshaft replacement

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off.

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Oil Flow Diagram

ENGINE

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ENGINE

To Valve Cover

To Crank Case

7-8 ft-lbs (9-11 Nm)

To Air Box

To One-Way Valve

ENGINE SYSTEMS SERVICE

Breather / Oil Separator

The breather / oil separator is located on the upper re ar cab support. This system provides ventilation for the valve cover and engine crankcase to the air box. A one-way valve (A) allows pulses from the crankcase to travel in one direction only , thereby vacuuming the crankcase. NOTE: Over-filling of crankcase will result in oil in the air box. Always keep oil volume at recommended level.

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ENGINE

Air To Cylinder Head Exhaust Passage

To Intake (impulse)

Air In

7-8 ft-lbs (9-11 Nm)

16 ft-lbs (22 Nm)

7-8 ft-lbs (9-11 Nm)

Emissions Secondary Air System

The secondary air system is located on the upper rear cab support and engine. This system introduces air into the exhaust system for more comple te burning of the exhaust em issions. The air control valve (A) is operated by intake manifold pulses from the intake manifold, which releases the air to the one-way valve (B) to combine with the pull of the exhaust gas stream from the cylinder head. Check the air control valve (A), one-way valve (B), filter housing (C) and related components according to the maintenance schedu le in Chapter 2 for proper operation and emissions compliance.

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ENGINE

= T

A. Fan Shroud

C. Housing

B. Air Horn Assembly

Cooling Shroud Exploded View

MAG View

PTO View

Cooling Shroud Removal/Installation

The cooling shroud directs air generated by the fan arou nd the cylinder and casing for cooling.

REMOVAL:

1. Remove the carburetor and intake.

2. Remove the exhaust pipe.

3. Remove the screws that attach the fan shroud (A) to the housing (C).

4. Remove the bolts that attach the fan shroud to the stator housing.

5. Remove the screws that attach the upper and lower housings together (C).

6. Remove the bolt that attaches the housing to the engine case on the PTO side.

7. Separate the upper and lower housings at the snaphooks and lift housings away from the engine.

INSTALLATION:

8. Install the upper and lower housings (C), making sure the snap-hooks are secure. Install the housing scr ews

and attaching bolt into the engine case. Han d tighte n sufficiently, using care not to over-tighten.

9. Install the fan shroud (A) and attaching screws to housing (C). Install the fan shroud bolts to the stator housing. Hand tighten sufficiently, using care not to over-tighten.

10. Install the exhaust pipe onto the cylinder. Torque to specification.

Pipe Flange Fasteners:

7-8 ft. lb. (9-11 Nm)

11. Install the carburetor and intake. Torque fasteners to specification.

Fasteners:

7-8 ft. lb. (9-11 Nm)

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ENGINE

Engine Removal

1. Clean work area.

2. Thoroughly clean the engine and chassis.

3. Disconnect battery.

4. Drain engine oil.

5. Disconnect spark plug high tension lead.

6. Disconnect all electrical wires from the engine.

7. Remove the following parts as required:

• Rear Cab Assembly (Refer to Chapter 5)

8. Remove exhaust pipe.

9. Remove the carburetor . Insert a clean shop towel into the carburetor flange to prevent dirt from entering the intake.

10. At the starter motor, note the chassis ground cable location and remove it.

11. Mark the positive (+) cable mounting angle and remove cable.

12. Remove the transmission shift cables from the transmission and secure out of the way.

13. Raise the rear of the unit until the wheels are off the ground. Secure with jackstands under the frame.

14. Remove the drive chain.

Engine Installation Notes

After the engine is installed in the frame, review this checklist and perform all steps that apply:

General Items

• Install previously removed components using new gaskets, seals, and fasteners where applicable.

• Perform checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter

2).

CVT System

• Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing.

• Inspect clutch rollers, shoes and springs before reassembly.

Transmission

• Inspect transmission operation and adjust linkage if necessary.

Exhaust

• Replace exhaust gaskets. Seal connections if desired with high temp sealant.

• After running the engine, verify all bolted exhaust connections are tight and in good condition.

15. Remove the top rear shock bolts and allow the swing arm to drop. (OPTIONAL - Refer to Chapter 5 to remove the axle and swing arm as an assembly)

16. Remove all engine mount bolts and / or engine mount plates.

17. Using the aid of an assistant, lift and remove engine out the rear of the vehicle.

Engine Mount Torque

• Front Mount

•Rear Mounts

Engine Break In Period

4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel.

• Use only Performance Synthetic (PS-4) Extreme Duty Oil, or API certified “SH” oil equivalent.

• Use fuel with a minimum octane of 87 (R+M)/2 method.

• Change break-in oil at 10 hours or 100 miles, whichever comes first.

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ENGINE

Single TDC Mark Aligned

TDC Mark

Rotation

TOP-END DISASSEMBLY

Engine Removal/Installation

Refer to page 3.12 for engine removal / installation notes.

Finding Top Dead Center (TDC)

1. Remove the cooling shroud.

2. Remove the inspection cap from the stator housing.

3. Remove the valve cover and emissions pipe assembly.

To posit ion the crankshaft at Top Dead Center (TDC) on the compression stroke:

4. Rotate the engine slowly in the direction of rotation while watching the intake valve open and start to close.

5. Continue to rotate slowly while watching the camshaft sprocket marks and timing mark in the inspection hole.

6. The engine is at Top Dead Center when the single (TDC) mark on flywheel is visible within the inspection hole and the cam sprocket hole is facing upward.

NOTE: The sprocket marks should align with the gasket surface, the cam lobes must be pointed downward and the rockers must have valve clearance at this point.



Cam Chain Tensioner Inspection

1. Remove the two cam chain tensioner flange bolts.

NOTE: The plunger is under spring tension. Maintain inward pressure on the tensioner body while removing.

2. Allow the cam chain tensioner plunger to extend outward to the end of its travel. Inspect tensioner and plunger (A) for wear or damage.

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ENGINE

Inspect

Exhaust

3. Using a small flat blade screwdriver , turn the tensioner clockwise to retract the plunger. The plunger should move smoothly in and out of the tensioner body.

4. Tap lightly on tensioner body with a soft face hammer to loosen and remove tensioner if required.

5. Replace tensioner assembly if any part is worn or damaged.

Rocker Assembly  Disassembly and Inspection

NOTE: Orientation of the components is important for reassembly. Mark components as needed before disassembly.

1. Remove the valve cover and secondary air injection pipe as an assembly.

2. Loosen each of the four cylinde r head nu ts evenly 1/ 4 turn each time in a cross pattern until loose.

5. Remove each rocker arm shaft using a hex bolt.

NOTE: Place the hex bolt head in a vise and lightly tap the rocker housing with a non-marring hammer to pull the rocker arm shafts.

6. Measure O.D. of rocker shafts for out-of-round. Inspect for wear or damage. Replace if excessive wear is evident. NOTE: Orientation of the rocker

shafts is important for reassembly . Place only the exhaust rocker shaft into the e xhaust si de of the cam support.

3. Remove the nuts and tap the rocker assembly with a plastic hammer to loosen, then remove. Mark or tag rocker arms to keep them in order for assemb ly.

4. Inspect each rocker arm cam follower surface. If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobes if

rocker arms are worn or damaged.

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7. Measure I.D. of each rocker arm for out-of-round and visually inspect the I.D. surface. Replace arm if excessive wear is evident.

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ENGINE

Inspect for Areas of

Tooth Wear or Damage

Compression Release One-Way Operation

Lobe Height

Bearings

8. Inspect the lash adjusters for wear, pitting, or damage to threads of the adjuster or locknut. Replace all worn or damaged parts. NOTE: The end of the lash

adjuster is hardened and cannot be ground or r esurfaced.

Camshaft Removal

NOTE: Cam chain tensioner must be removed before performing this procedure.

1. Verify the valve cover and cam chain tensioner have been removed.

2. Remove the 4 cylinder head bolts evenly by loosening each one 1/4 turn at a time until loose. Tap the rocker assembly with a non-marring hamme r to loosen and remove the assembly.

Camshaft Inspection

1. Inspect cam sprocket teeth for wear or damage. Replace if necessary.

2. Inspect the compression release mechanism. This is a one-way rotating shoulder that lift s the exhaust valve slightly during start-up. If the one-way mechanism is not functioning, replace the cam. Verify the stop bracket and spring is functioning correctly. Replace if excessive wear of components is found.

3. Remove the cam chain from the sprocket by tilting the cam assembly and simultaneously lifting the chain.

4. If not removing the cylinder for other service, secure the cam chain with a wire to prevent it from falling into the crankcase.

3. Visually inspect each cam lobe and bearing for wear, chafing or damage.

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= In. / mm.

Cam Lobe Height:

Compression Release-One-way stop

Intake

Std: 1.1730” (29.795 mm)

Limit: 1.1574” (29.40 mm)

Exhaust

Std: 1.1637” (29.56 mm)

Limit: 1.1480” (29.16 mm)

4. Thoroughly clean the cam shaft.

5. Measure height of each cam lobe using a micrometer . Replace cam if worn below minimum height.

Replace camshaft if damaged or if any part is worn excessively.

ENGINE

Cylinder Head Removal

NOTE: Cam chain and tensioner must be removed. If no crankshaft service is being performed, secure cam chain with mechanics wire to avoid chain falling into the crankcase.

1. Verify the valve cover and tensioner are removed.

2. Remove the two 6mm cylinder/head base screws.

3. Loosen each of the four cylinder head nuts evenly 1/ 4 turn each time in a cross pattern until loose.

4. Remove the nuts and tap th e rocker assembly with a plastic hammer until loose. Remove.

5. After removing the camshaft and securing the cam chain, tap the cylinder head lightly with a plastic hammer until loose. CAUTION: Tap only in

reinforced areas or on thick parts of cy linder head casting to avoid damaging casting.

6. Remove cylinder head (A) and head gasket (B).

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ENGINE

CAUTION

= In. / mm.

WARNING

Cylinder Head Inspection

1. Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

Use care not to damage sealing surface.

If there is damage found on the cylinder head

combustion chamber, it is recommended the

component be replaced.

Cylinder Head Warp Inspection

1. Lay a straight edge across the surface of the head at several different points and measure warpage by inserting a feeler gauge between the straight edge and the cylinder head surface. If warpage exceeds the service limit, replace the cylinder hea d.

Cylinder Head Disassembly

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

NOTE: Keep all parts in order with respect to their location in the cylinder head.

NOTE: Valves have inner and outer springs.

1. Using a valve spring compressor , compress the valve springs and remove the split keeper. NOTE: To prevent loss of tension, do not compress the valve spring more than necessary.

Cylinder Head Warp Limit: .002” (.05 mm)

Combustion Chamber Inspection

Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. Inspect the combustion chamber for cracks and/or damage from foreign debris.

2. Remove spring retainer and spring.

NOTE: The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs (A).

3. Push valve out, keeping it in order fo r reassembly in the same guide.

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ENGINE

Valve Spring Free Length

III.1

III.2

Coil Fatigue / Squareness

Measure valve stem in

several places

4. Measure free length of the inner and outer springs with a Vernier caliper, Ill.1. Check spring for squareness as shown in Ill.2. Replace spring if measurements are out of specification.

Valve Inspection

1. Remove all carbon from valve with a soft wire wheel.

2. Check valve face for runout, pitting, and burned spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and use a dial indicator.

3. Check end of valve stem for flaring, pitting, wear or damage (A).

5. Remove valve seals. NOTE: Replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

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4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be refaced or end ground. V alves must be replaced if worn, bent, or damaged.

5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). Replace if excessive wear is evident.

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ENGINE

CAUTION

Too

Wide

Uneven

Good Too

Narrow

6. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side.

7. Subtract valve stem measurement to obtain stem to guide clearance. NOTE: Be sure to measure each guide and valve combination individually.

8. Replace valve and/or guide if clearance is excessive.

NOTE: If valve guides are replaced, valve seats must be reconditioned. Refer to Valve Seat Reconditioning for procedure.

Follow the manufacturers instructions provided with the valve cutting kit (commercially available). Abrasive stone seat reconditioning equipment can also be used. Keep valves in order with their respective seat.

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced and the valve may overheat and warp, resulting in burned valves.

1. Install pilot into valve guide.

Valve Seat Reconditioning

Valv e Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked the cylinder head must be replaced.

Cylinder Head Reconditioning NOTE: Servicing the valve guides and valve seats

requires special tools and a thorough knowledge of reconditioning techniques.

Wear eye protection when

performing cylinder head service.

2. Apply cutting oil to valve seat and cutter.

3. Place 46 cutter on the pilot and make a light cut.

4. Inspect the cut area of the seat.

• If the contact area is less than 75% of the circumference of the seat, rotate the pilot 1 80 make another light cut.

• If the cutter now contacts the uncut port ion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.

 and

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ENGINE

(A)

Proper Seat Contact On Valve Face

(A)

(B)

Bottom 60o or 75

Top 30

Seat 45o or 46

• If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be replaced. Be sure the cylinder head is at the proper temperature and replace the guide.

• If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.

5. T o check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue™ paste to the valve seat. If using an interference angle (46 black marker to the entire valve face (A).

)apply

• If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.

• If the seat is too narrow, widen using the 45 cutter and re-check contact point on the valve face and seat width after each cut.

6. Insert valve into guide and tap valve lightly into place

7. Remove valve and check where the Prussian Blue™

a few times.

or black marker indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width (A).

 cutter to

• If the indicated seat contact is at the top edge of the valve face and contacts the margin area(B) it is

too high on the valve fa ce. Use the 30 lower the valve seat.

• If too low use the 60or 75 cutter to raise the seat. When contact area is centered on the valve face, measure seat width.

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ENGINE

Seat Width

CAUTION

Intake

Exhaust

NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point on the blac k ma rker, a ll t he way around the valve face.

8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.

9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. Lapping is not required with an interference angle.

10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.

12. Clean rocker assembly, cylinder head, valves, and camshaft oil supply passages thoroughly.

13. Spray electrical cont act cleaner into oil p assages and dry using compressed air.

Cylinder Head Assembly

Wear eye protection during assembly.

NOTE: Assemble the valves one at a time to maintain proper order.

11. Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping proce ss. Do this four to five times until the valve is fully seated, and repeat process for the other valve.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

4. Install valve carefully with a rotating motion to avoid damaging valve seal.

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ENGINE

Closely spaced coils toward cylinder head

5. Dip valve springs and retainer in clean en gine oil and install springs with closely spaced coils toward the cylinder head.

6. Place retainer on springs and install valve spring compressor. Compress spring only enough to allow split keeper installation and prevent loss of spring tension. Install split keepers with the gap even on both sides.

Cylinder Removal

Follow engine disassembly procedures to remove the valve cover, rocker assembly, camshaft and cylinder head.

1. Remove cam chain guide at front of cylinder.

2. Tap cylinder lightly with a soft-faced hammer in reinforced areas only until loose. NOTE: Orientation

of the dowels (arrows) is important for oil flow. Note their position for reassembly.

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the keepers.

Valve Sealing Test

1. Clean and dry the combustion chamber area.

2. Pour a small amount of cleaning solvent into each port and check for leakage around each valve. The valve seats should hold fluid with no leaking.

3. Rock cylinder back and forth while lifting it from the crankcase, piston and connecting rod. Support piston with Piston Support Block (PN 2870390).

Cam Chain Follower / Tensioner Guide Removal

1. Remove bolt securing the tensioner guide to crankcase (A). NOTE: CVT disassembly is

required to gain access to the tension guide bolt. Refer to Chapter 7.

2. Remove chain guides and inspect for cracks, wear or damage. Replace assemblies as required.

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ENGINE

= In. / mm.

1/2” Down From Top of Cylinder

1/2” Up From Bottom

Piston Removal

1. Remove circlip from either side of piston.

2. Push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The rings may lose radial tension.

3. Remove the compression rings, starting with the top ring.

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing surfaces.

2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge.

Cylinder Warp:

.002” (.05 mm) MAX

* Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.

* By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Use care to not scratch the ring lands.

4. Repeat procedure for second ring.

5. The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. Remove the top rail first followed by the bottom rail and expander.

3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2” down from top, in the middle, and 1/2” up from the bottom).



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ENGINE

= In. / mm.

CAUTION

= In. / mm.

EXAMPLE OF CROSS HATCH PATTERN

Piston

Piston Pin

7mm

5. Record measurements. If cylinder is tape red or out of round beyond specification, the cylinder must be honed, bored or replaced.

Cylinder Taper:

Limit: .002” (.05 mm) Max.

Cylinder Out of Round:

Limit: .002” (.05 mm) Max.

Cylinder Hone Selection / Honing Procedure

A hone which will straighten as well as remove

material from the cylinder is very important.

Using a common spring loaded glaze breaker for

honing is not advised. Polaris recommends

using a rigid hone or arbor honing mach ine .

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.

contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust.

If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. Hone only enough to deglaze the outer layer of the cylinder bore.

Piston Inspection

1. Measure piston outside diameter at a point 7 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Honing to Deglaze

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these guidelines:

• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinde r centered on arbor) and to bring the stones approximately 1/2” (1.3 cm) above and below the bore at the end of each stroke.

• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed, and to check for correct cross-hatch. NOTE: Do not allow cylinder to heat up during honing.

• After honing has been completed, inspect cylinder for thinning or peeling.

IMPORTANT: Clean the Cylinder After Honing

It is very important that the cylinder be thoro ughly cleaned after honing to remove all grit material. W ash the cylinder in a solvent, then in hot, soapy water. Use electrical

2. Subtract this measurement from the maximum cylinder measurement obtained earlier.

Piston to Cylinder Clearance

Std: .00039- .0015” (0.01- 0.04 mm)

Limit: .0039” (.1 mm)

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ENGINE

Piston Pin Bore

Piston Pin Measurement Locations

= In. / mm.

Feeler Gauge

Ring

Piston

Piston Ring

Cylinder

Feeler Gauge

25-50 mm

Piston ring end gap installed

3. Measure piston pin bore. Replace piston if out-ofround

4. Measure piston pin O.D. Replace piston pin if out-ofround.

groove clearance exceeds service limits.

Piston Ring Installed Gap

1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown.

5. Measure connecting rod small end ID. Replace crankshaft if out-of-round.

6. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-

Piston Ring Installed Gap:

Top Ring

Std: .0059- .013” (.15-.35 mm)

Limit: .0196” (0.5 mm)

Second Ring

Std: .0059- .013” (.15-.35 mm)

Limit: .196” (0.5 mm)

Oil Ring

Std: .0079-.0314” (0.2- 0.8 mm)

Limit: .059” (1.5 mm)

2. Measure the gap with a feeler gauge at both the top and bottom of the cylinder.

NOTE: Measure at two points in the cylinder A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

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ENGINE

Flywheel Nut

Washer

3. If the installed gap measurement exceeds the limit, replace the rings. If using new rings and the measurement is too small, file the ring ends to achieve the proper gap.

NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with an oil rag immediately to remove residue and prevent rust.

BOTTOM-END DISASSEMBLY

Starter Drive Gear Removal and Inspection

1. Remove the fan from the hub.

2. Remove the fan hub by removing the flywheel nut, washer and pulling the hub from the crankshaft.

3. Remove stator housing bolts and remove housing.

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ENGINE

CAUTION

4. Remove the start drive gear and shaft by pulling the shaft and tilting the gear slightly.

5. Measure the OD of the starter drive shaf t on both ends for out-of-round.

6. Measure the ID of the bushing in the stator housing (A) and in the crankcase (B) in two directions 90 to determine if out-of-round. Calculate the clearance. Replace components if clearance is excessive.

 apart

Flywheel Removal / Inspection

Avoid damage to the flywheel or crankshaft e nd.

Do not strike components or special tools with

hammers or heavy objects.

1. Before removing the flywheel, remove the shaft collar (A) from the crankshaft. NOTE: Shaft collar

installation is important for proper loading of the flywheel upon reassembly.

7. Inspect gear teeth on s tarter drive. Replace starter drive if gear teeth are cracked, worn, or broken.

8. Inspect the stator housing bearing. Replace if worn, rough or damaged.

2. Install Flywheel Adapter PA-49936 and Puller PA45153 and remove the flywheel.

NOTE: PA-45153 has left-hand threads which correspond with the left-hand threads on PA-49936. Use caution to avoid thread damage to flywheel or tools.



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ENGINE

Removal

PA-49935

Remove

Install

PA-49959

3. Inspect the flywheel for loose components, cracks or other damage. Replace flywheel if any damage is found.

Flywheel Special Tools

Flywheel Adapter PA-49936

Flywheel Puller PA-45153

Crankshaft One Way Gear / Drive Sprocket  Removal and Inspection

1. Remove the baffle plate.

NOTE: Slotted nut is left-hand thread.

2. Using the Slotted Nut Socket PA-49935, remove the crankshaft slotted nut (C) and washer (B) from the starter drive one-way gear assembly (A).

3. Remove the starter drive one-way gear assembly (A) from the crankshaft.

4. Remove drive sprocket (D) and woodruff key from the crankshaft.

Slotted Nut Socket Tool

PA-49935

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ENGINE

Inspect for Areas of

Tooth Wear or Damage

Drive Gear

One-way Assembly

Bearing

PA-47344

Remove

Install

PA-47344

5. Inspect sprocket teeth of both gears for wear or damage.

6. Inspect woodruff key for wear. Replace if damaged.

7. Replace any worn or damaged parts.

Starter Drive One-way Clutch  Removal and Inspection

1. The cooling shroud, stator housing and flywheel must be removed prior to accessing the one-way starter drive.

2. Pull the starter drive assembly fr om the crankshaft. Inspect the bearing surfaces and drive teeth for signs of wear or gouging. Replace the one-way clutch as an assembly if it is not working properly. Assembly should turn in one direction only.

Balance Shaft Sprocket  Removal and Inspection

1. The cooling shroud, stator housing and flywheel and starter drive one-way gear must be removed prior to accessing the balance shaft gear and oil pump gear

2. Using Slotted Nut Socket PA-47344, remove the balance shaft slotted nut and washer.

NOTE: Slotted nut is right-hand thread.

NOTE: One-way clutch components are not serviceable. Replace the component as an assembly.

3. Do not add specialized lubricants or greases to the bearing or one-way components, as this may cause undesirable operation.

3.30

Slotted Nut Socket

PA - 47344

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ENGINE

Note: Install new chain as

part of oil pump repair.

3. Remove the oil pump galley cover , oil pump gear a nd chain to facilitate removal of the balance shaft sprocket.

4. Remove the oil pump gear nut.

Oil Pump Removal / Drive Chain Inspection

NOTE: Oil pump is a replace-only assembly.

1. Remove the oil pump galley cover, pump gear nut, and balancer shaft nut prior to chain and sprocket removal.

2. Inspect the sprockets and chain for wear or damage. Inspect chain for wear or damage. Replace chain

anytime the oil pump is replaced or if excessively worn.

5. Remove drive sprocket (A), chain (B), pump sprocket (C) and the woodruff key from the balance shaft.

6. Inspect sprockets and gear teeth for wear or damage.

7. Inspect woodruff key for wear.

8. Replace any worn or damaged parts.

3. Remove the oil pump retaining screws and pull the pump from the engine case.

4. Thoroughly clean all oil passages with clean solvent.

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= T

Install with the oil galley pointing down

5. Install a new pump with the oil galley pointed down as shown.

6. Torque screws to specification.

Oil Pump Screw:

4-5 ft-lbs (5-7 Nm)

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ENGINE

Crankcase Separator Tool

PA-46087

CRANKCASE DISASSEMBLY

NOTE: Engine must be removed from the frame to perform any crankcase or crankshaft removal.

NOTE: The starter, starter drive, flywheel, st ator, oil pump and transmission can be serviced with the engine in the frame.

Crankcase Separation and  Cam Chain Removal

NOTE: Stator housing, flywheel and gears are previously removed for this procedure. Use care during the removal process to avoid damage to the cam chain.

NOTE: Cylinder head and cylinder removal must be performed prior to this procedure.

NOTE: Always replace the pto crankshaft seal after performing this procedure.

1. Remove two case bolts (circled) from the magneto side crankcase.

NOTE: Tapping the pto end of the crankshaft with a soft-face hammer may also separate the cases. Use care not to damage the crankshaft end or cases.

3. Watch the gap along the crankcase mating surface and separate the crankcase evenly.

4. Once the crankshaft bearing is free from the case, the crankshaft and cam chain can be removed by hand for replacement.

2. Separate crankcase using a press or by pres sing on the pto end of the crankshaft using special tool (PA-

46087).

Crankshaft Removal

1. Support the MAG side crankcase on blocks. Press the crankshaft out using a press or special tool (PA-

46087). Use care not to damage the crankshaft oil passage on the mag end crankshaft end.

NOTE: Tapping the pto end of the crankshaft with a soft-face hammer may also separate the cases. Use care not to damage the crankshaft end or cases.

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ENGINE

Note: Install new chain as

a part of crankshaft repair.

Crankshaft / Cam Chain / Sprocket Inspection

1. Inspect the crankshaft main bearings and cam chain sprocket for wear or damage.

NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly. The inner race of each bearing should fit tightly in the crankshaft. The outer race should be firm with minimal side to side movement and no detectable up and down movement.

2. Replace the crankshaft if the components fail visual inspection.

3. The connecting rod utilizes a roller bearing. Clearance is minimal and cannot be measured . Visually ins pe ct bearing journal for scoring, damage or excessive wear. Replace crankshaft if it fails visual inspection.

5. Remove cam chain. Inspect chain for wear or damage. Replace if worn e xcessively or a s part of

any crankshaft repair.

Crankcase / Bearing Inspection

NOTE: Removal and installation of new seals is recommended anytime the crankcase is disassembled.

1. Inspect the bearings in the crankcase.

NOTE: Due to extremely close tolerances and minimal side wear, the bearing must be inspected visually and by feel. Look for signs of discoloration, scoring or galling. Turn the inner race of bearing. The bearing should turn smoothly and quietly. The outer race should fit tightly in the crankcase. The inner race should be firm with minimal side to side movement and no detectable up and down movement.

2. To remove crankcase bearings, use a blind hole bearing puller.

4. Check oil passages to make sure they are clear.

3.34

NOTE: Bearings are damaged during the removal procedure and should not be re-used.

3. Remove all traces of gasket material from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.

Crankcase Oil Strainer Inspection

1. Remove drain plug.

2. Remove oil strainer and visually inspect for any damage or obstructions in screen.

3. Replace oil strainer if it fails visual inspection.

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ENGINE

CAUTION

Mag-side Crankcase

ENGINE REASSEMBLY

Bearing / Seal Installation

NOTE: To ease crankcase bearing installation, warm the crankcase until hot to the touch. Placing the bearings in a freezer prior to installation will assist the assembly process.

1. Install the bearings so the numbers are visible.

2. Drive or press the new bearings into the crankcase, using the proper driver.

Pre ss bea rin gs onl y o n ou ter ra ce o f b e ar in g to

prevent bearing damage.

3. Install new seals with the lip facing in.

Press seals only on outer diameter

to prevent damage.

NOTE: Tapping the end of the crankshaft with a softface hammer may also install the crankshaft. Use care not to damage the crankshaft end.

2. Install the balance shaft into the mag side of the crankcase.

Crankcase Reassembly

Crankshaft and Cam Chain Installation Lubricate all bearings with clean engine oil before

assembly.

1. Support the mag side crankcase cover on blocks high enough to allow the crankshaft to drop. Install the crankshaft using a hydraulic tool. Press on the pto end of the crankshaft. Use care not to damage the crankshaft end.

3. Install a new gasket onto the pto case half. Applying a thin amount of crankcase sealer to the gasket will help hold it in place.

4. Mate the mag side case, balancer and crankshaft to the PTO side.

loop the cam chain down into the chain room and over the pto end.

5. Press the mag and pto assembles together using a press. Verify the balance shaft is seated and both shafts turn freely once installed.

During installation of the crankshaft,

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ENGINE

= T

NOTE: Tapping the mag end of the crankshaft with a soft-face hammer may also install the crankshaft in the PTO side. Use care not to damage the crankshaft end.

6. Loop the cam chain through the chain room and secure with mechanic’s wire.

7. Install the two mag side flange bolts and torque to specification.

Chain Guide/Tensioner Installation

1. Install the chain guide and tighten the mou nting bolt to specified torque.

Chain Guide Bolt:

5-6.5 ft-lbs (7-9 Nm)

Crankcase Bolt Torque:

14 - 15 ft-lbs (19-21 Nm)

Crankcase Sealant

PN 2871557

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ENGINE

= T

Alignment marks

Install

= T

Install

Crankshaft, Balance Shaf t and Starter Drive Gear Installation

1. Install woodruff keys on the balancer shaft and crankshaft.

2. Install and align the marks of the balance shaft gear and the crankshaft gear as shown.

3. Install the oil pump drive sprocket, washer and slotted nut onto the balance shaft.

5. Install the Starter Drive one-way gear assembly, washer and slotted nut.

6. Using Slotted Nut Socket P A-49935, tighten the cra nk shaft nut to the specified torque. NOTE: Slotted nut is left hand threaded.

4. Using Slotted Nut Socket PA-47344, tighten the nut to the specified torque.

Balance Shaft Slotted Nut:

43 ft-lbs(59 Nm)

Special Tool:

PA-47344

Crankshaft Slotted Nut Torque:

43 ft-lbs (59 Nm)

Special Tool:

PA-49935

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ENGINE

= T

Install with the oil galley pointing down

= T

7. Install the baffle plate and torque to specification.

Baffle Plate Screw:

5-7 ft-lbs (7-9 Nm)

Oil Pump and Chain Installation

NOTE: Oil pump is not a serviceable assembly. Do not disassemble pump. Replace entire component.

3. Install the chain (A) over the sprocket on the balance shaft gear (B).

4. Loop the chain around the oil pump drive sprocket ( C) and install the sprocket onto the oil pump shaft.

NOTE: The oil pump sprocket and shaft have a “D” configuration for alignment.

5. Install the pump gear washer and nut. Torque to specification.

1. Inspect the oil pump sealing surface on the crankcase. Apply a liberal amount of engine oil to the surfaces and pump.

NOTE: Do not use gasket sealer on the pump mating surfaces.

2. Install oil pump as shown. Install and torque screws to specification.

Oil Pump Gear Nut:

5-7 ft-lbs (7-9 Nm)

6. Install the oil baffle plate (Item D -See illustration) and torque screws to specification.

Oil Pump Baffle Plate Screw:

5-7 ft-lbs (7-9 Nm)

Oil Pump Cover Screw:

4-5 ft-lbs (5-7 Nm)

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ENGINE

Top

Ring Profile

Second Ring Profile

Install chamfer up

CAUTION

Piston Ring Installation

NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston. If the piston has been in service, clean any accumulated carbon from the ring grooves and oil control ring holes.

1. Oil Control Ring: Place the oil control ring expander in oil ring groove with the end gap facing forward. The expander has no up or down marking and can be installed either way. The ends should butt squarely together and must not overlap.

2. Install the oil ring top rail with the end gap at least 30 from the end of the expander.

3. Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap.

Piston Installation

Do not re-use circlips. Circlips become

deformed during the removal process. Do not

compress the new clip more than necessary to

prevent loss of radial tension. Severe engine

damage may result if circlips are re-used or

deformed during installation.

1. Install a new circlip on one side of the piston with the end gap facing up or down.

2. Apply clean engine oil all components before assembly. Generously lubricate the connecting rod (both ends) and crankshaft main bearing area.

3. Install the wrist pin and piston onto the connecting ro d.

IMPORTANT: Install the piston on the connecting rod with the ’IN” casting mark facing the intake side of engine. The piston pin should be a push fit into the piston.

4. Second Ring: Install the second ring with the mark facing up (if applicable). Position the end gap toward the rear (intake) side of the piston.

5. T op Ring: Install the top ring with the chamfered edge facing up (if applicable).

6. Check to make sure the rings rotate freely in the groove when compressed by hand. Verify that the

ring gaps are 120 degrees apart from each other before installation.

4. Install the other circlip with the gap facing up or down. (See note with Step 3 above). Push the piston pin in both directions to make sure the clips are properly seated in the groove.

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ENGINE

5. Place the dowel pins in the PTO side of the crankcase and install a new cylinder base gasket.

6. Lubricate the piston and rings with assembly lube and install a ring compressor on the piston assembly.

Verify that the ring gaps are 120 degrees apart from each other before installation.

Cylinder Installation

NOTE: Clean the gasket surfaces on the crankcase and cylinder. Remove all traces of old gasket material and apply a new base gasket

4. Push the rings into the cylinder taper using a nonmetallic, blunt-edge tool while pushing the cylinder down. This will help push the piston past the ring taper into the cylinder.

5. Remove the support block once the piston rings are inside the cylinder . Seat the cylinder firmly on the base gasket.

6. Install the cam chain guide and dowel pins into the cylinder. Verify the bottom end of the guide is se ated properly in the crankcase.

1. Verify the cylinder base dowel pin(s) and a new base gasket are installed. Position the Piston Support Block (PN 2870390) (A) beneath the piston skirt to support the piston during cylinder installation.

NOTE: Route cam chain through the cylinder chain room and secure it, holding it up while rotating the engine to avoid damage to the chain, drive sprocket teeth or tensioner blade.

2. Apply clean engine oil liberally to the bore and taper ed area of the cylinder. Place the cylinder on to the studs.

3. Loop the cam chain through the cylinder chain room and secure with mechanic’s wire. Seat the cylinder fully on the piston and support block.

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ENGINE

CAUTION

Cylinder Head and Camshaft Installation

NOTE: Verify the gasket surfaces on the cylinder head and cylinder are clean. Remove all traces of old gasket material.

1. Install the dowel pin(s) and a new cylinder head gasket over the cylinder studs.

2. Pull the cam chain through the cylinder head chain room and secure with mechanic’s wire.

3. Place the cylinder head onto the cylinder.

4. Install the two 6 mm base bolts, but do not tighten at this time.

5. Install the cam according to the “Cam Shaft Timing” procedure. Ver ify the cam chain is in place around the crankshaft gear.

NOTE: Verify camshaft timing is accurate before installing the rocker and tensioner assemblies.

Camshaft Timing

Serious engine damage will result if the

camshaft is not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located at Top Dead Center (TDC). This can be accomplished using one of two methods.

1. Install the cam chain over the crankshaft. When the stator housing is removed, use Method 1. This

method uses the camshaft gear marks and the crankshaft keyway to establish TDC (see Method 1 illustration). It is important to note that this method can only be used when the stator housing is removed and the crankshaf t keyway is in view. The camshaft sprocket alignment marks are parallel to the gasket surface, and camshaft lobes are pointing down. Cam chain plate links are not used to time the camshaft.

When the stator housing is installed, use Method 2. This method establishes Top Dead Center (TDC) by aligning the single mark on the flywheel in the timing inspection hole (see Method 2 illustration). The camshaft sprocket alignment marks are parallel to the gasket surface, and camshaft lobes are pointing down. Cam chain plate links are not used to time the camshaft.

Camshaft Installation - Timing Method 1 Reference Illustration Page 3.43

Stator ho using is removed. NOTE: Use this method only when the stator is removed and cam shaft drive sprocket is in view.

1. Rotate the crankshaft until the keyway on the crankshaft is pointed ’UP” (keyway facing upward) and the piston is at TDC.

2. Align the cam chain onto the teeth of the crankshaft sprocket. Use a wire to pull the chain up through the cylinder and cylinder head and to hold it in place.

Secure and maintain tension so that the chain does not fall off the crankshaft sprocket.

3. Apply engine assembly lubricant to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil.

4. Orientate the camshaft for installation with the lobes facing downward.

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ENGINE

TDC Cam Alignment

5. Disconnect the wire securing the cam chain and loop the cam chain over the camshaft sprocket while verifying the cam is inserted with the alignment marks parallel to the gasket surface.

6. Verify all cam timing mar ks to verify proper cam timing, and install the rocker arm assembly (see Method 1 illustration). Torque the cylinder stud nuts to specification.

NOTE: Do not rotate engine until rocker assembly and tensioner are installed.

7. Install the tensioner . T orque fasteners to specification.

8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.

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Crankshaft Keyway ‘UP’

Method 1 - Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on

compression stroke (cam lobes facing downward)

ENGINE

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ENGINE

Method 2 - Camshaft Timing Using Flywheel TDC Mark

Sprocket marks aligned with gasket surface at

TDC on compression stroke

(cam lobes facing downward)

Single TDC Mark Aligned

TDC Mark

Rotation

Cam Timing

(View through timing inspection hole)

Position crankshaft at TDC

Camshaft Installation - Timing Method 2  Reference Illustration Page 3.44

Stator housing is installed. NOTE: Use this method only when the stator is installed and cam shaft drive sprocket

is in view.

1. Rotate the crankshaft until the single (TDC) timing mark (T op Dead Center) on the flywheel is view in the center of the timing inspection window. Be sure to use the single TDC mark when installing the cam. Do not use any advance marks (if evident).

2. Align the cam chain onto the teeth of the cam chain drive sprocket. Use a wire to pull the chain up through the cylinder and cylinder head and to hold it in place. Secure the chain.

the chain does not fall off the crankshaft sprocket.

Secure and maintain tension so that

3. Apply engine assembly lubricant to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil.

4. Orientate the camshaft for installation with the lobes facing downward.

5. Disconnect the wire securing the cam chain and loop the cam chain over the sprocket while verifying the cam is inserted with the alignment marks parallel to the gasket surface.

6. Check all cam timing marks to verify proper cam timing, and install the rocker arm assembly. Torque the cylinder stud nuts to specification.

NOTE: Do not rotate engine until tensioner and rocker assembly is installed.

7. Install the tensioner . T orque fasteners to specification.

8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.

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ENGINE

Intake

Exhaust

= T

Torque in 3 step cross pattern

Rocker Arm / Shaft Assembly

1. Apply engine assembly lube to all components and assemble the arms, shafts and decompression components into the rocker assembly.

IMPORTANT: Install rocker shafts in their correct positions. The exhaust side shaft is shorter and is held in place by the cylinder stud. The intake side shaft has a ‘half-moon’ section that aligns with the cylinder stud to hold it in place.

2. Apply engine lube to the shafts and cam follower surfaces.

Rocker Assembly Installation

3. Install cylinder head nuts and torque to specification.

Cylinder Head Nut:

18 ft-lbs (25 Nm)

4. Torque the cylinder base screws to specification.

5. Adjust valves according to the “VALVE CLEARANCE ADJUSTMENT” procedures.

1. Apply engine lube to all components and assembly arms, shafts and decompression components of the rocker assembly.

2. Verify the cam is still in the TDC position before installing the rocker assembly onto the cylinder studs.

6. Install valve cover and secondary air assembly with new gaskets. Torque bolts to specification.

Valve Cover/ Secondary Air Pipe Bolt:

7-8 ft-lbs (9-11 Nm)

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ENGINE

= T

= In. / mm.

Cam Chain Tensioner Installation

1. Using a small flat blade screwdriver, turn the tensioner clockwise to retract the plunger (B) all the way into the tensioner body.

2. Keeping the plunger retracted, install the tensioner assembly with a new gasket and tighten the bolts to specification.

Intake Valve Clearance Adjustment

1. Remove the valve cover and secondary air pipe assembly.

2. Verify cam lobes are pointed down.

3. Insert the correct thickness feeler gauge between end of intake valve stem and adjuster screw.

4. When clearance is correct, hold adjuster screw and tighten locknut securely.

5. Re-check the valve clearance.

6. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

Valve Clearance:

.003” (.07 mm)

Exhaust Valve Clearance Adjustment

1. Remove the valve cover and secondary air pipe assembly.

Tensioner Bolt and Cap:

5-7 ft-lbs (7-9 Nm)

3. Release the tensioner and install the tensioner cap. Torque cap to specification.

4. Slowly rotate engine two to three revolutions and recheck cam timing once chain is tight.

2. Verify cam lobes are pointed down.

3. Insert the correct thickness feeler gauge between end of exhaust valve stem and adjuster screw.

4. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge.

5. When clearance is correct, hold adjuster screw and tighten locknut securely.

6. Re-check the valve clearance.

7. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

Valve Clearance:

.003” (.07 mm)

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Starter Drive Assembly

1. Apply St arter Drive Grease (PN 28714 60) to the drive bushings in the cases.

2. Slide the starter drive gear into position on the oneway gear and install the shaft.

Starter Drive Grease:

(PN 2871460)

Stator Installation

NOTE: The stator, flywheel, and starter drive components can be serviced with the engine in the frame.

1. Install the stator and pulse coil. Route the wires appropriately to avoid contact with any moving parts. Torque bolts to specification.

3. Install stator housing and torque bolt s to specification.

Flywheel Installation

Install flywheel key, flywheel and the flywheel spacer. Proceed to “Stator Housing Installation” if the stator assembly is already installed.

IMPORTANT: Flywheel spacer installation is critical for proper clamp-load when applying torque to the flywheel nut. Verify spacer is installed before assembly of the stator housing to the crankcase.

Stator Bolt:

7-8 ft-lbs (9-11 Nm)

Pulse Coil Bolt:

4-5 ft-lbs (5-7 Nm)

2. Apply a small amount of Crankcase Sealant (PN

2871557) to the stator wire grommet and install into the housing cavity.

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ENGINE

= T

RH Crankcase - St ator Cover

(#1, #2 RH case bolts)

= T

Stator Housing Installation

NOTE: The stator, flywheel, starter drive, and stator can be serviced with the engine in the frame.

1. Apply a small amount of Crankcase Sealant (PN

2871557) to the mounting surface and install a new gasket. Install the dowel pins if removed.

2. Install the housing. Torque bolts in sequence to specification.

3. Install the fan hub, washer, and flywheel nut. Torque the flywheel nut to specification.

Flywheel Nut:

43 ft-lbs (58 Nm)

4. Install the fan and fan bolts. Tighten bolts evenly to specification.

Fan Bolt:

4-5 ft-lbs (5-7 Nm)

5. Install the cooling shroud and tighten the fasteners sufficiently. Use care not to over-tighten.

Stator Housing Bolt:

7-8 ft-lbs (9-11 Nm)

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Polaris RANGER RZR 170 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual