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General| Brand | Polaris |
|---|---|
| Model | RZR 170 2009 |
| Category | Offroad Vehicle |
| Language | English |
Details about the model identification and numbering system.
Information related to publication numbers and paint codes.
Key specifications like dimensions, weight, and capacities.
Useful charts like conversion tables and torque specs.
Outlines scheduled maintenance tasks and intervals.
Identifies locations of key maintenance points on the vehicle.
Lists recommended lubricants, fluids, and service products.
Quick reference for lube/fluid recommendations and frequencies.
Covers pre-ride inspections and general maintenance checks.
Details how to inspect and adjust the shift cable.
Provides instructions for replacing the shift cable assembly.
Instructions for removing, cleaning, and installing the air filter.
How to adjust the choke cable for proper free play.
Procedure for replacing the choke cable assembly.
How to adjust the engine idle speed.
How to adjust the pilot air screw for fuel mixture.
Checking fuel tank, crankcase, and transmission vent lines.
Instructions for replacing the fuel filter.
Locating the fuel valve on the vehicle.
How to drain the carburetor float bowl for storage.
Checking fuel pump and fuel lines for wear or leaks.
Checking throttle pedal for excessive play or lack of play.
Procedure to control the maximum throttle opening.
How to adjust the throttle pedal free play.
Step-by-step guide for replacing the throttle cable.
How to check and maintain the engine oil level.
Step-by-step instructions for changing the engine oil.
Inspecting the crankcase breather hoses.
Inspecting engine and transmission mounts for damage.
Procedures for performing compression and leakdown tests.
How to adjust intake valve clearance.
How to adjust exhaust valve clearance.
Cleaning and inspecting the spark arrestor.
Details on transmission service, specifications, and maintenance.
Torque specifications for wheel, hub, and spindle components.
Step-by-step guide for removing wheels.
Step-by-step guide for installing wheels.
Inspecting tires for proper inflation and wear.
Information on when to replace tires based on tread depth.
Correct tire pressure specifications.
How to lubricate and adjust the drive chain.
Procedures for maintaining the vehicle's battery.
Steps for safely removing the battery.
Steps for safely installing the battery.
How to clean battery terminals.
Recommendations for storing the battery during off-season.
Guide to charging sealed (maintenance-free) batteries.
Testing battery voltage for proper charge.
Performing a load test to check battery capacity.
How to inspect, clean, and replace the spark plug.
Inspecting the engine ground cable connection.
General inspection of steering components for wear and damage.
How to check and measure steering wheel freeplay.
Inspecting tie rod ends and front hub for looseness.
How to measure and check vehicle toe alignment.
Procedure for adjusting the toe alignment of the wheels.
Details on suspension components and adjustments.
Adjusting spring preload on shock absorbers.
Comprehensive section on the vehicle's brake system.
How to inspect brake fluid level and condition.
Inspecting brake pads and discs for wear and damage.
Inspecting brake hoses and fittings for cracks or leaks.
A log for recording maintenance performed on the vehicle.
Lists special tools required for engine service.
Provides torque values for engine fasteners.
General engine details, exploded views, and lubrication.
Service procedures for specific engine systems.
Procedures for disassembling the cylinder head and related components.
Procedures for disassembling the lower end of the engine.
Steps for separating the crankcase and removing internal components.
Procedures for reassembling the engine after disassembly.
Common engine problems and their solutions.
Detailed torque specifications for engine fasteners.
Illustrates torque sequences for cylinder head and crankcase.
Exploded diagrams of engine components.
Details on oil type, capacity, and specifications.
Information on piston marking and orientation.
Lists components serviceable with engine in frame vs. removed.
Specifications for cylinder head and valvetrain components.
Illustrates the engine's oil circulation path.
Service information for the breather and oil separator system.
Details on the secondary air system for emissions control.
Procedures for removing and installing the cooling shroud.
Step-by-step instructions for removing the engine from the vehicle.
Checklist for performing after engine installation.
How to locate Top Dead Center for engine timing.
How to inspect the cam chain tensioner.
Procedures for disassembling and inspecting the rocker arm assembly.
Steps for removing the camshaft.
How to inspect the camshaft and its components.
Step-by-step instructions for removing the cylinder head.
General inspection of the cylinder head.
How to check the cylinder head for warpage.
Inspecting the combustion chamber for carbon and damage.
Procedures for disassembling the cylinder head.
How to inspect valves, stems, and keepers.
Procedures for inspecting and reconditioning valve seats.
Step-by-step process for removing the piston from the cylinder.
Inspecting the cylinder for warpage, wear, and damage.
Guidelines for honing the cylinder bore.
Inspecting the piston for proper diameter.
How to measure and set the piston ring installed gap.
Procedures for removing and inspecting the starter drive gear.
Steps for removing and inspecting the flywheel.
Removing and inspecting the crankshaft one-way gear and drive sprocket.
Removing and inspecting the starter drive one-way clutch.
Removing and inspecting the balance shaft sprocket.
Removing the oil pump and inspecting the drive chain.
Separating crankcases and removing the cam chain.
Procedure for removing the crankshaft.
Inspecting crankshaft main bearings and cam chain sprocket.
Inspecting crankcase bearings and mating surfaces.
Inspecting the crankcase oil strainer.
Installing new bearings and seals into the crankcase.
Reassembling the crankcase halves.
Installing crankshaft, balance shaft, and starter drive gear.
Installing the chain guide and tensioner.
Installing the oil pump and chain.
Proper installation of piston rings onto the piston.
Step-by-step guide for installing the piston into the cylinder.
Procedures for installing the cylinder onto the crankcase.
Installing the cylinder head and camshaft.
Critical procedure for setting camshaft timing.
Timing the camshaft with the stator housing removed.
Timing the camshaft with the stator housing installed.
Assembling the rocker arm and shaft components.
Installing the rocker assembly onto the cylinder head.
Installing the cam chain tensioner.
Adjusting the intake valve clearance.
Adjusting the exhaust valve clearance.
Installing the starter drive components.
Installing the flywheel and related parts.
Installing the stator and pulse coil.
Installing the stator housing.
Installing and checking the exhaust system components.
Common engine problems and their solutions.
General info, special tools, and torque specs for the chapter.
Procedures for removing various body panels and components.
Exploded views and assembly of the cab frame.
Exploded view of the main vehicle frame.
Exploded view and replacement of front A-arms.
Exploded view and service for front hubs.
Information on shock removal, replacement, and installation.
Exploded view and service procedures for the rear swing arm.
Exploded view and service for the rear axle.
Comprehensive section on steering system service.
Exploded view and service for tie rods and steering knuckles.
Exploded views and procedures for wheel removal and installation.
Lists specialized tools for body, suspension, and steering.
Torque values for body, steering, suspension, and final drive fasteners.
Steps for removing the driver and passenger seats.
Steps for installing the driver and passenger seats.
Procedures for removing and installing the front bumper.
Steps for removing and installing the front cab assembly.
Steps for removing the rocker panels.
Procedures for removing and installing the rear bumper.
Steps for removing the rear cab assembly.
How to remove the service panel.
Steps for removing the console cover.
How to replace the key switch and indicator lights.
Procedure for flame treating and applying decals.
Exploded diagram of the vehicle's body components.
Exploded diagram and assembly of the cab frame.
Exploded view of the main vehicle frame.
Exploded diagram of the front A-arms.
Step-by-step guide for replacing the front A-arm.
Procedures for removing the front wheel hub.
Steps for installing the front wheel hub.
Information on shock removal, replacement, and installation.
Exploded diagram of the rear swing arm assembly.
Steps for removing the rear swing arm assembly.
Steps for installing the rear swing arm assembly.
Procedures for removing the rear axle housing.
Service procedures for axle housing bearings and seals.
Steps for installing the rear axle housing.
Steps for removing the rear axle assembly.
Comprehensive section on the steering system service.
Exploded diagram of steering components.
Procedures for removing the steering shaft.
Steps for installing the steering shaft.
Steps for removing the steering gearbox.
Steps for installing the steering gearbox.
Exploded view and service for tie rods and steering knuckles.
Exploded diagram of tie rod and steering knuckle assembly.
Procedures for removing and installing tie rods.
Exploded views and procedures for wheel removal and installation.
Exploded diagram of the front wheel assembly.
Exploded diagram of the rear wheel assembly.
Steps for removing vehicle wheels.
Steps for installing vehicle wheels.
General specs, tools, and torque for brake system.
Important precautions and tips for brake system maintenance.
Table of possible causes and remedies for brake noise.
Explanation of how the hydraulic brake system functions.
Identifies key mechanical components of the brake system.
Information and service for the brake pedal.
Details on parking brake adjustment and cable replacement.
Procedures for front brake pad removal, inspection, and installation.
Inspection and replacement of front brake discs.
Service procedures for the front brake caliper.
Procedures for rear brake pad removal, inspection, and installation.
Inspection and replacement of rear brake discs.
Service procedures for the rear brake caliper.
Steps for removing and installing the master cylinder.
Common brake system problems and their solutions.
CVT and transmission specifications and required tools.
Details on CVT system maintenance, inspection, and operation.
Procedures for removing, disassembling, and inspecting the driven clutch.
Procedures for disassembling and inspecting the transmission.
How to adjust the output gear pinion depth using shims.
Procedures for disassembling and assembling the output shaft housing.
General info, special tools, and service notes for electrical system.
Information on key switch, brake/parking brake switches, and ETC.
Adjustment and operation of the Electronic Throttle Control system.
Testing and replacement of daytime running lights.
Procedure for replacing the tail light bulb.
How to replace indicator lamps on the dash.
Wiring diagram and testing procedure for the transmission switch.
Components, troubleshooting, and testing of the ignition system.
Flowchart for testing the ignition system for spark issues.
Diagnosing and testing the vehicle's charging system.
Procedures for battery maintenance, testing, charging, and storage.
Information on the starter system, including relay, motor, and testing.
Information on servicing the starter motor.
Inspecting and replacing starter brushes.
Testing the starter motor armature for shorts or damage.
Steps for reassembling the starter motor.
Troubleshooting common starter system issues.
Flowchart for testing the starter system.
