Polaris Ranger RZR 170 Repair Service Manual 2009

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


APPLICABLE MODELS :

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


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

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


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

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

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

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

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9922134_Ch_01-GENERAL INFORMATION
    TABLE OF CONTENTS
        MODEL INFORMATION
            Model Identification
            Engine Designation Number
            VIN Identification
            Engine Serial Number Location
            Unit Serial Number (VIN) and Emissions Decal Locations
        VEHICLE INFORMATION
            Publication Numbers
            Paint Codes
            Replacement Keys
        SPECIAL TOOLS
        GENERAL SPECIFICATIONS
            MODEL: 2009 RANGER RZR 170
            MODEL: 2009 RANGER RZR 170
        MISC. SPECIFICATIONS AND CHARTS
            Conversion Table
            Standard Torque Specifications
            SAE Tap / Drill Sizes
            Metric Tap / Drill Sizes
            Decimal Equivalents
            Glossary of Terms
            
9922134_Ch_02-MAINTENANCE
    TABLE OF CONTENTS
        PERIODIC MAINTENANCE CHART
            Periodic Maintenance Overview
            Maintenance Chart Key
            Pre-Ride - 25 Hour Maintenance Interval
            30 - 100 Hour Maintenance Interval
        MAINTENANCE REFERENCES / SERVICE LOCATIONS
            Front and Rear View
            RH and LH Side Views
        LUBRICANTS / SERVICE PRODUCTS
            Polaris Lubricants, Maintenance and Service Products
        MAINTENANCE REFERENCES
        GENERAL VEHICLE INSPECTION AND MAINTENANCE
            Pre-Ride / Daily Inspection
            Frame, Nuts, Bolts, and Fasteners
            Shift Cable Inspection / Adjustment
            Shift Cable Replacement
        FUEL SYSTEM AND AIR INTAKE
            Air Filter Service
            Choke Cable Adjustment
            Choke Cable Replacement
            Idle Speed Adjustment
            Pilot Air Screw Adjustment
            Vent Lines
            Fuel System
            Fuel Filter
            Fuel Valve Location
            Carburetor Draining
            Fuel Pump / Fuel Lines
            Throttle Pedal Inspection
            Throttle Stop Speed Control
            Throttle Freeplay Adjustment
            Throttle Cable Replacement
        ENGINE
            Engine Oil Level
            Engine Oil Change 
            Engine Crankcase Ventilation System Inspection
            Engine/Transmission Mount Locations
            Compression / Leakdown Test
            Intake Valve Clearance Adjustment
            Exhaust Valve Clearance Adjustment
            Exhaust - Spark Arrestor
        TRANSMISSION
            Transmission Specification Chart
            Transmission Oil Change
        FINAL DRIVE / WHEEL AND TIRE
            Wheel, Hub, and Spindle Torque Table
            Wheel Removal
            Wheel Installation
            Tire Inspection
            Tire Pressure
            Drive Chain Lubrication and Adjustment
        ELECTRICAL AND IGNITION SYSTEM
            Battery Maintenance
            Battery Removal
            Battery Installation
            Battery Off Season Storage
            Battery Charging (Maintenance Free)
            Spark Plug Service
            Engine To Frame Ground
        STEERING
            Steering Inspection
            Steering Wheel Freeplay
            Steering Inspection / Tie Rod Ends and Hubs 
            Toe Alignment Inspection
            Toe Adjustment
        SUSPENSION
            Spring Preload Adjustment
        BRAKE SYSTEM
            Brake Fluid Inspection
            Brake Pad / Disc Inspection
            Brake Hose and Fitting Inspection
        MAINTENANCE LOG
        
9922134_Ch_03-ENGINE
    TABLE OF CONTENTS
        TOOLS
            Special Tools
        TORQUE SPECIFICATIONS
            Engine Torque Specifications
            Torque Patterns
        ENGINE INFORMATION
            Engine Exploded Views
            Engine Lubrication
            Piston Identification
            Accessible Components
            Engine Service Data
            Engine Service Data
            Oil Flow Diagram
        ENGINE SYSTEMS SERVICE
            Breather / Oil Separator
            Emissions Secondary Air System
            Cooling Shroud Removal/Installation
            Engine Removal
            Engine Installation Notes
        TOP-END DISASSEMBLY
            Engine Removal/Installation
            Finding Top Dead Center (TDC)
            Cam Chain Tensioner Inspection
            Rocker Assembly Disassembly and Inspection
            Camshaft Removal
            Camshaft Inspection
            Cylinder Head Removal
            Cylinder Head Inspection
            Cylinder Head Warp Inspection
            Combustion Chamber Inspection
            Cylinder Head Disassembly
            Valve Inspection
            Valve Seat Reconditioning
            Cylinder Head Assembly
            Valve Sealing Test
            Cylinder Removal
            Cam Chain Follower / Tensioner Guide Removal
            Piston Removal
            Cylinder Inspection
            Cylinder Hone Selection / Honing Procedure
            Honing to Deglaze
            Piston Inspection
            Piston Ring Installed Gap
        BOTTOM-END DISASSEMBLY
            Starter Drive Gear Removal and Inspection
            Flywheel Removal / Inspection
            Crankshaft One Way Gear / Drive Sprocket Removal and Inspection
            Starter Drive One-way Clutch Removal and Inspection
            Balance Shaft Sprocket Removal and Inspection
            Oil Pump Removal / Drive Chain Inspection
        CRANKCASE DISASSEMBLY
            Crankcase Separation and Cam Chain Removal
            Crankshaft Removal
            Crankshaft / Cam Chain / Sprocket Inspection
            Crankcase / Bearing Inspection
            Crankcase Oil Strainer Inspection
        ENGINE REASSEMBLY
            Bearing / Seal Installation
            Crankcase Reassembly
            Chain Guide/Tensioner Installation
            Crankshaft, Balance Shaft and Starter Drive Gear Installation
            Oil Pump and Chain Installation
            Piston Ring Installation
            Piston Installation
            Cylinder Installation
            Cylinder Head and Camshaft Installation
            Camshaft Timing
            Rocker Arm / Shaft Assembly
            Rocker Assembly Installation
            Cam Chain Tensioner Installation
            Intake Valve Clearance Adjustment
            Exhaust Valve Clearance Adjustment
            Starter Drive Assembly
            Flywheel Installation
            Stator Installation
            Stator Housing Installation
            Exhaust System
        TROUBLESHOOTING
            Spark Plug Fouling 
            General Troubleshooting
            
9922134_Ch_05-BODY / SUSPENSION / STEERING
    TABLE OF CONTENTS
        GENERAL INFORMATION
            Special Tools
            Torque Specifications
        BODY REMOVAL
            Seat Removal
            Seat Installation
            Front Bumper Removal / Installation
            Front Cab Removal / Installation
            Rocker Panel Removal
            Rear Bumper Removal / Installation
            Rear Cab Removal
            Service Panel (Seat Shield) Removal
            Console Cover Removal
            Key Switch / Indicator Light Replacement
            Decal Replacement
            Body Exploded View
        CAB FRAME
            Exploded View
            Cab Frame Assembly
        MAIN FRAME
            Exploded View
        FRONT A-ARMS
            Exploded View
            A-arm Replacement
        FRONT HUB
            Hub Removal
            Hub Seal and Bearing Replacement
            Hub Installation
        SHOCKS
            Shock Exploded View
            Shock Removal
            Shock Replacement
            Shock Installation
        Rear Swing Arm
            Exploded View
            Swing Arm Removal
            Swing Arm Installation
        Rear Axle
            Axle Housing Removal
            Axle Housing Service
            Axle Housing Installation
            Axle Removal
            Axle Installation
        STEERING
            Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View
            Steering Shaft Removal
            Steering Shaft Installation
            Steering Gearbox Removal
            Steering Gearbox Installation
        Tie Rod
            Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View
            Tie Rod Removal / Installation
        WHEELs
            Front Wheel Exploded View
            Rear Wheel Exploded View
            Wheel Removal
            Wheel Installation
            
9922134_Ch_06-BRAKES
    TABLE OF CONTENTS
        GENERAL SPECIFICATIONS
        TORQUE SPECIFICATIONS
        SPECIAL TOOLS
        BRAKE SYSTEM SERVICE NOTES
        BRAKE NOISE TROUBLESHOOTING
        HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION
        BRAKE SYSTEM - MECHANICAL COMPONENTS
            Brake System - Mechanical Components
        BRAKE SYSTEM - HYDRAULIC COMPONENTS
        BRAKE BLEEDING / FLUID CHANGE
        BRAKE PEDAL
            Brake Pedal Removal
            Pedal Installation
            Brake Pedal Inspection / Adjustment
        PARKING BRAKE
            Parking Brake Adjustment
            Parking Brake Cable Replacement
        FRONT BRAKE PADS
            Front Pad Removal
            Pad Inspection
            Front Brake Pad Assembly / Caliper Installation
        FRONT BRAKE DISC
            Disc Inspection
            Disc Replacement
        FRONT CALIPER
            Front Caliper Removal 
            Caliper Installation
        REAR BRAKE PAD
            Rear Brake Pad Removal
            Rear Brake Pad Inspection
            Rear Brake Pad Assembly / Caliper Installation
            Brake Burnishing Procedure
        REAR BRAKE DISC
            Disc Inspection
            Rear Brake Disc Replacement
        REAR CALIPER SERVICE
            Rear Caliper Removal
            Rear Brake Caliper Installation
        MASTER CYLINDER
            Removal
            Installation
        TROUBLESHOOTING
            Brakes Squeal / Poor Brake Performance
            Pedal Vibration
            Caliper Overheats (Brakes Drag)
            Brakes Lock
            Parking Brake Drags or Ineffective Brake
            
9922134_Ch_07-CVT / TRANSMISSION
    TABLE OF CONTENTS
        SPECIFICATIONS / TOOLS
            Torque Specifications
            Special Tools
        CVT SYSTEM
            CVT Maintenance / Inspection
            Drive Clutch Operation
            Driven Clutch Operation
            CVT System Drying
            CVT Overheating / Water Ingestion Diagnostics
            Clutch (CVT) Cover Removal / Inspection
            Clutch (CVT) Cover Installation
            Drive Belt Removal
            Drive Belt Inspection
            Drive Belt Installation
        Drive Clutch Service
            Drive Clutch Removal, Disassembly and Inspection
            Drive Clutch Assembly
        Driven Clutch Service
            Driven Clutch Removal, Disassembly, Inspection
            Driven Clutch Assembly
            Driven Clutch Installation
        TRANSMISSION SERVICE
            Transmission Disassembly and Inspection
            Input Shaft Removal / Inspection
            Transmission Main Shaft Assembly View
            Transmission Assembly 
            Output Gear Pinion Depth Adjustment
            Output Shaft Housing Disassembly / Assembly
            
9922134_Ch_08-ELECTRICAL
    TABLE OF CONTENTS
        General Information
            Special Tools
            Electrical System Service Notes
        Switches and Controls
            Key Switch
            Brake Pedal / Parking Brake Switches
            Electronic Throttle Control (ETC)
            ETC Operation
            ETC Switch Adjustment
        Daytime Running Lights
            “DRL” Test
            “DRL” Lamp Replacement
        Tail Light
            Tail Light Lamp Replacement
        Indicator lamps
            Indicator Lamp Replacement
        Transmission Switch
            Transmission Switch - Circuit Breakout
            Testing
            Removal
            Installation
        Ignition System
            Overview
            Ignition System Troubleshooting
            Ignition System Testing
            RPM Ignition Limiter Functions
            RPM Limiter Specifications
            Ignition Coil Test
            CDI Output Test Using Peak Reading Adaptor
            Pulser Coil Output / Resistance Tests 
        Charging System
            Charging System Testing
            Main Fuse / Fuse Holder Location
            Voltage Regulator / Rectifier
            Stator / Alternator Tests
        Battery
            Battery Maintenance Service Notes
            New Battery Activation
            Battery Removal
            Battery Cleaning
            Battery Installation
            Battery Voltage Test
            Battery Load Test
            Battery Charging Procedure
            Battery Storage
        Starter System
            Starter Relay
            Starter Motor Service
            Starter Disassembly
            Starter Brush Inspection / Replacement
            Armature Test
            Starter Reassembly
            Voltage Drop Test
            Starter System Troubleshooting
            Starter System Testing 
            
9922134_WIRE_DIAGRAM

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