Polaris Ranger RZR 170 2013, Owner'S Manual

Page 1: ...2013 Owner s Manual for Maintenance and Safety FOUR STROKE ...

Page 2: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...re than one passenger on hills steeper than 15 degrees 15 on paved surfaces pavement may seriously affect handling and control with non Polaris approved accessories they may seriously affect stability at speeds that are too fast for the operator s skills the conditions and or the terrain ALWAYS require operator and passenger to wear seat belts grab hand holds passenger and plant feet firmly on the...

Page 4: ...1 Visit us at www polarisindustries com ...

Page 5: ...esult between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are...

Page 6: ...on pages 42 43 Never allow a child under age 12 to operate or ride as a passenger in this vehicle Children differ in skills physical abilities and judgement Please supervise the use of the vehicle at all times Permit continued use only if you determine that your child has the ability and maturity to operate safely For your child s safety be sure your child can reach and operate all RZR 170 control...

Page 7: ...uctions and warnings in the owner s manual and video Ask your parents to explain anything you don t understand Your safety and the safety of others is the most important thing to think about at all times Pay attention when you see this symbol This is the safety alert symbol When you see this symbol on your vehicle or in this manual it means PAY ATTENTION because you could die or be seriously injur...

Page 8: ...CONTENTS Introduction 6 Safety 9 Features and Controls 24 Operation 36 Emission Control Systems 52 Maintenance 53 Specifications 92 POLARIS Products 94 Troubleshooting 95 Warranty 99 Maintenance Log 105 Index 108 ...

Page 9: ...situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicat...

Page 10: ... vehicle Keep this manual with the vehicle Never operate this vehicle without proper instruction All operators and super vising adults must watch the instructional video that was provided with the vehicle For your child s safety be sure your child can reach and operate all RZR 170 controls including steering wheel accelerator and brake pedals and ignition switch Complete the New Operator Driving P...

Page 11: ...with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number ______________________________________________ Engine Serial Number ___________________________________________________ Key Number ____________________________________________________________ Engine Serial Nu...

Page 12: ... equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories may change the handling character istics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle European Vibration and Noise The driver perceived noise and hand arm an...

Page 13: ...eds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the l...

Page 14: ...ield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots Do not ride a POLARIS vehicle with bare feet Clothing Wear long sleeves and long pants to protect arms ...

Page 15: ... on different types of terrain Complete the New Operator Driving Procedures outlined on pages 42 43 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has read this manual and all product labels and has completed the New Operator Driving Procedures outlined on page...

Page 16: ...out wearing an approved helmet and protective eyewear increases the risk of serious injury in the event of an accident Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear ...

Page 17: ...rol and accident or overturn Never carry more than one passenger in this vehicle Operating on Pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control This vehicle s tires are designed for off road use only not for use on pavement Avoid operating the...

Page 18: ...high speeds Practice turning at slow speeds before attempting to turn at faster speeds Physical Control of the Vehicle Removing hands from the steering wheel or hand holds or removing feet from the floor while riding increases the risk of loss of control and accident or overturn The operator should always keep both hands on the steering wheel during operation A passenger should always be seated in...

Page 19: ... vehicle on hills steeper than 15 degrees Always check the terrain carefully before driving down a hill Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Use extreme caution when operating on hills Alwa...

Page 20: ...ng on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 47 Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an acciden...

Page 21: ... or person Always follow proper operating procedures as outlined in this manual See page 50 Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Improper Tires and Maintenance Installing non approved tires may seriously affect vehicle handling and stability which could result in loss of control or an accident Never install ...

Page 22: ...pery surfaces as described in the owner s manual When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Water Operating through deep or fast flowing water can cause loss of traction loss of control overturn or accident Never operate in fast flowi...

Page 23: ... this vehicle Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems Operating on Frozen Bodies of Water Operating on frozen bodies of water can result in the vehicle a...

Page 24: ...of consciousness or death in a short time Never start the engine or let it run in an enclosed area Operate this vehicle only outdoors or in well ventilated areas Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust syst...

Page 25: ...s manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Rear Warning Label Dash Warning Label 7176060 12 UNDER ...

Page 26: ...nger and plant feet firmly on the floor secure cab nets keep hands and feet inside vehicle avoid quick turns of the steering wheel and driving stunts such as jumps donuts or power slides reduce speed and use extra caution when carrying a passenger watch for branches or other hazards that could enter vehicle WARNING Operation of this vehicle by children under age 12 increases the risk of severe inj...

Page 27: ...t all times Promptly replace worn or damaged cab nets with new cab nets available from your authorized POLARIS dealer The vehicle illustrated below is shown without cab nets only to allow component identification Always use the cab nets Dash Hip Bar Fuel Tank Cap Seat Belts Seat battery under driver s seat Shifter Passenger Hand Hold Fuel Valve Parking Brake Cab Net ...

Page 28: ...25 FEATURES AND CONTROLS Component Locations Running Lights Brush Guard Steering Wheel Cab Frame Taillight Brake Light Muffler Spark Arrester ...

Page 29: ...Seat Removal 1 To remove the driver s seat lift the seat latch lever 2 While holding the lever upward slide the seat completely forward to remove it from the seat mounting rails 3 Before operating the vehicle always make sure the driver s seat is installed and securely latched 4 To remove the passenger seat remove the two bolts located at the front of the seat mounting rails Slide the seat forward...

Page 30: ...osition for your passen ger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments 1 Remove the retainer from the end of the adjustment pin Remove the pin from the post 2 Slide the post inward or outward to the desired position 3 Reinstall the pin through the mounting bracket hole through both post adjustment holes and through the remaining brack...

Page 31: ...uckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted Tip The position of the shoulder strap can be adjusted to the height of the opera tor Have an adult relocate the mount ing bolt to a different position making sure the nut and bolt are tightened securely 2 Push the latch plate into the buckle until it c...

Page 32: ...h the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat belt...

Page 33: ...ting the vehicle Always inspect cab nets for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets with new cab nets avail able from your authorized POLARIS dealer Storage Bag The storage bag is attached to the cab frame behind the seats Use the storage bag to carry lightweight items such as water bott...

Page 34: ...m pump octane number of 87 R M 2 octane Non ethanol fuel is recommended Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Fuel Valve The fuel valve is located on the left side of the vehicle near the fuel cap It has three settings OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted The reserve setting...

Page 35: ...switch when it is in the OFF position Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 40 OFF The engine is off Electrical circuits are off except accessory 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released Ignitio...

Page 36: ...mission could result Always shift when the vehicle is stationary and the engine is at idle Parking Brake 1 Apply the brakes 2 When the vehicle is fully stopped pull the parking brake lever rear ward as far as possible to set the parking brake 3 Stop the engine 4 To release the parking brake apply the brakes and push the lever toward the passenger seat and forward 5 See page 64 for parking brake ad...

Page 37: ...Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle pedal the engine will stop and power to the rear wheels will cease The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Modifications to the electronic throttle control co...

Page 38: ...hat their child is capable of handling addi tional speed The unrestricted top speed for this model is approximately 25 MPH 40 km h The adjustable throttle limiting screw is located behind the throttle pedal Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw outward to reduce speed Turn the screw inward to increase speed 3 Tighten the jam nut aft...

Page 39: ...of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Per form the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do n...

Page 40: ...Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 38 7 Change the engine oil at 10 hours or one month 8 Adjust and lubricate the drive chain at 10 hours or one month Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake ...

Page 41: ...and pressure 23 76 Wheels fasteners Inspect ensure fastener tightness 77 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 31 59 Grass and debris Remove grass and debris from the vehicle especially on the underside and near the exhaust system Throttle Ensure proper operation 69 Indicator lights switches Ensure proper operation Air filter Inspect and clean or rep...

Page 42: ...or highway including dirt and gravel roads 7 Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds DO NOT attempt to do power slides donuts jumps or other driving stunts Keep both hands on the steering wheel at all times 8 Never consume alcohol or drugs before or while operating this vehi cle 9 Always use the size and type of tires specified for ...

Page 43: ...before operating the vehicle 8 If the engine does not start within five seconds return the ignition switch to the OFF position and wait five seconds Repeat steps 7 and 8 until the engine starts Tip If a warm engine has cooled to a point where it does not readily start inter mittent use of the choke pulled half way out may be necessary If the engine is over choked when warm depress the throttle lev...

Page 44: ...ne braking 2 Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls Parking the Vehicle 1 Stop the vehicle on a level surface When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot li...

Page 45: ...d parking pages 40 41 4 Perform the pre ride inspection page 38 5 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots 6 Select a level open area to practice driving Make sure you have adult supervision and permission to drive in this area 7 Sit in the driver s seat and fasten the seat belt 8 Do not operate or ride in this vehicle if the clearance between the t...

Page 46: ...kes and press the throttle with your right foot to begin driving 18 Drive slowly at first Practice starting stopping turning using the throttle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed 19 Increase speed only after mastering all maneuvers at a slow speed 20 After you become skilled at making turns and begin to operate at f...

Page 47: ... one passenger in this vehicle 7 Never allow a passenger to ride on the back of the vehicle Allow a passenger to ride only in the passenger seat 8 Make sure the passenger is wearing helmet eye protection gloves long sleeve shirt long pants and over the ankle boots See page 10 9 Make sure the passenger secures the seat belt 10 Tell your passenger to always keep hands and feet inside the vehicle at ...

Page 48: ...low down and use extra caution to help prevent skidding or sliding Always use extra caution when operating on sand or on rough slippery or loose terrain Do not operate on excessively rough slippery or loose terrain Follow these precautions when driving in slippery conditions 1 Slow down before entering slippery areas 2 Be alert watch the path ahead and avoid quick turns which can cause skids 3 Cor...

Page 49: ...at a steady rate of speed Never press the throttle suddenly 6 Avoid unnecessary changes in speed or direction 7 Never go over the crest of a hill at a high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 8 If the vehicle stalls while climbing a hill apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight do...

Page 50: ...e or cause the vehicle to slide 4 If the vehicle begins to slide downhill immediately turn downhill to stop the slide Driving Downhill Whenever driving down a hill follow these precautions 1 Avoid steep hills 15 maximum 2 Slow down Never travel down a hill at high speed 3 Always check the terrain carefully before driving down a hill 4 Always drive down a hill with the transmission in forward gear ...

Page 51: ...ill help dry out the pads NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 53 Give special attention to engine oil transmission oil and all grease fittings If your vehicle is operated in water deeper than the floor level take it to your dealer for service before starting the eng...

Page 52: ...s such as logs rocks and low hanging branches 3 Drive slowly and use extra caution when driving on unfamiliar ter rain Obstacles are not always clearly visible 4 Do not drive over large obstacles such as rocks and fallen trees If it s unavoidable use extreme caution and drive slowly 5 Always have a passenger dismount and move away from the vehicle before driving over an obstacle that could cause a...

Page 53: ...hese precautions when driving in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never apply the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns ...

Page 54: ...n serious injury Avoid parking on an incline If parking on an incline is unavoidable follow these precau tions 1 Place the transmission in neutral 2 Set the parking brake 3 Stop the engine 4 Turn the fuel valve off 5 Always block the rear wheels on the downhill side ...

Page 55: ...y the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at POLARIS specifications to achieve optimal performance Engine idle speed is the only adjustment POLARIS recommends ...

Page 56: ... service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately ten 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 styl...

Page 57: ...lead to serious injury or death Have an authorized POLARIS dealer perform these services Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related service failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services ...

Page 58: ...stem Wheels fasteners Frame fasteners Engine oil level E Air filter Daily Inspect clean often replace as needed Daytime running lights taillight Daily Check operation Drive chain Daily Inspect daily adjust and lubricate if needed CVT housing if equipped Weekly Drain water as needed check often if driving in wet conditions D Brake pad wear 10 Monthly 100 160 Inspect periodically Idle speed 10 Month...

Page 59: ...etc D E Throttle cable ETC switch 50 6 M 300 480 Inspect adjust lubricate replace if necessary Carburetor float bowl 50 6 M 500 800 Drain bowl periodically and prior to storage D E Choke cable 50 6 M 500 800 Inspect adjust lubricate replace if necessary E Carburetor air intake ducts flange 50 6 M 500 800 Inspect duct for proper seal ing air leaks Shift Linkage 50 6 M 500 800 Inspect lubricate adju...

Page 60: ... D Ignition timing 100 12 M 1000 1600 Inspect Wiring 100 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive and driven 100 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 12 M 1000 1600 Inspect replace as needed D Front wheel bearings 100 12 M 1000 1600 Inspect replace as needed D Brake fluid 200 24 M 20...

Page 61: ...dures more often for vehicles subjected to severe use Item Lube Method Engine Oil Performance Synthetic PS 4 Extreme Duty 4 Cycle Oil See page 59 Brake Fluid DOT 4 See page 73 Transmission Oil Main Gearcase Premium AGL Synthetic Gearcase Lube See page 61 Drive Chain POLARIS Chain Lube or SAE 80 90 See page 62 A Arm Pivots POLARIS All Season Premium Grease or grease conforming to NLGI No 2 Grease a...

Page 62: ...cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Check Maintain the oil level within the safe range on the dipstick Do not overfill 1 Position the vehicle on a level surface 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick com pletely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in ...

Page 63: ...ean the pre filter plug Install a new sealing washer on the plug The sealing surfaces on the plug and crankcase should be clean and free of burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug 10 Reinstall the pre filter drain plug Torque to 11 ft lbs 15 Nm 11 Remove the dipstick Add 37 oz 1 1 liters of the recommended oil Do not overfill See the specificat...

Page 64: ...le on a level surface 2 Remove the fill plug 3 Check the fluid level 4 Add the recommended fluid as needed 5 Reinstall the fill plug Fluid Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring Torque...

Page 65: ...djusting or operating the vehicle with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications Drive Chain Slack 1 Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain 2 Raise the rear of the vehicle and support securely under the ...

Page 66: ...djuster lock nuts 3 Turn the chain adjusters clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nuts to 18 ft lbs 25 Nm Hold the adjuster stud securely while tightening the nut to avoid break ing the stud 5 Tighten the four rear housing mount bolts to 43 ft lbs 60 Nm Housing Mount Bolts Chain Adjusters ...

Page 67: ...parking brake 2 Position the vehicle on a level surface Place the transmission in neutral 3 Carefully elevate the rear of the vehicle slightly Use an appropriate lift 4 Loosen the jam nut on the parking brake adjustment bolt 5 While rotating the rear wheels by hand tighten the adjustment bolt until significant brake drag is detected Then back the adjustment bolt out 1 4 turn 6 Hold the adjustment ...

Page 68: ...ype and heat range for the engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes ...

Page 69: ...ystem is intended for use on POLARIS products only Do not install it in any other product Always make sure the CVT housing is securely in place during operation CVT Drying There may be some instances when water is accidently ingested into the CVT system Use the following instructions to dry it out before operat ing The drain plug is located on the bottom of the CVT cover 1 Remove the drain plug Al...

Page 70: ... the air box cover spring clips and remove the cover 3 Loosen the air filter clamp Remove the air filter 4 Clean away any oil or sediments in the air box 5 Apply a commercially available chas sis lubricant to the inside lip of the new air filter Install the filter and tighten the clamp 6 Reinstall the air box cover and secure the clips NOTICE Never operate the vehicle with the filter element remov...

Page 71: ...carbon monoxide gas To remove accumulated carbon clean the spark arrester at the intervals recommended in the Periodic Maintenance Chart beginning on page 53 1 Remove the six bolts and remove the arrester from the end of the muffler 2 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air...

Page 72: ...s excessive play due to cable stretch or misad justment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Adjust the...

Page 73: ...e it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Move the cable adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page 69 While adjusting lightly flip the throttle pedal up and down 5 Tighten the lock nut 6 Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its origi nal...

Page 74: ...f the engine without proper jetting when required can cause poor performance overheating or engine damage See your POLARIS dealer for more information about jetting the vehicle for condi tions in your area Carburetor Engine Idle RPM Adjustment If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Place the transmission in neutral 2 Set...

Page 75: ... pedal can result in loss of braking which could cause an accident resulting in severe injury or death Never operate the vehicle with a spongy feeling brake pedal Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the brake pads for wear damage and loose ness 4 Inspect the brake pad wear surface for exces sive wear 5 Chan...

Page 76: ...ake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown Access the brake fluid reservoir through the left front wheel well 1 Position the vehicle on a level surface 2 Place the transmission in neu tral Set the p...

Page 77: ...catchy have the steering system inspected by an autho rized POLARIS dealer Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster either clockwise or counter clockwise to make adjustments Always apply the same adjustment set ting to all four wheels WARNING Uneven adjustment may cause poor handling of the vehicle w...

Page 78: ...this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both marks are the same distance from the floor 4 Measure the distance between the marks and record the measurement 1 5 Move the vehicle to rotate the tires 180 Position the wheels with the chalk marks at the rear of the tire...

Page 79: ...ire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Position the vehicle on a level surface 2...

Page 80: ...icle to the ground 6 Torque the wheel nuts to specification Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and ...

Page 81: ...y pull the lamp out 4 Install the new lamp Make sure the filament is horizontal 5 Reinstall the lamp retainer Press the retainer inward and turn it clockwise about 1 4 turn 6 Start the engine to make sure the lights come on If the lights do not operate see your POLARIS dealer for service 7 Reinstall the rubber cover and reconnect the lights to the harness Tail Light Lamp Replacement If the brakeli...

Page 82: ...y the air box and replace the filter with a new filter Thoroughly dry the air pre filter See page 67 4 Remove the spark plugs 5 Loosen the carburetor drain screw 6 Turn the engine over several times 7 Dry the spark plugs and reinstall them or install new plugs 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If neces sary repeat the drying procedure 11 T...

Page 83: ...ce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery ha...

Page 84: ... Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable last 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Battery ...

Page 85: ...he vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Coat the terminals ...

Page 86: ...ery Tender charger or by charging about once a month to make up for normal self dis charge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre deter mined point See page 94 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the ba...

Page 87: ... the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop chargi...

Page 88: ...ndard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At le...

Page 89: ...S recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper bod...

Page 90: ...ur POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLAR...

Page 91: ...nt Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pro...

Page 92: ...Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Air Filter Air Box Inspect and clean or replace the air filter See page 67 Clean the ai...

Page 93: ...or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Removal from Storage 1 Check the battery electrolyte level and charge the battery if neces sary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 2 Make sure the spark plug is tight 3 Fill the fuel tan...

Page 94: ...prevent loss dur ing transporting 5 Secure the fuel cap and seats NOTICE Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front control arm bolt pockets 6 Wrap the front tie strap through the frame tubes or attach a tie down hook around each of the tubes 7 Wrap the rear tie strap around the swing arm Step 6 S...

Page 95: ...5 cm Ground Clearance 6 in 15 2 cm Engine Type 4 Stroke Displacement 169 cc Cooling Air Cooled Bore x Stroke 61 mm x 57 8 mm Alternator Output 80 watts Compression Ratio 9 5 1 Carburetor 1 22 mm VM Type Pilot Jet 35 Main Jet 100 Air Screw 2 Turns Out Jet Needle 2MKNN 4 clip Starting System Electric Ignition System CDI Spark Plug Gap NGK CR6HSA 0 6 0 7 mm Front Suspension Single A arm w 5 in 12 7 c...

Page 96: ...0 45 to 65 Above 60 C Below 35 34 to 23 26 to 15 18 to 7 9 to 2 1 to 10 7 to 18 Above 16 0 600 0 2000 Main Jet 102 102 100 100 100 100 100 100 Pilot Jet 38 38 38 35 35 35 35 35 Clip Position 4 4 4 4 4 4 4 4 600 1200 2000 4000 Main Jet 102 102 100 100 100 100 100 100 Pilot Jet 38 38 38 35 35 35 35 35 Clip Position 4 4 4 4 4 4 4 4 1200 1800 4000 6000 Main Jet 102 102 100 100 100 100 100 100 Pilot Je...

Page 97: ...ubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 l 2872348 Chain Lube Aerosol Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 All Season Premium Grease 3 oz 89 ml 2871423 All Season Premium Grease 14 oz 414 ml 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus ...

Page 98: ...low easy clutch engage ment Use the throttle quickly and effectively Belt slippage from water or snow ingestion into the CVT system Dry out the CVT see page 66 Prevent water from enter ing the CVT inlet and outlet ducts see page 86 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material...

Page 99: ...replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and ...

Page 100: ...lugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filt...

Page 101: ...lugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle...

Page 102: ...void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified negle...

Page 103: ...f materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON F...

Page 104: ...her rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty Spark Arrester POLARIS ...

Page 105: ...e your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle If Purchased ...

Page 106: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followi...

Page 107: ...d by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or...

Page 108: ...105 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 109: ...106 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 110: ...107 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 111: ...cations 24 25 Condition Spark Plugs 65 C Constant Variable Transmission 66 Corrosion Removal Chrome 88 Cover for Storage 90 Crankcase Emission Control System 52 CVT Break In 37 CVT Drying 66 CVT System 66 D Drive Belt Wear 95 Drive Chain Lubrication 62 Drive Chain Slack 62 Drive Chain Slack Adjustment 63 Drivetrain Break In 37 Driving Downhill 47 Driving in Reverse 50 Driving on a Sidehill 47 Driv...

Page 112: ...justment 71 Ignition Switch 32 Inspection Brakes 72 Inspection Pre Ride 38 Inspection Seat Belts 29 Inspection Steering Wheel 74 Inspection Throttle Freeplay 69 Installation Battery 82 Installation Wheels 77 Interference Electromagnetic 52 J Jetting Chart 93 K Key Periodic Maintenance Chart 54 L Lamp Replacement Tail Light 78 Daytime Running Lights 78 Lights 78 Lubricant Part Numbers 94 Lubricatio...

Page 113: ...Tires Maintenance 18 Instruction 12 Jumps and Stunts 15 S Safety Warnings 12 21 Multiple Passengers 14 Obstacles 19 Operating a Damaged Vehicle 20 Operating on Sand 18 Operating Through Water 19 Overloading 20 Pavement 14 Physical Control 15 Protective Apparel 13 Public Roads 14 Reverse 18 Rider Height 12 Seat Belts 13 Skidding or Sliding 19 Slippery Terrain 18 Stalling on a Hill 17 Turning Improp...

Page 114: ... 69 Throttle Pedal 34 Throttle System 69 Tire Tread Depth 76 Tires 76 77 Front Wheel Hub Tightening 76 Wheel Nut Torque 77 Toe Alignment 75 Torque Spark Plug 65 Transmission Oil 61 Transmission 61 Transporting the Vehicle 91 Tread Depth Tire 76 V Vehicle Identification Numbers 8 Vehicle Immersion 79 Vehicle Transport 91 W Warning Symbols 6 Washing the Vehicle 86 87 Water Immersion of Vehicle 79 We...