Page1 86
Page1 86
Page1 86
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) AND EMISSIONS DECAL LOCATIONS . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: 2009 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
1.1
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
}
}
}
}
Model Year Emissions &
Designation Model Option
Basic Chassis
Designation Engine Designation
VIN Identification
World
Mfg. ID Vehicle Description Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A V A 1 7 A * 9 P 0 0 0 0 0 0
}
Model
Engine Year Individual Serial No.
Body Style
Emissions Plant No. * This could be either
Powertrain a number or a letter
Check Digit
1.2
GENERAL INFORMATION
Unit Serial Number (VIN) and Emissions Decal Locations
The machine model information decal (A) and vehicle identification number (VIN) are important for identification. The VIN number 1
(B) is stamped on a portion of the front left frame rail close to the left front wheel.
The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.
1.3
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
NOTE: When ordering service parts be sure to use the correct parts manual.
Paint Codes
Replacement Keys
Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the
original. Should both keys become lost, ignition switch replacement is required.
P/N 0453013
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools
maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris
product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or
on-line at http://polaris.spx.com/.
1.4
GENERAL INFORMATION
GENERAL SPECIFICATIONS
1
MODEL: 2009 RANGER RZR 170
MODEL NUMBER: R09VA17AA
ENGINE MODEL: S35C
Category Dimension / Capacity
Length 85 in. / 216 cm
Width 48 in. / 122 cm
Height 55 in. / 139.7 cm
Wheel Base 65 in. / 165 cm
Ground Clearance 6 in. / 15.2 cm
Dry Weight 500 lbs. / 227 kg
Gross Vehicle Weight 840 lbs. / 381 kg
Maximum Weight 300 lbs. / 81.7 kg
Capacity (Includes people, cargo, accessories)
1.5
GENERAL INFORMATION
MODEL: 2009 RANGER RZR 170 Drivetrain
Transmission Type Polaris Automatic CVT
MODEL NUMBER: R09VA17AA
ENGINE MODEL: S35C Shift Type In Line Shift - H / N / R
Engine Transmission Oil Requirements Polaris AGL
Main Gearcase 23.7 oz. (700 ml)
Single Cylinder, Air/Oil Cooled
Platform Drive Belt 0454497
4-Stroke
Engine Model Number S35C Drive Chain - Type / # Links 520 / 30
Engine Displacement 169cc Steering / Suspension
Number of Cylinders 1 Front Suspension Single A-arm
Bore & Stroke (mm) 61 x 57.8 mm Front Travel 5 in. / 12.7 cm
Compression Ratio 9.5:1 Rear Suspension Dual Shock Swingarm
Compression Pressure 130-160 psi @ W.O.T. Rear Travel 5 in. / 12.7 cm
Engine Idle Speed 1700 ± 100 RPM Shock Preload Adjustment Cam Adjustable
Engine Max Operating RPM 8000 ± 200 RPM Front / Rear (Factory Setting - Softest)
Lubrication Wet Sump Toe Out 1/8-1/4 in. / 3-6.35 mm
Above 32° F ( 0° C ) Wheels / Brakes
Polaris ‘YOUTH’ oil Front Tire Size 19 x 7 - 8
Oil Requirements Below 32° F ( 0° C ) Rear Tire Size 20 x 10 - 9
20W-40 oil
Bolt Pattern 110mm
Oil Capacity 37 oz.. / 1.1 liters Tire Air Pressure - Front / Rear 3 psi (20.7 kPa)
Exhaust System Single Headpipe / Single Silencer Foot Actuated - 4 Wheel
Brake - Front / Rear
Fuel System Hydraulic Disc
Carburetor Type Keihin Brake Fluid DOT 4
Pilot Jet 35
JETTING CHART
Main Jet 100
Ambient Temperature
Air Screw 2 1/4 Turns Out (initial)
Altitude Below 40! F Above +40! F
Jet Needle 2MKNN - #4 clip position
Below 5! C Above +5! C
Fuel Delivery Fuel Pump
0-3048
Fuel Filters See Chapter 4 102 100
Meters (0-10000)
2.5 gal. (9.5 liters) (Feet)
Fuel Capacity / Requirement Above 3048 98
87 Octane (minimum) 100
(Above 10,000) #3 needle clip position
Electrical
Alternator Max Output 80 Watts @ 3000 RPM CLUTCH CHART
2 - Single Beam
Lights: Main Headlights Altitude Shift Weight
Daytime Running Lamps (DRL)
Tail / Brake 5 Watts / 21 Watts 0-3048
6 @ 17 grams
Starting System Electric Start Meters (0-10,000)
Ignition System CDI (Feet) Above 3048 *** 6 @ 15 grams
Ignition Timing Non-Adjustable (Above 10,000) PN 0454619
NGK CR6HSA ***15 gram weights are optional and are not a High Altitude
Spark plug / Gap
.024-.028 in. (0.6-0.7 mm) (H.A.) Warranty item.
GTX12-BS / Low Maintenence
Battery
12 Amp Hr. / 12 Volt
Fuses Main: 20 Amp
1.6
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
1
1.7
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.8
GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
1
1.9
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm).
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Rollers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close
and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm²: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in²: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.10
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
2
30 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
MAINTENANCE REFERENCES / SERVICE LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 2.6
FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
CHOKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
CHOKE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
PILOT AIR SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
FUEL VALVE LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
FUEL PUMP / FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
THROTTLE STOP SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
THROTTLE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . 2.21
ENGINE/TRANSMISSION MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COMPRESSION / LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
DRIVE CHAIN LUBRICATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.30
TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.2
MAINTENANCE
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
2
parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed
of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
!= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
WARNING
2.3
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Periodic Maintenance Chart
Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles (KM)
! Steering - Daily -
" Front-Suspension - Daily -
" Rear-Suspension - Daily -
Tires - Daily -
" Brake Pedal Travel - Daily -
Brake Fluid Level - Daily -
Check each day before driving the vehicle.
Daytime Running Lights - Daily -
Make adjustments as needed. See the Pre-
Drive Chain - Daily - Ride Checklist in the Owner’s Manual.
Brake Lamp / Tail Lamp - Daily -
Throttle - Daily -
Wheels / Fasteners - Daily -
Frame Fasteners - Daily -
" Engine Oil Level - Daily -
E
Fuel Level - Daily -
" Air Filter (main element) - Daily - Inspect; clean often, replace as needed
E
Open CVT drain as needed, check often if
CVT Housing - Weekly -
operating in wet conditions
" Brake Pad Wear 10 H 1M 100 (160) Inspect regularly
!
Idle Speed 10 H 1M 100 (160) Check; adjust as needed
!
Choke 10 H 1M 100 (160) Check for proper operation
E
Engine Oil Change Perform a break-in oil change after the first
" (Break-In Period) 10 H 1M 100 (160)
10 hours of operation
Transmission Oil Perform break-in oil change after the first
" (Break-In Period) 10 H 1M 100 (160)
10 hours of operation
Drive Chain Adjust and lubricate after the first 10 hours
" (Break-In Period) 10 H 1M 100 (160)
of operation
Check clearance after the first 10 hours of
!
Valve Clearance 10 H 1M 100 (160) operation; Adjust to specification if
E
required
Battery 25 H Monthly 250 (400) Check terminals; clean; test
" Transmission Oil 25 H 12 M 250 (400) Inspect level; change yearly
"Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
! Have an authorized Polaris dealer perform these services.
2.4
MAINTENANCE
30 - 100 Hour Maintenance Interval
Periodic Maintenance Chart
Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles (KM)
" Oil Change 30 H 6M 300 (480) Lubricate all grease fittings, pivots, & cables 2
Clean filter at every oil change; clean annually
" Oil Pre-Filter Screen 30 H 6M 300 (480)
if operated less than 10 hours
" General Lubrication 50 H 3M 500 (800) Lubricate all grease fittings, pivots, & cables
Check clearance; adjust to specification if
!
Valve Clearance 50 H - 500 (800) required; perform break-in adjustment after the
E
first 10 hours of operation
Carburetor Float Bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage
! Throttle Cable /
50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E ETC Switch
!
Choke Cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E
Carburetor Air Intake
E 50 H 6M 500 (800) Inspect for proper sealing / air leaks
Ducts / Flange
Shift Cables 50 H 6M 500 (800) Inspect; lubricate; adjust
" Brake Pad Wear 50 H 6M 500 (800) Inspect; replace as needed
!
! Drive Belt 50 H - 500 (800) Inspect; replace as needed
! Check for leaks at tank cap, lines, fuel valve,
Fuel System 100 H 12 M 600 (1000)
E filter, carburetor, replace lines every two years
!
Fuel Filter 100 H 12 M 600 (1000) Replace yearly
E
" Engine Mounts 100 H 12 M 600 (1000) Inspect
! Exhaust Emissions / Inspect secondary air system filter and
100 H 12 M 600 (1000)
E Muffler / Pipe exhaust - clean as required
!
Ignition Timing 100 H 12 M 600 (1000) Inspect
E
" Spark Plug 100 H 12 M 600 (1000)
Clean; check condition; adjust gap;
E replace as needed
Inspect for wear, routing, security; apply
" Wiring 100 H 12 M 600 (1000) dielectric grease to connectors subjected to
water, mud, etc.
CVT Clutches / Drive Belt
! 100 H - 600 (1000) Inspect;clean; replace worn parts
(Drive and Driven)
! Wheel / Axle Bearings 100 H 12 M 600 (1000) Inspect; replace as needed
Spark Arrestor 100 H 12 M 600 (1000) Clean
Inspect periodically; adjust when parts are
! Toe Adjustment - - -
replaced
Idle Speed - - - Adjust as needed
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
! Have an authorized Polaris dealer perform these services.
2.5
MAINTENANCE
MAINTENANCE REFERENCES / SERVICE LOCATIONS
Front and Rear View
Daytime Running
Lamps
Grease Steering Pivots
Inspect Exhaust
2.6
MAINTENANCE
RH and LH Side Views
2.7
MAINTENANCE
2.8
MAINTENANCE
MAINTENANCE REFERENCES
Item Ref. Rec. Lube / Fluid Method Frequency*
Change after 10 hrs, and then
Polaris YOUTH 40W Engine every 50 hours, 6 months or
Engine Oil Page 2.7
Oil or 20-W40 Synthetic.
(Ambient air temperatures
Add oil to proper level on
dipstick.
100 hours thereafter; Change
more often in extremely dirty 2
apply- see page 2.19) conditions, or short trip cold
weather operation.
Fill reservoir between MAX Fill as required. Change
Brake Fluid Page 2.7 DOT 4 (PN 2872189)
and MIN lines. brake fluid every 2 years.
AGL Synthetic Gearcase Add lube to bottom of fill
Transmission Page 2.7 Change annually***
Lubricant (PN 2873602) plug threads. 24 oz. (710 ml)
Front A -Arm and
Polaris Premium All Season Locate grease fittings and
Steering Pivot Page 2.6 Semi-annually**
Grease (PN 2871423) grease with grease gun.
Bushings
* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
2.9
MAINTENANCE
GENERAL VEHICLE INSPECTION 1. Locate the shift cable in the rear wheel well area.
AND MAINTENANCE
Pre-Ride / Daily Inspection Shift Cables
Perform the following pre-ride inspection daily, and when Dust Boot
servicing the vehicle at each scheduled maintenance.
• Inability to engage into a gear 6. Once the proper adjustment is obtained, tighten the lower
jam nut against the mount.
• Excessive gear clash (noise)
• Gear selector moving out of desired range 7. Start engine and shift through all gears to ensure the shift
cable is properly adjusted. If transmission still ratchets
after cable adjustment, verify the idle RPM is set correctly,
otherwise the transmission may require service.
2.10
MAINTENANCE
Shift Cable Replacement 8. Raise the vehicle and support it with jackstands in order to
access the underside to remove the cables.
Shift cable replacement may be necessary if symptoms include:
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
• Inability to engage into a gear reassembly.
• Inability to adjust cables for proper operation 9. Install new cables and adjust for proper operation and lever
• Gear selector moving out of desired range travel without binding.
IMPORTANT: Do not allow cables to hang below
2
1. Locate the shift cables in the rear wheel well area. vehicle frame.
2. Loosen the lower and upper jam nuts and remove the 10. Once installed, lower the vehicle. Start engine and shift
cables. through all gears to ensure the shift cables are properly
adjusted. If transmission still ratchets after cable
Upper adjustment, verify the idle RPM is set correctly, otherwise
Jam Nut the transmission may require service.
11. Reassemble the console cover, seats and shift knob as
outlined in Chapter 5.
Lower
Jam Nut
6. Loosen the lower and upper jam nuts and remove the
cables.
Upper
Jam Nut
Lower
Jam Nut
2.11
MAINTENANCE
FUEL SYSTEM AND AIR INTAKE 4. Inspect the air filter element for tears or damage.
NOTE: Filter is washable. Do not discard.
Air Filter Service
5. Wash the filter in warm soapy water and allow it to air dry.
It is recommended that the air filter be inspected as part of
pre-ride inspection. If riding in extremely dusty conditions, 6. Apply air filter oil (commercially available) to the filter,
apply a small amount of grease to the seal under the air box cap. following the directions on the label.
In extremely dusty conditions, air filter cleaning will be required NOTE: If unable to clean the filter, replace it.
more often.
NOTE: Service the filter more frequently if vehicle is
The filter should be serviced using the following procedure. operated in wet conditions, dusty conditions or at
high throttle openings for extended periods.
Removal
Installation
1. The air box is located on the upper frame by the rear LH
wheel. Access the air box by removing the panel located at 1. Verify the air box and support screen are thoroughly clean.
the top of the rear cab (under rear basket, if installed). 2. Install a clean, pre-oiled foam filter over the filter support.
NOTE: Apply a small amount of general purpose
grease to the sealing edge of the air box cap seal
Air Box Access before installing.
3. Install air box cap and secure with clips.
2. Unlatch the clips and remove the air box cap. Inspect the
seal. It should adhere tightly to the cover and seal all the
way around.
Secure Clips
2.12
MAINTENANCE
Choke Cable Adjustment 3. Remove the retaining screws and pull the choke assembly
out at the dash.
Verify free play of 3/16” (4.76 mm) and smooth operation of the
choke cable at the dash.
Decrease
2
Increase
2.13
MAINTENANCE
Idle Speed Adjustment Pilot Air Screw Adjustment
1. Start engine and warm it up thoroughly.
CAUTION
2. Adjust idle speed by turning the slide adjustment screw in
(clockwise) to increase or out (counterclockwise) to
The pilot air screw is calibrated at the factory to
decrease RPM. (Refer to illustration).
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.
Idle Speed
Screw 1. Using a portable tachometer, start the engine and verify
IDLE SPEED the idle speed is set to specification. Always check throttle
cable freeplay after adjusting idle speed and adjust if
necessary.
Decrease 2. Using ‘D’-shaped screwdriver Special Tool PA-47361
adjust the pilot air screw setting, turn the screw clockwise
until engine idle RPM begins to decrease. Stop turning at
this point and note the screw setting.
Increase
Special Tool:
PA-47361
2.14
MAINTENANCE
Vent Lines Fuel Filter
1. Check fuel tank, crankcase, carburetor and transmission The fuel filter should be replaced in accordance with the
vent lines for signs of wear, deterioration, damage or “Periodic Maintenance Chart” or whenever sediment is visible
leakage. Replace every two years. in the filter.
WARNING
2.15
MAINTENANCE
Fuel Valve Location Fuel Pump / Fuel Lines
The fuel valve is located on the passenger side of the vehicle NOTE: Thoroughly clean the exterior of all fuel
below the gas cap. Always turn off the fuel when the vehicle is related components before servicing.
not in use
The RZR170 fuel pump is located in the right rear wheel well.
1. Turn fuel valve to the ‘OFF’ position. NOTE: For all other information related to the fuel
2. Place a container beneath the bowl drain hose. System, refer to Chapter 4.
3. Loosen drain screw and allow fuel in the float bowl and fuel
line to drain completely.
Close
Open
Drain Screw
Throttle Pedal
Jam Nut
SPEED Stop Screw
Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust if necessary.
Decrease / Increase
2.17
MAINTENANCE
Throttle Freeplay Adjustment Throttle Cable Replacement
Inspection
1. Place the transmission in the Neutral (N) position. WARNING
2. Start the engine and warm it up thoroughly. Follow the factory cable routing as installed to
3. Measure the distance the throttle pedal moves before the prevent cable pinching, binding or damage.
engine begins to pick up speed. Freeplay should be 1/16”
- 1/8” (1.5 - 3 mm). Do not allow cable to hang below vehicle frame.
Failure to install properly could result in loss of
Adjustment vehicle control, resulting in severe injury or death.
1. The throttle cable adjuster is located at the throttle pedal 1. Engine is off. Place the vehicle in neutral and apply the
housing, outside of the cab well. parking brake.
2. Remove the foot pedal ETC cover screws and ONE left-
side housing mounting screw.
Throttle Cable
Adjuster
2.18
MAINTENANCE
4. Remove the carburetor slide assembly from the carburetor 12. Install the new cable onto the carburetor slide assembly and
body and disconnect the throttle cable. install the slide into the carburetor. Hand-tighten the slide
5. Raise the vehicle and support it with jack stands in order to cap sufficiently.
access the underside of the vehicle. 13. Place the throttle cable end into the foot pedal housing.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for 14. Place a new gasket on the housing and install the cover.
reassembly.
6. Remove the panduit straps retaining the throttle cable to the
Torque the retaining screws to specification.
2
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.
Pivot Bearing
=T
ETC Throttle Housing Screws:
8.5-10 ft. lbs. (11.5-13.5 Nm)
=T
9. Fasten the cable with cable ties at the same locations they Throttle Pedal Mounting Screws:
were previously removed. 16-20 ft. lbs. (21-27 Nm)
10. Continue to route the cable towards the front of the vehicle
using the brake line routing as a general guide. 15. Start the engine and allow it to warm up.
16. Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Freeplay should be 1/16" -
1/8" (1.5 - 3 mm).
• If freeplay is correct, proceed to step 21.
• If adjustment is required, refer to “Throttle Freeplay
Adjustment” procedure.
17. After reassembly and adjustment, field test vehicle to
ensure proper throttle operation.
11. Use cable ties to retain the throttle cable, using the same
locations they were previously removed.
NOTE: Be sure to route the throttle cable inside the
retainers.
2.19
MAINTENANCE
6. Remove the drain plug and pre-filter screen. Allow the oil
to drain completely.
Dipstick
Safe Range
{
2.20
MAINTENANCE
10. Reinstall the drain plug. Torque to specification. Engine Crankcase Ventilation System
Inspection
=T The engine is equipped with a crankcase ventilation. Follow
the breather hoses from the airbox to the engine and inspect
Crankcase Drain Plug: 18 ft. lbs. (23 Nm)
the hoses for possible kinks or wear. The hoses are form-fitted
11. Remove the dipstick. Add recommended oil. Do not for a proper fit. 2
overfill.
Capacity:
NOTE: Make sure lines are not kinked or pinched.
37 oz. (1.1 ltr)
Engine/Transmission Mount Locations
12. Reinstall the dipstick. Periodically inspect engine/transmission upper and lower
mounts for cracks or damage.
13. Start the engine. Allow it to idle for a short period.
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.
2.21
MAINTENANCE
Compression / Leakdown Test Intake Valve Clearance Adjustment
IMPORTANT: Use of a compression tester adaptor 1. Remove the valve cover and secondary air pipe assembly.
that is too long WILL CAUSE DAMAGE to the cylinder 2. Verify cam lobes are pointed down.
head. The adaptor length should be no longer than 3. Insert the correct thickness feeler gauge between end of
the length of the spark plug threads (1/2” or 12.07mm). intake valve stem and adjuster screw.
Compression tester adaptor threads 4. When clearance is correct, hold adjuster screw and tighten
should not exceed spark plug threads.
locknut securely.
1/2” (12.07mm)
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.
= In. / mm.
Cylinder Compression
Valve Clearance:
Standard: 130 - 160 psi .003” (.07 mm)
Cylinder Leakage
Exhaust Valve Clearance Adjustment
Service Limit: 15%
Inspect if leakage exceeds 15% 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.
= In. / mm.
Valve Clearance:
.003” (.07 mm)
2.22
MAINTENANCE
Exhaust - Spark Arrestor
WARNING
Silencer
Screen
Retaining Arrestor
Screws
=T
Spark Arrestor Fasteners
7 ft. lbs. (9.5 Nm)
2.23
MAINTENANCE
TRANSMISSION
Transmission Specification Chart
NOTE: It is important to follow the transmission and The fill plug is located on the side of the gearcase next to the shift
lever bell crank. Maintain the fluid level even with the bottom
gearcase maintenance intervals described in the of the fill plug hole.
Periodic Maintenance Chart.
Transmission Specifications
Specified Lubricant:
AGL Synthetic Gearcase Lubricant
(PN 2873602) Transmission Oil Fill/Check
3. Add the recommended fluid through the fill plug hole until
it is at the bottom 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.
2.24
MAINTENANCE
Transmission Oil Change: FINAL DRIVE / WHEEL AND TIRE
1. Remove the level check plug (refer to “Lubricant Level
Check”). Wheel, Hub, and Spindle Torque Table
2. Place a drain pan under the main gearcase drain plug.
Item Nut Type Specification
3. Remove the drain plug and allow to drain completely.
Aluminum Wheels
Lug Nut
(#1)
90 ft. lbs. (122 Nm) 2
Flange Nut
Steel Wheels 27 ft. lbs. (37 Nm)
(#2)
Hub Retaining Nuts
- 40 ft. lbs. (54 Nm)
(Front & Rear)
Transmission Drain Plug Torque: NOTE: Do not lubricate the stud or the lug nut.
18 ft. lbs. (24 Nm)
6. Add the recommended fluid through the fill plug hole. Wheel Removal
Maintain the fluid level at the bottom of the fill plug hole 1. Position the vehicle on a level surface.
when filling. Do not overfill.
7. Reinstall the fill plug. 2. Place the transmission in gear and stop the engine.
8. Check for leaks. Discard the used lubricant properly.
3. Loosen the wheel nuts slightly. If wheel hub removal is
required, remove the cotter pin and loosen the hub nut
slightly.
Wheel Installation
1. Verify the transmission is in gear.
2.25
MAINTENANCE
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts and/or hub nut to the proper torque WARNING
specification listed in the torque table at the beginning of
this section. Operating a RANGER 170 with worn tires will
7. If hub nut was removed, install a new cotter pin after the increase the possibility of the vehicle skidding
hub nut has been tightened. easily with possible loss of control.
Tire Pressure
Hub Nut
CAUTION
Always replace tires when tread depth is worn to 1/8" (3 mm) or 1. Check the amount of chain slack by moving the vehicle
less. slightly forward to gain slack at the top side of the chain.
2. Raise the rear of the vehicle and support securely under the
Tread mainframe. Allow the swing arm to hang at full shock
Depth 1/8" (3 mm) extension without touching the ground. This establishes the
tightest chain position.
2.26
MAINTENANCE
3. Pull down on the chain tensioner to move it out of the way, ELECTRICAL AND IGNITION SYSTEM
then measure chain deflection. It should have 1/4"-1/2" (6-
12 mm) deflection. 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 tablespoon baking soda and
one cup water. Rinse well with tap water and dry off with clean 2
shop towels. Coat the terminals with dielectric grease or
petroleum jelly.
WARNING
=T
Chain Adjuster Locknuts: 18 ft. lbs. (25 Nm)
=T
Rear Housing Mounting Bolts: 43 ft. lbs. (60 Nm)
2.27
MAINTENANCE
Battery Removal Battery Off Season Storage
1. Remove or pull the driver’s seat forward to access the Whenever the vehicle is not used for a period of three months or
battery. 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
Battery
needed to maintain a full charge.
3. Disconnect the red (positive) battery cable. The single most important thing about maintaining a sealed
battery is to keep it fully charged. Since the battery is sealed and
4. Remove the rubber strap and lift the battery out of the the sealing strip cannot be removed, you must use a voltmeter or
vehicle. multimeter to measure the DC voltage at the battery terminals.
2.28
MAINTENANCE
Spark Plug Service 6. Measure gap with a wire gauge. Refer to specifications in
the following illustration for proper spark plug type and
1. Clean plug area so no dirt or debris can fall into the gap. Adjust gap if necessary by carefully bending the side
cylinder when the plug is removed. electrode.
Spark Plug Gap
WARNING
Ground
Terminal Location
2.29
MAINTENANCE
WARNING
• Elevate front end of machine so front wheels are off the
Due to the critical nature of the procedures outlined in ground. Check for any looseness in front hub and wheel
this chapter, Polaris recommends steering assembly by grasping the tire firmly at top and bottom
component repair and adjustment be performed first, and then at front and rear. Try to move the wheel
by an authorized Polaris MSD-certified technician and hub by pushing inward and pulling outward.
when replacing worn or damaged steering parts.
Use only genuine Polaris replacement parts. Check for Loose Wheel or Hub
U-Joints
Gearbox
2.30
MAINTENANCE
Toe Alignment Inspection Toe Adjustment
1. Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between
vehicle center and each wheel. This will tell you which tie rod
2. Set steering wheel in a straight ahead position and secure needs adjusting.
the steering wheel in this position.
CAUTION
Measurement “B” Chalk Mark • Loosen jam nuts at both ends of the tie rod.
Measurement “A”
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as specified in
NOTE: It is important that the height of both marks
Toe Alignment Inspection.
be equally positioned in order to get an accurate
measurement. • IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent rod
4. Measure the distance between the marks and record the end damage and premature wear. Damage may not be
measurement. Call this measurement “A”. immediately apparent if done incorrectly.
5. Rotate the tires 180! by moving vehicle forward or • After alignment is complete, torque jam nuts to
backward. Position chalk marks facing rearward, even with specification. Keep tie rod parallel to the mounting
the hub/axle center line. surface.
6. Again measure the distance between the marks and record.
Call this measurement “B”. Subtract measurement “B” =T
from measurement “A”. The difference between
measurements “A” and “B” is the vehicle toe alignment. Tie Rod Jam Nut Torque:
The recommended vehicle toe tolerance is 1/8” to 1/4” 12-14 ft. lbs. (16-19 Nm)
(.3 to .6 cm) toe out. This means the measurement at the
front of the tire (A) is 1/8” to 1/4” (.3 to .6 cm) wider than
the measurement at the rear (B).
= In. / mm.
Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
2.31
MAINTENANCE
WARNING Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
Uneven adjustment may cause poor handling of the contaminated, the fluid level is below the minimum level, or if
vehicle, which could result in an accident and the type and brand of the fluid in the reservoir is unknown.
serious injury or death. Always adjust all spring
preloads equally. The brake fluid master cylinder reservoir can be accessed
through the left front wheel well.
Suspension Spring Adjustment
1. Position the vehicle on a level surface. Engine off.
1. Position the vehicle on a level surface and stop the engine.
2. Place the transmission in gear and lock the parking brake.
2. Raise and safely support the front or rear of the vehicle off
the ground to allow the suspension to fully extend. 3. View the brake fluid level in the reservoir. The level should
be between the MAX and MIN level lines.
NOTE: The tires should not be touching the ground.
4. If the fluid level is lower than the MIN level line, add brake
3. To adjust the shock spring preload, rotate the adjustment fluid until it reaches the MAX level line.
cam clockwise to increase spring tension or counter-
clockwise to decrease spring tension using the supplied 5. Install the reservoir cap and apply the brake pedal
spanner wrench. forcefully for a few seconds, then check for fluid leaks
around the master cylinder and brake caliper fittings.
Decrease Increase
Preload Preload
Special Tool:
Shock Spanner Wrench
2.32
MAINTENANCE
Brake Pad / Disc Inspection
1. Check the brake pads for wear, damage, or looseness.
2
3. Pads should be changed when the friction material is worn
to .040” (1 mm).
Rear Front
Disc Disc
Service Limit:
.170" (4.32 mm)
2.33
MAINTENANCE
MAINTENANCE LOG
Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician
2.34
ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE SYSTEMS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
EMISSIONS SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
COOLING SHROUD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TOP-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ENGINE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
FINDING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ROCKER ASSEMBLY
DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CAM CHAIN FOLLOWER / TENSIONER GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . 3.22
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.24
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.1
ENGINE
BOTTOM-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
STARTER DRIVE GEAR REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.26
FLYWHEEL REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
CRANKSHAFT ONE WAY GEAR / DRIVE SPROCKET
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE ONE-WAY CLUTCH
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
BALANCE SHAFT SPROCKET
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP REMOVAL / DRIVE CHAIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE SEPARATION AND
CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE / BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
BEARING / SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CHAIN GUIDE/TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CRANKSHAFT, BALANCE SHAFT AND STARTER DRIVE GEAR INSTALLATION . . 3.35
OIL PUMP AND CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
ROCKER ARM / SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ROCKER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
STATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
STATOR HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
3.2
ENGINE
TOOLS Oil Pump Sprocket Nut 6mm 7-8 (9-11 Nm)
Special Tools
Oil pump baffle plate 6mm 4-5 (5-7 Nm)
PART NUMBER TOOL DESCRIPTION
Stator Assembly 6mm 7-8 (9-11 Nm)
2870390 Piston Support Block
PA-45153 Flywheel Puller Stator Housing 6mm 7-8 (9-11 Nm)
Transmission Output
PA-49959
Shaft Collar Tool Valve Cover 6mm 7-8 (9-11 Nm)
Balance Shaft Slotted
PA-47344
Nut Socket
Crankshaft Slotted Nut
Valve Adjuster Lock Nut 5mm 4-5 (5-7 Nm) 3
PA-49335
Socket Starter Motor 6mm 5-7 (7-9 Nm)
Flywheel Puller Adaptor
PA-49336
(Use with PA-45153) Spark Plug 12mm 11 (15 Nm)
3.3
ENGINE
ENGINE INFORMATION
Engine Exploded Views
Crankcase Cylinder / Cylinder Head
3.4
ENGINE
Engine Lubrication Accessible Components
Oil Type:** The following components can be serviced or removed with the
Above 32!F engine installed in the frame:
Polaris Youth 4-Stroke Oil (40 W)
Quart - (PN 2876248) • Flywheel
Gallon - (PN2876249)
• Alternator/Stator
Below 32!F • Starter Motor/Starter Drive
Polaris Semi-Synthetic Engine Oil (20W-40)
Quart - (PN 2872175) • Oil pump / Chain
Gallon - (PN2872176)
Piston Identification The following components require engine removal for service:
• Cam Chain and Sprockets
The piston may have or may not have an identification mark for
piston placement. If the piston has an identification mark, follow • Crankshaft
the directions for piston placement below. If the piston does not
• Crankshaft Main Bearings
have an identification mark, the direction for placement of the
piston does not matter. • Crankcase/Bearings
Note the directional and identification marks when viewing the • Balancer/Bearings
pistons from the top. The letters “IN” must always be toward the NOTE: Cam chain service requires crankshaft
intake side of the engine. The other numbers are used for removal, as the chain is located on the pto side of
identification as to diameter, length and design. Four stroke the engine.
engine rings are rectangular profile. Any numbers or letters on
the rings (except oil control rings) must be positioned upward. NOTE: Crankshaft components are not serviceable.
See text for oil control ring upper rail installation. Replace crankshaft as an assembly.
3.5
ENGINE
Engine Service Data
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off
3.6
ENGINE
Engine Service Data
Surface warpage limit (mating with cylinder head) .002” (0.05 mm)
Connecting Rod Connecting rod big end axial clearance Std .0039 - .011" (0.1 - 0.3 mm)
Oil pump chain Install new as a part of any oil pump replacement
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.
3.7
ENGINE
Oil Flow Diagram
3.8
ENGINE
ENGINE SYSTEMS SERVICE
Breather / Oil Separator
The breather / oil separator is located on the upper rear 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.
To Valve Cover
To Crank Case
3.9
ENGINE
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 complete burning of the exhaust emissions. 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 schedule
in Chapter 2 for proper operation and emissions compliance.
C
A Air In
3.10
ENGINE
Cooling Shroud Removal/Installation
The cooling shroud directs air generated by the fan around the cylinder and casing for cooling.
REMOVAL:
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.
3
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 snap-hooks 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 screws and attaching bolt
into the engine case. Hand tighten 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 pipe flange fasteners to 7-8 ft. lb. (9-11 Nm).
11. Install the carburetor and intake. Torque fasteners to 7-8 ft. lb. (9-11 Nm).
A
Cooling Shroud Exploded View
MAG View PTO View
A. Fan Shroud
C B
3.11
ENGINE
Engine Removal Engine Installation Notes
1. Clean work area. After the engine is installed in the frame, review this checklist
and perform all steps that apply:
2. Thoroughly clean the engine and chassis.
General Items
3. Disconnect battery.
• Install previously removed components using new
4. Drain engine oil.
gaskets, seals, and fasteners where applicable.
5. Disconnect spark plug high tension lead.
• Perform checks on fluid levels, controls, and all
6. Disconnect all electrical wires from the engine. important areas on the vehicle as outlined in the daily
pre-ride inspection checklist (refer to Chapter 2).
7. Remove the following parts as required:
CVT System
• Rear Cab Assembly (Refer to Chapter 5)
8. Remove exhaust pipe. • Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing.
9. Remove the carburetor. Insert a clean shop towel into the
carburetor flange to prevent dirt from entering the intake. • Inspect clutch rollers, shoes and springs before
reassembly.
10. At the starter motor, note the chassis ground cable location
and remove it. Transmission
11. Mark the positive (+) cable mounting angle and remove • Inspect transmission operation and adjust linkage if
cable. necessary.
12. Remove the transmission shift cables from the transmission Exhaust
and secure out of the way.
• Replace exhaust gaskets. Seal connections if desired
13. Raise the rear of the unit until the wheels are off the ground. with high temp sealant.
Secure with jackstands under the frame.
• After running the engine, verify all bolted exhaust
14. Remove the drive chain. connections are tight and in good condition.
15. Remove the top rear shock bolts and allow the swing arm Engine Mount Torque
to drop. (OPTIONAL - Refer to Chapter 5 to remove the
axle and swing arm as an assembly) • Front Mount
16. Remove all engine mount bolts and / or engine mount • Rear Mounts
plates.
Engine Break In Period
17. Using the aid of an assistant, lift and remove engine out the
rear of the vehicle. 4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.
3.12
ENGINE
TOP-END DISASSEMBLY Cam Chain Tensioner Inspection
1. Remove the two cam chain tensioner flange bolts. NOTE:
Engine Removal/Installation
The plunger is under spring tension. Maintain inward
Refer to page 3.12 for engine removal / installation notes. pressure on the tensioner body while removing.
Rotation
A
3.13
ENGINE
Rocker Assembly 5. Remove each rocker arm shaft using a hex bolt. NOTE:
Disassembly and Inspection Place the hex bolt head in a vise and lightly tap the rocker
housing with a non-marring hammer to pull the rocker
NOTE: Orientation of the components is important arm shafts.
for reassembly. Mark components as needed before
disassembly.
2. Loosen each of the four cylinder head nuts evenly 1/4 turn
each time in a cross pattern until loose.
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 assembly.
Exhaust
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.
Inspect
3.14
ENGINE
7. Measure I.D. of each rocker arm for out-of-round and 3. Remove the cam chain from the sprocket by tilting the cam
visually inspect the I.D. surface. Replace arm if excessive assembly and simultaneously lifting the chain.
wear is evident.
1. Verify the valve cover and cam chain tensioner have been
removed.
3.15
ENGINE
3. Visually inspect each cam lobe and bearing for wear, Cylinder Head Removal
chafing or damage.
NOTE: Cam chain and tensioner must be removed. If
no crankshaft service is being performed, secure
Bearings
cam chain with mechanics wire to avoid chain falling
into the crankcase.
3. Loosen each of the four cylinder head nuts evenly 1/4 turn
each time in a cross pattern until loose.
Lobe Height
4. Remove the nuts and tap the rocker assembly with a plastic
hammer until loose. Remove.
3.16
ENGINE
Cylinder Head Inspection Cylinder Head Disassembly
1. Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon. WARNING
= In. / mm.
3.17
ENGINE
4. Measure free length of the inner and outer springs with a Valve Inspection
Vernier caliper, Ill.1. Check spring for squareness as
shown in Ill.2. Replace spring if measurements are out of 1. Remove all carbon from valve with a soft wire wheel.
specification.
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.
Valve Spring
Free Length
III.1
III.2
5. Remove valve seals. NOTE: Replace seals whenever the
cylinder head is disassembled. Hardened, cracked or worn 4. Inspect split keeper groove for wear or flaring of the keeper
valve seals will cause excessive oil consumption and seat area (B). NOTE: The valves cannot be re-faced or end
carbon buildup. ground. Valves must be replaced if worn, bent, or damaged.
3.18
ENGINE
6. Measure valve guide inside diameter at the top middle and Cylinder Head Reconditioning
end of the guide using a small hole gauge and a micrometer.
NOTE: Servicing the valve guides and valve seats
Measure in two directions, front to back and side to side.
requires special tools and a thorough knowledge of
reconditioning techniques.
CAUTION
3.19
ENGINE
3. Place 46! cutter on the pilot and make a light cut. 7. Remove valve and check where the Prussian Blue™ 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).
(B)
(A)
(A)
6. Insert valve into guide and tap valve lightly into place a few
times.
3.20
ENGINE
NOTE: When using an interference angle, the seat 12. Clean rocker assembly, cylinder head, valves, and camshaft
contact point on the valve will be very narrow, and is oil supply passages thoroughly.
a normal condition. Look for an even and
continuous contact point on the black marker, all the
way around the valve face.
Seat
Width
Intake Exhaust
3
13. Spray electrical contact cleaner into oil passages and dry
using compressed air.
8. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air. Cylinder Head Assembly
9. Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
CAUTION
valve. Lapping is not required with an interference angle.
10. Insert the valve into its respective guide and lap using a Wear eye protection during assembly.
lapping tool or a section of fuel line connected to the valve
stem. 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 process. Do this four to five times
2. Apply engine oil to valve guides and seats.
until the valve is fully seated, and repeat process for the
other valve. 3. Coat valve stem with molybdenum disulfide grease.
3.21
ENGINE
5. Dip valve springs and retainer in clean engine oil and install Cylinder Removal
springs with closely spaced coils toward the cylinder head.
Follow engine disassembly procedures to remove the valve
cover, rocker assembly, camshaft and cylinder head.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the keepers.
3.22
ENGINE
Piston Removal Cylinder Inspection
1. Remove circlip from either side of piston. 1. Remove all gasket material from the cylinder sealing
surfaces.
3. Remove the compression rings, starting with the top ring. = In. / mm.
Cylinder Warp:
.002” (.05 mm) MAX
* Using a piston ring pliers: Carefully expand ring and lift it off X Y
the piston. CAUTION: Do not expand the ring more than the
amount necessary to remove it from the piston, or the ring may
break.
Y
X
* 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.
Y
4. Repeat procedure for second ring. X
3.23
ENGINE
5. Record measurements. If cylinder is tapered or out of round It is very important that the cylinder be thoroughly cleaned after
beyond specification, the cylinder must be honed, bored or honing to remove all grit material. Wash the cylinder in a
replaced. solvent, then in hot, soapy water. Use electrical contact cleaner
if necessary to clean these areas. Rinse thoroughly, dry with
compressed air, and oil the bore immediately with Polaris 4
= In. / mm. Cycle Lubricant to prevent the formation of surface rust.
CAUTION
3.24
ENGINE
3. Measure piston pin bore. Replace piston if out-of-round Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown.
Feeler Gauge
Piston Pin Bore
Cylinder
25-50 mm
3
4. Measure piston pin O.D. Replace piston pin if out-of-round.
Piston Ring
= In. / mm.
2. Measure the gap with a feeler gauge at both the top and
bottom of the cylinder.
3.25
ENGINE
BOTTOM-END DISASSEMBLY 4. Remove the start drive gear and shaft by pulling the shaft
and tilting the gear slightly.
Starter Drive Gear Removal and Inspection
1. Remove the fan from the hub.
2. Remove the fan hub by removing the flywheel nut, washer 6. Measure the ID of the bushing in the stator housing (A) and
and pulling the hub from the crankshaft. in the crankcase (B) in two directions 90! apart to
determine if out-of-round. Calculate the clearance. Replace
components if clearance is excessive.
Washer
A B
Flywheel Nut
3.26
ENGINE
Flywheel Removal / Inspection 3. Inspect the flywheel for loose components, cracks or other
damage. Replace flywheel if any damage is found.
CAUTION
PA-49
93 6
PA-45153
3.27
ENGINE
Crankshaft One Way Gear / Drive Sprocket 3. Remove the starter drive one-way gear assembly (A) from
Removal and Inspection the crankshaft.
Removal
C Install
PA-49959
Remove
3.28
ENGINE
Starter Drive One-way Clutch Balance Shaft Sprocket
Removal and Inspection Removal and Inspection
1. The cooling shroud, stator housing and flywheel must be 1. The cooling shroud, stator housing and flywheel and
removed prior to accessing the one-way starter drive. starter drive one-way gear must be removed prior to
accessing the balance shaft gear and oil pump gear
2. Pull the starter drive assembly from the crankshaft. Inspect
the bearing surfaces and drive teeth for signs of wear or 2. Using Slotted Nut Socket PA-47344, remove the balance
gouging. Replace the one-way clutch as an assembly if it shaft slotted nut and washer.
is not working properly. Assembly should turn in one
direction only. NOTE: Slotted nut is right-hand thread.
Drive Gear 3
One-way Assembly E
D
C
PA-47344
Bearing
PA-47344
Install
3.29
ENGINE
3. Remove the oil pump galley cover, oil pump gear and chain Oil Pump Removal / Drive Chain Inspection
to facilitate removal of the balance shaft sprocket.
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.
3. Remove the oil pump retaining screws and pull the pump
from the engine case.
3.30
ENGINE
4. Thoroughly clean all oil passages with clean solvent.
=T
Oil Pump Screw Torque:
4-5 ft. lbs. (5-7 Nm)
3.31
ENGINE
CRANKCASE DISASSEMBLY NOTE: Tapping the pto end of the crankshaft with a
soft-face hammer may also separate the cases. Use
NOTE: Engine must be removed from the frame to care not to damage the crankshaft end or cases.
perform any crankcase or crankshaft removal. Crankcase Separator Tool
PA-46087
NOTE: The starter, starter drive, flywheel, stator, oil
pump and transmission can be serviced with the
engine in the frame.
3.32
ENGINE
Crankshaft / Cam Chain / Sprocket 5. Remove cam chain. Inspect chain for wear or damage.
Inspection Replace if worn excessively or as part of any crankshaft
repair.
1. Inspect the crankshaft main bearings and cam chain
sprocket for wear or damage.
Note: Install new chain as
a part of crankshaft repair.
3.33
ENGINE
ENGINE REASSEMBLY 2. Install the balance shaft into the mag side of the crankcase.
CAUTION
3. Install a new gasket onto the pto case half. Applying a thin
Press bearings only on outer race of bearing to amount of crankcase sealer to the gasket will help hold it
prevent bearing damage. in place.
3. Install new seals with the lip facing in. 4. Mate the mag side case, balancer and crankshaft to the PTO
side. During installation of the crankshaft, loop the cam
chain down into the chain room and over the pto end.
CAUTION
5. Press the mag and pto assembles together using a press.
Press seals only on outer diameter Verify the balance shaft is seated and both shafts turn freely
to prevent damage. once installed.
6. Loop the cam chain through the chain room and secure with
mechanic’s wire.
3.34
ENGINE
7. Install the two mag side flange bolts and torque to Crankshaft, Balance Shaft and Starter Drive
specification. 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
Alignment marks
=T
Crankcase Bolt Torque:
14 - 15 ft. lbs. (19-21 Nm) 3. Install the oil pump drive sprocket, washer and slotted nut
onto the balance shaft.
Crankcase Sealant
PN 2871557
=T
Install A
Chain Guide Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
=T
Balance Shaft Slotted Nut Torque:
43 ft. lbs. (59 Nm)
Special Tool:
PA-47344
3.35
ENGINE
5. Install the Starter Drive one-way gear assembly, washer 7. Install the baffle plate and torque to specification.
and slotted nut.
Crankshaft Slotted Nut Torque: 2. Install oil pump as shown. Install and torque screws to
43 ft. lbs. (59 Nm) specification.
Special Tool:
PA-49935
=T
Oil Pump Cover Screw Torque:
4-5 ft. lbs. (5-7 Nm)
3.36
ENGINE
3. Install the chain (A) over the sprocket on the balance shaft Piston Ring Installation
gear (B).
NOTE: Apply clean engine oil to all ring surfaces
and ring lands. Always check piston ring installed
A B
gap before rings are installed on piston. If the piston
C has been in service, clean any accumulated carbon
from the ring grooves and oil control ring holes.
Install chamfer up
Second
Ring Profile
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. Top Ring: Install the top ring with the chamfered edge
facing up (if applicable).
=T
6. Check to make sure the rings rotate freely in the groove
Oil Pump Gear Nut Torque: when compressed by hand. Verify that the ring gaps are
5-7 ft. lbs. (7-9 Nm) 120 degrees apart from each other before installation.
=T
Oil Pump Baffle Plate Screw Torque:
5-7 ft. lbs. (7-9 Nm)
3.37
ENGINE
Piston Installation 5. Place the dowel pins in the PTO side of the crankcase and
install a new cylinder base gasket.
CAUTION
1. Install a new circlip on one side of the piston with the end
gap facing up or down.
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.
3.38
ENGINE
Cylinder Installation Cylinder Head and Camshaft Installation
NOTE: Clean the gasket surfaces on the crankcase NOTE: Verify the gasket surfaces on the cylinder
and cylinder. Remove all traces of old gasket head and cylinder are clean. Remove all traces of old
material and apply a new base gasket gasket material.
1. Verify the cylinder base dowel pin(s) and a new base 1. Install the dowel pin(s) and a new cylinder head gasket
gasket are installed. Position the Piston Support Block (PN over the cylinder studs.
2870390) (A) beneath the piston skirt to support the piston
during cylinder installation.
2. Apply clean engine oil liberally to the bore and tapered 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.
2. Pull the cam chain through the cylinder head chain room
and secure with mechanic’s wire.
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 seated properly in the
crankcase.
3.39
ENGINE
Camshaft Timing
CAUTION
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.
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 crankshaft 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.
Stator housing 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.
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.
TDC
Cam Alignment
6. Verify all cam timing marks 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. Torque fasteners to specification.
8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.
3.40
ENGINE
3.41
ENGINE
Camshaft Installation - Timing Method 2
Reference Illustration Page 3.43
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 (Top 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. 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.
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.
8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.
3.42