Polaris Ranger RZR 170 Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Ranger RZR 170 has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL: 2009 RANGER RZR 170
MODEL NUMBER: R09VA17AA
ENGINE MODEL: S35C

TABLE OF CONTENTS :

Ch_01-GENERAL INFORMATION
Ch_02-MAINTENANCE
Ch_03-ENGINE
Ch_05-BODY / SUSPENSION / STEERING
Ch_06-BRAKES
Ch_07-CVT / TRANSMISSION
Ch_08-ELECTRICAL
WIRE_DIAGRAM

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9922134
Total Pages : 187

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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9922134_Ch_01-GENERAL INFORMATION
TABLE OF CONTENTS
MODEL INFORMATION
Model Identification
Engine Designation Number
VIN Identification
Engine Serial Number Location
Unit Serial Number (VIN) and Emissions Decal Locations
VEHICLE INFORMATION
Publication Numbers
Paint Codes
Replacement Keys
SPECIAL TOOLS
GENERAL SPECIFICATIONS
MODEL: 2009 RANGER RZR 170
MODEL: 2009 RANGER RZR 170
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
Standard Torque Specifications
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Glossary of Terms

9922134_Ch_02-MAINTENANCE
TABLE OF CONTENTS
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Maintenance Chart Key
Pre-Ride – 25 Hour Maintenance Interval
30 – 100 Hour Maintenance Interval
MAINTENANCE REFERENCES / SERVICE LOCATIONS
Front and Rear View
RH and LH Side Views
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service Products
MAINTENANCE REFERENCES
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Frame, Nuts, Bolts, and Fasteners
Shift Cable Inspection / Adjustment
Shift Cable Replacement
FUEL SYSTEM AND AIR INTAKE
Air Filter Service
Choke Cable Adjustment
Choke Cable Replacement
Idle Speed Adjustment
Pilot Air Screw Adjustment
Vent Lines
Fuel System
Fuel Filter
Fuel Valve Location
Carburetor Draining
Fuel Pump / Fuel Lines
Throttle Pedal Inspection
Throttle Stop Speed Control
Throttle Freeplay Adjustment
Throttle Cable Replacement
ENGINE
Engine Oil Level
Engine Oil Change
Engine Crankcase Ventilation System Inspection
Engine/Transmission Mount Locations
Compression / Leakdown Test
Intake Valve Clearance Adjustment
Exhaust Valve Clearance Adjustment
Exhaust – Spark Arrestor
TRANSMISSION
Transmission Specification Chart
Transmission Oil Change
FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table
Wheel Removal
Wheel Installation
Tire Inspection
Tire Pressure
Drive Chain Lubrication and Adjustment
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Removal
Battery Installation
Battery Off Season Storage
Battery Charging (Maintenance Free)
Spark Plug Service
Engine To Frame Ground
STEERING
Steering Inspection
Steering Wheel Freeplay
Steering Inspection / Tie Rod Ends and Hubs
Toe Alignment Inspection
Toe Adjustment
SUSPENSION
Spring Preload Adjustment
BRAKE SYSTEM
Brake Fluid Inspection
Brake Pad / Disc Inspection
Brake Hose and Fitting Inspection
MAINTENANCE LOG

9922134_Ch_03-ENGINE
TABLE OF CONTENTS
TOOLS
Special Tools
TORQUE SPECIFICATIONS
Engine Torque Specifications
Torque Patterns
ENGINE INFORMATION
Engine Exploded Views
Engine Lubrication
Piston Identification
Accessible Components
Engine Service Data
Engine Service Data
Oil Flow Diagram
ENGINE SYSTEMS SERVICE
Breather / Oil Separator
Emissions Secondary Air System
Cooling Shroud Removal/Installation
Engine Removal
Engine Installation Notes
TOP-END DISASSEMBLY
Engine Removal/Installation
Finding Top Dead Center (TDC)
Cam Chain Tensioner Inspection
Rocker Assembly Disassembly and Inspection
Camshaft Removal
Camshaft Inspection
Cylinder Head Removal
Cylinder Head Inspection
Cylinder Head Warp Inspection
Combustion Chamber Inspection
Cylinder Head Disassembly
Valve Inspection
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Cylinder Removal
Cam Chain Follower / Tensioner Guide Removal
Piston Removal
Cylinder Inspection
Cylinder Hone Selection / Honing Procedure
Honing to Deglaze
Piston Inspection
Piston Ring Installed Gap
BOTTOM-END DISASSEMBLY
Starter Drive Gear Removal and Inspection
Flywheel Removal / Inspection
Crankshaft One Way Gear / Drive Sprocket Removal and Inspection
Starter Drive One-way Clutch Removal and Inspection
Balance Shaft Sprocket Removal and Inspection
Oil Pump Removal / Drive Chain Inspection
CRANKCASE DISASSEMBLY
Crankcase Separation and Cam Chain Removal
Crankshaft Removal
Crankshaft / Cam Chain / Sprocket Inspection
Crankcase / Bearing Inspection
Crankcase Oil Strainer Inspection
ENGINE REASSEMBLY
Bearing / Seal Installation
Crankcase Reassembly
Chain Guide/Tensioner Installation
Crankshaft, Balance Shaft and Starter Drive Gear Installation
Oil Pump and Chain Installation
Piston Ring Installation
Piston Installation
Cylinder Installation
Cylinder Head and Camshaft Installation
Camshaft Timing
Rocker Arm / Shaft Assembly
Rocker Assembly Installation
Cam Chain Tensioner Installation
Intake Valve Clearance Adjustment
Exhaust Valve Clearance Adjustment
Starter Drive Assembly
Flywheel Installation
Stator Installation
Stator Housing Installation
Exhaust System
TROUBLESHOOTING
Spark Plug Fouling
General Troubleshooting

9922134_Ch_05-BODY / SUSPENSION / STEERING
TABLE OF CONTENTS
GENERAL INFORMATION
Special Tools
Torque Specifications
BODY REMOVAL
Seat Removal
Seat Installation
Front Bumper Removal / Installation
Front Cab Removal / Installation
Rocker Panel Removal
Rear Bumper Removal / Installation
Rear Cab Removal
Service Panel (Seat Shield) Removal
Console Cover Removal
Key Switch / Indicator Light Replacement
Decal Replacement
Body Exploded View
CAB FRAME
Exploded View
Cab Frame Assembly
MAIN FRAME
Exploded View
FRONT A-ARMS
Exploded View
A-arm Replacement
FRONT HUB
Hub Removal
Hub Seal and Bearing Replacement
Hub Installation
SHOCKS
Shock Exploded View
Shock Removal
Shock Replacement
Shock Installation
Rear Swing Arm
Exploded View
Swing Arm Removal
Swing Arm Installation
Rear Axle
Axle Housing Removal
Axle Housing Service
Axle Housing Installation
Axle Removal
Axle Installation
STEERING
Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View
Steering Shaft Removal
Steering Shaft Installation
Steering Gearbox Removal
Steering Gearbox Installation
Tie Rod
Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View
Tie Rod Removal / Installation
WHEELs
Front Wheel Exploded View
Rear Wheel Exploded View
Wheel Removal
Wheel Installation

9922134_Ch_06-BRAKES
TABLE OF CONTENTS
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM – OVERVIEW OF OPERATION
BRAKE SYSTEM – MECHANICAL COMPONENTS
Brake System – Mechanical Components
BRAKE SYSTEM – HYDRAULIC COMPONENTS
BRAKE BLEEDING / FLUID CHANGE
BRAKE PEDAL
Brake Pedal Removal
Pedal Installation
Brake Pedal Inspection / Adjustment
PARKING BRAKE
Parking Brake Adjustment
Parking Brake Cable Replacement
FRONT BRAKE PADS
Front Pad Removal
Pad Inspection
Front Brake Pad Assembly / Caliper Installation
FRONT BRAKE DISC
Disc Inspection
Disc Replacement
FRONT CALIPER
Front Caliper Removal
Caliper Installation
REAR BRAKE PAD
Rear Brake Pad Removal
Rear Brake Pad Inspection
Rear Brake Pad Assembly / Caliper Installation
Brake Burnishing Procedure
REAR BRAKE DISC
Disc Inspection
Rear Brake Disc Replacement
REAR CALIPER SERVICE
Rear Caliper Removal
Rear Brake Caliper Installation
MASTER CYLINDER
Removal
Installation
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
Pedal Vibration
Caliper Overheats (Brakes Drag)
Brakes Lock
Parking Brake Drags or Ineffective Brake

9922134_Ch_07-CVT / TRANSMISSION
TABLE OF CONTENTS
SPECIFICATIONS / TOOLS
Torque Specifications
Special Tools
CVT SYSTEM
CVT Maintenance / Inspection
Drive Clutch Operation
Driven Clutch Operation
CVT System Drying
CVT Overheating / Water Ingestion Diagnostics
Clutch (CVT) Cover Removal / Inspection
Clutch (CVT) Cover Installation
Drive Belt Removal
Drive Belt Inspection
Drive Belt Installation
Drive Clutch Service
Drive Clutch Removal, Disassembly and Inspection
Drive Clutch Assembly
Driven Clutch Service
Driven Clutch Removal, Disassembly, Inspection
Driven Clutch Assembly
Driven Clutch Installation
TRANSMISSION SERVICE
Transmission Disassembly and Inspection
Input Shaft Removal / Inspection
Transmission Main Shaft Assembly View
Transmission Assembly
Output Gear Pinion Depth Adjustment
Output Shaft Housing Disassembly / Assembly

9922134_Ch_08-ELECTRICAL
TABLE OF CONTENTS
General Information
Special Tools
Electrical System Service Notes
Switches and Controls
Key Switch
Brake Pedal / Parking Brake Switches
Electronic Throttle Control (ETC)
ETC Operation
ETC Switch Adjustment
Daytime Running Lights
“DRL” Test
“DRL” Lamp Replacement
Tail Light
Tail Light Lamp Replacement
Indicator lamps
Indicator Lamp Replacement
Transmission Switch
Transmission Switch – Circuit Breakout
Testing
Removal
Installation
Ignition System
Overview
Ignition System Troubleshooting
Ignition System Testing
RPM Ignition Limiter Functions
RPM Limiter Specifications
Ignition Coil Test
CDI Output Test Using Peak Reading Adaptor
Pulser Coil Output / Resistance Tests
Charging System
Charging System Testing
Main Fuse / Fuse Holder Location
Voltage Regulator / Rectifier
Stator / Alternator Tests
Battery
Battery Maintenance Service Notes
New Battery Activation
Battery Removal
Battery Cleaning
Battery Installation
Battery Voltage Test
Battery Load Test
Battery Charging Procedure
Battery Storage
Starter System
Starter Relay
Starter Motor Service
Starter Disassembly
Starter Brush Inspection / Replacement
Armature Test
Starter Reassembly
Voltage Drop Test
Starter System Troubleshooting
Starter System Testing

9922134_WIRE_DIAGRAM