Polaris RZR 170 Utility Vehicle Complete Workshop Service Repair Manual 2012 2013

2012-2013 RANGER RZR® 170 SERVICE MANUAL FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com . This Service Manual is designed primarily for use by certified Polaris Master Service Dealer  technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you ha ve any doubt as to yo ur ability to perform any of th e procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual/Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed July 2012 (PN 9923983)

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Some Polaris factory publications can be downloaded from www.polaris.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE / TRANSMISSION 4 FUEL SYSTEM 5 BODY / SUSPENSION / STEERING 6 BRAKES 7 CVT 8 ELECTRICAL

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: 2012 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: 2012 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL: 2013 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL: 2013 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISCELLANEOUS SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

1.2 GENERAL INFORMATION 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL NUMBER DESIGNATIONS Model Number Designation Example: R12VA17AA VEHICLE IDENTIFICATION NUMBER VIN Number Designation Example: RF3VA17A6BT012516 Engine Designation Number S35C-Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start Engine Serial Number Location Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the clutch-side engine case. GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** R= RANGER 12 13 V = RZR A = 2x4 Chain Displacement in cc (i.e. 17 = 170cc) A = ORV A * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. World Mfg. ID Vehicle Descriptors Vehicle Identifiers Chassis Driveline Engine Size Engine Modifier Category Check Digit Model Year * Mfg. Location Individual Serial No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 R F 3 V A 1 7 A 6 B T 0 1 2 5 1 6 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013 ENGINE SERIAL NUMBER

1.3 GENERAL INFORMATION 1 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc. 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 (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. A B C

1.4 GENERAL INFORMATION 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. 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. Model Model No. Owner’s Manual PN Parts Manual PN 2012 RANGER RZR 170 R12VA17AA R12VA17AC 9923583 9923584 2013 RANGER RZR 170 R13VA17AA R13VA17AB 9923980 9923981 Painted Part Color Description Polaris Number Frame / Bumpers / Racks Gloss Black P-067 Plastic - Hood / Dash / Fenders Indy Red White P-293 P-133 P/N 0453013

1.5 GENERAL INFORMATION 1 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polar is 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/ . Select “SPX Website - Tools, diagnostics” from the “Service and Warranty” drop down menu

1.6 GENERAL INFORMATION 9923983 - 2012-2013 RZR 170 Service Manual © Copyright 2012 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2012 RANGER RZR 170 MODEL NUMBER: R12VA17AA / R12VA17AC 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 Capacity 300 lbs. / 81.7 kg (Includes people, cargo, accessories)

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Polaris RZR 170 Utility Vehicle Complete Workshop Service Repair Manual 2012 2013

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