GENERAL INFORMATION

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.

Machine Model Number Identification

R 09 VA 17 AD

}
}

}
}
Model Year Emissions &
Designation Model Option
Basic Chassis
Designation Engine Designation

Engine Designation Number

S35C ................................................................................................. Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start

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

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.

ENGINE SERIAL NUMBER

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

Model Model No. Owner’s Manual PN Parts Manual PN

9922131 (produced before 2/10/2009)
2009 RANGER RZR 170 R09VA17AA 9922132
9922569 (produced after 2/10/2009)

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

Painted Part Color Description Polaris Number

Frame / Bumpers / Racks Gloss Black P-067
Plastic - Hood / Dash / Fenders Indy Red P-293

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

°C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C

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

Metric Tap / Drill Sizes

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.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

!= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.

"= SEVERE USE ITEM -- See Above

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with a!could

result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

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

Grease A-arm Pivots

Inspect Brake Pads

Trail / Brake Lamp

Inspect Exhaust

Inspect / Clean Air Filter

Clean / Lubricate Chain Inspect Brake Pads

2.6
 MAINTENANCE
RH and LH Side Views

2.7
MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at

your local Polaris dealer.
Polaris Lubricants, Maintenance and Service
Products Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
Part No. Description
2870585 Loctite™ Primer N, Aerosol, 25 g
Engine Lubricant
Loctite™ Thread Sealant 565
2871956
2870791 Fogging Oil (12 oz. Aerosol) (50 ml.) (6 Count)
Polaris YOUTH Synthetic 0W-40 4-Cycle Loctite™ Threadlock 242
2876248 2871949
Engine Oil (Quart) (50 ml.) (10 Count)
Polaris Semi - Synthetic 20W-40 4-Cycle Loctite™ Threadlock 242
2872175 2871950
Engine Oil (Quart) (6 ml.) (12 Count)
Gearcase / Transmission Lubricants Loctite™ Threadlock 262
2871951
AGL - Synthetic ATV Gearcase Lubricant (50 ml.) (10 Count)
2873602
(1 Qt.) (12 Count) Loctite™ 518 Gasket Eliminator / Flange
2870587
AGL - Synthetic ATV Gearcase Lubricant Sealant (50 ml.) (10 Count)
2873603
(1 Gal.) (4 Count) Premium Carbon Clean
2871326
AGL - Synthetic ATV Gearcase Lubricant (12 oz.) (12 Count)
2873604
(2.5 Gal.) (2 Count) 2870652 Fuel Stabilizer (16 oz.) (12 Count)
ATV Angle Drive Fluid Black RTV Silicone Sealer
2871653 2871957
(8 oz.) (12 Count) (3 oz. tube) (12 Count)
ATV Angle Drive Fluid Black RTV Silicone Sealer
2872276 2871958
(2.5 Gal) (2 Count) (11 oz. cartridge) (12 Count)
Premium Demand Drive Fluid LT 2872189 DOT 4 Brake Fluid (12 Count)
2871654
(1 Qt.) (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2870465 Oil Pump for 1 Gallon Jug
2872893 Engine Degreaser (12oz.) (12 Count)
Grease / Specialized Lubricants
2871312 Grease Gun Kit NOTE: The number count indicated by each part
number in the table above indicates the number of
Premium All Season Grease units that are shipped with each order.
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease
2871423
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871329 Dielectric Grease (Nyogel™)
Chain Lubricant, Aerosol
2872348
(16 oz.) (12 Count)

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.

• Tires - check condition and pressures

Shift Cable
• Fuel tank - fill to proper level Mount

• All brakes - check operation and adjustment

• Throttle - check for free operation and closing Clevis Pin

• Running lights/Taillight/Brakelight - also check

operation of all indicator lights and switches 2.
• Ignition switch - check for proper function
3.
• Wheels - check for tightness of wheel nuts and axle
nuts; check to be sure axle nuts are secured by cotter
pins
• Air cleaner element - check for dirt; clean or replace
Inspect shift cable, clevis pin, pivot bushings, and dust
boot. Replace if worn or damaged.
If adjustment is required, loosen the lower jam nut and pull
the cable out of the mount to move the upper jam nut.
Upper
Jam Nut

• Steering - check for free operation noting any unusual

looseness in any area

• Loose parts - visually inspect vehicle for any damaged

or loose nuts, bolts or fasteners

• Check all front and rear suspension components for

wear or damage.
Lower
Jam Nut
Frame, Nuts, Bolts, and Fasteners
Periodically inspect the torque of all fasteners in accordance 4. Adjust the shift cables so there is an equal amount of lever
with the maintenance schedule. Check that all cotter pins are in travel when shifting past the Neutral detent into HIGH (H)
place. Refer to specific fastener torques listed in each chapter. and REVERSE (R).

5. Thread the upper jam nuts as required to obtain proper cable

Shift Cable Inspection / Adjustment adjustment without binding.
Shift cable adjustment may be necessary if symptoms include:
NOTE: This procedure may require a few attempts to
• Ratcheting noise on deceleration obtain the proper adjustment.

• Inability to engage into a gear
• Excessive gear clash (noise)
• Gear selector moving out of desired range
6. Once the proper adjustment is obtained, tighten the lower
jam nut against the mount.
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

3. Inspect shift cable arm. Replace if worn or damaged.

4. Remove the shift knob to prepare for seat panel removal.

Refer to Chapter 5.

5. Refer to Chapter 5 for console cover removal in order to

access the shift cable mount on the lever assembly.

6. Loosen the lower and upper jam nuts and remove the
cables.

Upper
Jam Nut

Lower
Jam Nut

7. Inspect shift lever assembly. Replace parts as required if

worn or damaged.

2.11
MAINTENANCE
FUEL SYSTEM AND AIR INTAKE
Air Filter Service
It is recommended that the air filter be inspected as part of
pre-ride inspection. If riding in extremely dusty conditions,
apply a small amount of grease to the seal under the air box cap.
In extremely dusty conditions, air filter cleaning will be required
more often.
The filter should be serviced using the following procedure.
Removal
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
the top of the rear cab (under rear basket, if installed).
Air Box Access
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.
3. Remove air filter and the filter support screen.
2.12
4. Inspect the air filter element for tears or damage.
NOTE: Filter is washable. Do not discard.
5. Wash the filter in warm soapy water and allow it to air dry.
6. Apply air filter oil (commercially available) to the filter,
following the directions on the label.
NOTE: If unable to clean the filter, replace it.
NOTE: Service the filter more frequently if vehicle is
operated in wet conditions, dusty conditions or at
high throttle openings for extended periods.
Installation
1. Verify the air box and support screen are thoroughly clean.
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
before installing.
3. Install air box cap and secure with clips.
Secure Clips
4. Reattach the access panel and tighten the fasteners
sufficiently.
 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

CHOKE CABLE FREEPLAY

Adjustments to the freeplay can be made by loosening the choke
cable bracket at the carburetor and moving the cable in or out to
gain the desired freeplay.
If smooth choke operation is not obtainable, inspect choke cable
for kinks or sharp bends in routing.
Choke Cable Replacement
The choke cable is replaced as an assembly.
1. Engine is off. Place the vehicle in neutral and apply the
parking brake.
2. Remove the cable end from the carburetor.
4. Raise the vehicle and support it with jackstands in order to
access the underside.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
reassembly.
5. Pull the cable out from under the dash and the underside of
the vehicle.
6. Route the new cable from front-to-back, through the
retainers at the bottom of the frame, following the routing
noted during disassembly. Place cable ties at the
appropriate locations.
IMPORTANT: Do not allow cable to hang below
vehicle frame.
7. Reinstall the choke assembly into the dash. Hand-tighten
fasteners sufficiently, using care not to over-tighten.
8. Reinstall the choke cable onto the carburetor.
9. Adjust cable to desired freeplay.

If smooth choke operation is not obtainable, inspect for kinks,

sharp bends in the routing or a linkage obstruction.

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

PILOT AIR SCREW

Idle Speed Increase

1700 ± 100
Decrease
NOTE: Always check throttle cable freeplay after
adjusting the idle speed and readjust if necessary.

Pilot Air Screw Base Setting:

2.25 turns out (initial)

Special Tool:
PA-47361

3. Slowly turn mixture screw counterclockwise until idle

speed returns to Idle RPM. Continue turning
counterclockwise until idle RPM begins to drop. Stop
turning at this point and note the screw setting

4. Center the mixture screw between points in Step 2 and 3.

5. Readjust idle speed if not within specification.

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.

2. Verify vent lines are routed properly and secured with

cable ties.
Fuel Filter Location - Located in-line between fuel pump
and carburetor inlet. 2
Fuel System

WARNING

Gasoline is extremely flammable and explosive

under certain conditions.
Always stop the engine and refuel outdoors or in
a well ventilated area.
Do not smoke or allow open flames or sparks in
or near the area where refueling is performed or
where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. To service the fuel filter:
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water 1. Shut off fuel supply at fuel valve.
and change clothing. 2. Remove line clamps at both ends of the filter.
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and 3. Remove fuel lines from filter.
can result loss of consciousness or death 4. Install new filter and clamps onto fuel lines.
in a short time.
Never drain the fuel when the engine is hot. 5. Turn fuel valve to ‘ON’.
Severe burns may result. 6. Start engine and inspect for leaks.

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.

Turn knob to operate

the fuel valve

1. Check the fuel lines for signs of wear, deterioration,

Carburetor Draining
The carburetor float bowl should be drained before extended
periods of storage, or periodically to remove accumulated
moisture or sediment from the bowl.
damage or leakage. Replace if necessary.
2. Be sure fuel line is routed properly.
IMPORTANT: Make sure line is not kinked or pinched.
3. Replace fuel lines every two years.

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

4. Tighten drain screw.

5. Turn fuel valve to “ON” and check for fuel leaks.
6. Start engine and re–check for leaks.
2.16

Throttle Pedal Inspection
If the throttle pedal has excessive play due to cable stretch or
cable misadjustment, it will cause a delay in throttle response.
Also, the throttle may not open fully. If the throttle pedal has no
play, the throttle may be hard to control, and the idle speed may
be erratic.
MAINTENANCE
Throttle Stop Speed Control
Use the following procedure to control how far the throttle
opens.
IMPORTANT: This procedure should be performed
by consumers only when they determine that their
child is capable of handling the additional speed. 2

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

1. Loosen the jam nut.

2. Turn the screw clockwise to increase speed or counter-

clockwise to reduce speed.

3. Tighten the jam nut after adjusting.

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. Slide back the cable adjuster boot. Pivot Bearing

3. Using an open-end wrench, loosen the adjustment jam nut.
4. Using an open-end wrench, move the cable adjuster until NOTE: Pivot bearing inside the housing is a slip-fit
1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the and will require some light prying to separate the
throttle pedal. housing. Use caution.
NOTE: While adjusting, lightly move the throttle
3. Remove the cable from the housing and the ball-end from
pedal in and out.
the throttle pedal arm.
5. Re-tighten the jam nut.
6. Apply a small amount of grease to the inside of the boot and
slide it over the cable adjuster to its original position.

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)

9. Fasten the cable with cable ties at the same locations they
were previously removed.
10. Continue to route the cable towards the front of the vehicle
using the brake line routing as a general guide.
=T
Throttle Pedal Mounting Screws:
16-20 ft. lbs. (21-27 Nm)
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

ENGINE Engine Oil Change

1. Position the vehicle on a level surface.
Engine Oil Level
Maintain the oil level within the safe range on the dipstick. Do 2. Clean area around the drain plug.
not overfill.
3. Run engine until warm.
To check the oil level:
4. Stop the engine.
1. Position the vehicle on a level surface.

2. Remove the dipstick. Wipe it dry with a clean cloth. CAUTION

Hot oil can cause serious burns to skin. Do not

allow hot oil to come in contact with skin.

5. Place a drain pan beneath the engine crankcase.

6. Remove the drain plug and pre-filter screen. Allow the oil
to drain completely.

Dipstick

Safe Range
{

Add Oil Full Drain Plug

3. Reinstall the dipstick completely.

4. Remove the dipstick and check the oil level.

7. Wash the oil pre-filter screen with solvent to remove any
NOTE: Rising oil level between checks in cool debris. Allow the screen to air dry.
weather driving, can indicate moisture collecting in
the oil reservoir. If the oil level is over the full mark,
change the oil.

5. Add the recommended oil as needed.

NOTE: Do not fill the over the normal oil operating

range. Filling over the normal operating range could
cause a mist of oil to enter the air box. 8. Inspect the O-ring on drain plug, replace if needed.
6. Reinstall the dipstick. NOTE: The sealing surfaces on the drain 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.

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.

Recommended Engine Oil:

Polaris Synthetic Youth 4-Stroke Oil

SAE 40 (Above 32!F)
Quart - (PN 2876248)
Gallon - (PN 2876249)

Polaris Semi-Synthetic Oil

20W-40 (Below 32!F)
Quart - (PN 2872175)
Gallon - (PN 2872176)

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.

IMPORTANT: Over-filling engine crankcase will result

in oil entering the air box. Maintain the recommended
oil level.

2.21
MAINTENANCE
Compression / Leakdown Test
IMPORTANT: Use of a compression tester adaptor
that is too long WILL CAUSE DAMAGE to the cylinder
head. The adaptor length should be no longer than
the length of the spark plug threads (1/2” or 12.07mm).
Compression tester adaptor threads
should not exceed spark plug threads.
1/2” (12.07mm)
Intake Valve Clearance Adjustment
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
intake valve stem and adjuster screw.
4. When clearance is correct, hold adjuster screw and tighten
locknut securely.
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

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system
becomes very hot. Serious burns could result from
2
contact with the exhaust components. Allow
components to cool sufficiently before proceeding.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas that can
cause loss of consciousness or death in a very
short time.

To remove accumulated carbon, clean the spark arrestor at the

interval recommended in the Periodic Maintenance Chart.

1. Remove the retaining screws and remove the arrestor from

the end of the silencer.
2. Use a non-synthetic brush to clean the arrestor screen. A
synthetic brush may melt if components are warm.
3. Inspect the screen for wear and damage. Replace if
required.
4. Reinstall the arrestor and torque the fasteners to
specification.

Silencer

Screen

Retaining Arrestor
Screws

=T
Spark Arrestor Fasteners
7 ft. lbs. (9.5 Nm)

2.23
MAINTENANCE

TRANSMISSION
Transmission Specification Chart

DRAIN / LEVEL CHECK

GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE
PLUG TORQUE

Transmission AGL - Synthetic ATV

24 oz. (710 ml) 18 ft. lbs. (24 Nm) 30-45 in. lbs. (3-5 Nm)
(Main Gearcase) Gearcase Lubricant

Transmission Oil Change Transmission Oil Level Check:

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

Approximate Capacity at Change:

23.7 oz. (700 ml)

Drain / Level Plug Torque:

30-45 in. lbs. (3-5 Nm)

Fill Plug Torque: • Be sure vehicle is positioned on a level surface when

checking or changing fluid.
18 ft. lbs. (24 Nm)
• Check vent hose to be sure it is routed properly and
unobstructed.

1. Position vehicle on a level surface.

2. Remove the fill plug.

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)

4. Clean the drain plug.

#1 #2
5. Reinstall the drain plug with a new o-ring and torque to
specification.

Aluminum Wheel Steel Wheel

=T 90 ft. lbs. (122 Nm) 27 ft. lbs. (37 Nm)

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.

4. Elevate the appropriate side of the vehicle by placing a

suitable jack and stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and washers.

Wheel Installation
1. Verify the transmission is in gear.

2. Install the wheel hub, washers, and hub nut, if previously

removed.

3. Place the wheel in the correct position on the wheel hub.

Be sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.

4. Attach the wheel nuts and finger tighten them.

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.

Use a new Worn tires can cause an accident.

cotter pin
Note
Tire Rotation Always replace tires when the tread depth
measures 1/8", (.3 cm) or less.

Tire Pressure
Hub Nut

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal
Valve stem applied to the vehicle.
Wheel Nuts (4) facing outward

Tire Pressure Inspection (Cold)

CAUTION
If wheels are improperly installed it could affect
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
of nut seats properly into taper on wheel.
Tire Inspection
• Improper tire inflation may affect vehicle
maneuverability.
• When replacing a tire always use original equipment
size and type.
• The use of non-standard size or type tires may affect
vehicle handling.
Tire Tread Depth
Front Rear
3 psi (20.7 kPa) 3 psi (20.7 kPa)
Drive Chain Lubrication and Adjustment
Lubricate the drive chain with Polaris chain spray lube or an
approved chain lube at the interval specified in the Periodic
Maintenance Chart. Lubricate more often under severe use, such
as in dirty or wet conditions.
IMPORTANT: Washing the drive chain with a high
pressure washer or solvents can cause premature
wear and chain failure. Do not use a high pressure
washer or gasoline to clean the drive chain. Operating
the vehicle with improper rear drive chain deflection
can result in severe damage to the transmission and
drive components. Always make sure the chain
adjusted within the stated specifications.

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

3. Pull down on the chain tensioner to move it out of the way,
then measure chain deflection. It should have 1/4"-1/2" (6-
12 mm) deflection.
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM
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

Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get

prompt medical attention.

Batteries produce 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.
4. Loosen the four rear housing mount bolts (two on each end
NOTE: Batteries must be fully charged before use or
of axle).
battery life will be reduced by 10-30% of full
5. Loosen the chain adjuster locknuts. potential. Charge battery for 3-5 hours at a current
6. Turn the chain adjusters evenly to achieve 1/4"-1/2" (6-12 equivalent to 1/10 of the battery’s rated amp/hour
mm) chain deflection. capacity. Do not use the vehicle’s stator/alternator
7. Torque the chain adjuster locknuts. Hold the adjuster stud to charge a new battery.
securely while tightening the nut to avoid breaking the stud.

=T
Chain Adjuster Locknuts: 18 ft. lbs. (25 Nm)

8. Torque the four rear housing mount bolts.

=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.

NOTE: Battery charge can be maintained by using a

Polaris battery tender charger or by charging about
once a month to make up for normal self-discharge.
Battery tenders can be left connected during the
storage period, and will automatically charge the
battery if the voltage drops below a pre-determined
point.

Battery Charging (Maintenance Free)

The sealed battery is already filled with electrolyte and has been
sealed at the factory. Never pry the sealing strip off or add any
2. Disconnect the black (negative) battery cable. type of fluid to this battery.

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.

1. Check the battery voltage with a voltmeter or multimeter.

CAUTION The battery voltage should read 12.8 VDC or higher.
2. If the voltage is less than 12.8 volts, charge the battery at
To reduce the chance of sparks: Whenever
1.2 amps or less until battery voltage is 12.8 VDC or
removing the battery, disconnect the black
greater.
(negative) cable first. When reinstalling the
battery, install the black (negative) cable last. NOTE: When using an automatic charger, refer to
the charger manufacturer’s instructions for battery
charging directions. When using a constant current
Battery Installation
charger, follow the guidelines in the following table:
IMPORTANT: Using a new battery that has not been
fully charged can damage the battery and result in a State of Charge
shorter life. It can also hinder vehicle performance. Voltage Action
Charge Time
Follow the battery charging procedure before
installing the battery. None, check
None
100% 12.8 - 13.0 VDC again in 3
Required
1. Ensure the battery is fully charged. months
May need slight
2. Place the battery in the battery holder and secure with charge, check
rubber strap. 75% - 100% 12.5 - 12.8 VDC 3 - 6 hrs
again in 3
months
3. Coat the terminals with dielectric grease or petroleum jelly.
50% - 75% 12.0 - 12.5 VDC Needs Charge 5 - 11 hrs
4. Connect and tighten the red (positive) cable first. At least 13
hrs, verify
5. Connect and tighten the black (negative) cable last. 25% - 50% 11.5 - 12.0 VDC Needs Charge
state of
charge
6. Verify that cables are properly routed and reinstall the
driver’s seat. 0% - 25% 11.5 VDC or less Needs Charge 20 hrs

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

A hot exhaust system and engine can cause serious

2
burns. Allow engine to cool or wear protective
gloves when removing the spark plug.
Gap - .024-.028" (0.6-.07 mm)
2. Remove the spark plug cap.
7. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply anti-seize compound to the spark plug threads.
9. Install spark plug and torque to specification.

Recommended Spark Plug:

NGK CR6HSA

Spark Plug Torque:

11 ft. lbs. (15 Nm)

Engine To Frame Ground

Inspect engine ground cable connection. Be sure it is clean and
3. Remove spark plug. tight. The ground cable runs from the engine starter motor to the
4. Inspect electrodes for wear or carbon buildup. Look for a ground terminal location under the driver’s seat.
sharp outer edge on the electrode, with no rounding or
erosion.

Inspect electrode for

wear or buildup

Ground
Terminal Location

5. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A wire brush or coated
abrasive should not be used.

2.29
MAINTENANCE

STEERING Steering Inspection / Tie Rod Ends and Hubs

• To check for play in the tie rod end, grasp the steering
Steering Inspection
tie rod and pull in all directions feeling for movement.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, ball joints, and damage. Also
check to make sure all cotter pins are in place. If cotter pins are
removed, they must not be re–used. Always use new cotter pins.

Replace any worn or damaged steering components. Steering

should move freely through the entire range of travel without
binding. Check routing of all cables, hoses, and wiring to be
sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are

replaced, check front end alignment.

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

Steering Wheel Freeplay

Check the steering wheel for specified freeplay and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is excessive freeplay or the steering feels rough,
inspect the following components.
• If abnormal movement is detected, inspect the hub and
• Tie Rod Ends wheel assembly to determine the cause (possible loose
• Steering Shaft U-Joints wheel nuts or loose front hub components).
• Steering Gearbox
• Refer to Chapter 5 for front hub service procedures.

U-Joints

Tie Rod Location

Gearbox

2.30

Toe Alignment Inspection
1. Place machine on a smooth level surface.
2. Set steering wheel in a straight ahead position and secure
the steering wheel in 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.
Measurement “B” Chalk Mark
Measurement “A”
NOTE: It is important that the height of both marks
be equally positioned in order to get an accurate
measurement.
4. Measure the distance between the marks and record the
measurement. Call this measurement “A”.
5. Rotate the tires 180! by moving vehicle forward or
backward. Position chalk marks facing rearward, even with
the hub/axle center line.
6. Again measure the distance between the marks and record.
Call this measurement “B”. Subtract measurement “B”
from measurement “A”. The difference between
measurements “A” and “B” is the vehicle toe alignment.
The recommended vehicle toe tolerance is 1/8” to 1/4”
(.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)
MAINTENANCE
Toe Adjustment
If toe alignment is incorrect, measure the distance between
vehicle center and each wheel. This will tell you which tie rod
needs adjusting.
NOTE: Be sure steering wheel is straight ahead
before determining which tie rod(s) need 2
adjustment.
CAUTION
During tie rod adjustment, it is very important that
the following precautions be taken when
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not
pivot, and may break.
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both ends of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as specified in
Toe Alignment Inspection.
• IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent rod
end damage and premature wear. Damage may not be
immediately apparent if done incorrectly.
• After alignment is complete, torque jam nuts to
specification. Keep tie rod parallel to the mounting
surface.
=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
2.31
MAINTENANCE

SUSPENSION BRAKE SYSTEM

Spring Preload Adjustment Brake Fluid Inspection
The front and rear shock absorber springs are adjustable by Always check the brake pedal travel and inspect the brake fluid
rotating the adjustment cam to change spring tension preload. reservoir level before each operation. If the fluid level is low,
add DOT 4 brake fluid only.

WARNING
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and
serious injury or death. Always adjust all spring
preloads equally.
Suspension Spring Adjustment
1. Position the vehicle on a level surface and stop the engine.
2. Raise and safely support the front or rear of the vehicle off
the ground to allow the suspension to fully extend.
NOTE: The tires should not be touching the ground.
3. To adjust the shock spring preload, rotate the adjustment
cam clockwise to increase spring tension or counter-
clockwise to decrease spring tension using the supplied
spanner wrench.
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level, or if
the type and brand of the fluid in the reservoir is unknown.
The brake fluid master cylinder reservoir can be accessed
through the left front wheel well.
1. Position the vehicle on a level surface. Engine off.
2. Place the transmission in gear and lock the parking brake.
3. View the brake fluid level in the reservoir. The level should
be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add brake
fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal
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

4. Each notch of the adjustment will add 6% - 8% more

preload to the spring over the primary position.

2.32
 MAINTENANCE
Brake Pad / Disc Inspection
1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad wear surface for excessive wear.

2
3. Pads should be changed when the friction material is worn
to .040” (1 mm).

Measure Pad Material

Thickness Service Limit:
.040" (1 mm)

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

6. The disc(s) should be replaced if thickness is less than .170”

(4.32 mm).

Measure Brake Disc Thickness

Rear Front
Disc Disc

Service Limit:
.170" (4.32 mm)

Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks. Tighten any loose fittings and replace any
worn or damaged parts.

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)

TORQUE SPECIFICATIONS Pulse Coil Screws 5mm 4-5 (5-7 Nm)

Engine Torque Specifications

Torque Patterns
TORQUE SPECIFICATIONS
Tighten cylinder head, cylinder base, and crankcase fasteners in
Thread ES35C 3 steps following the sequence outlined. Refer to the table for
Fastener torque specifications.
Size Ft. Lbs. (Nm)
Camshaft Chain Guide
6mm 5-7 (7-9 Nm)
Pivot Bolt 3 2
5
Camshaft Chain 6 mm
6mm 5-7 (7-9 Nm)
Tensioner
Camshaft Chain 6
6mm 5-7 (7-9 Nm) 1 4
Tensioner Cap
Carburetor Intake 6mm 7-8 (9-11 Nm) Cylinder Base / Head and
Rocker Assembly
Cylinder/Head Nuts 10mm 18 (25 Nm)

Cylinder Base Screws 6mm 5-7 (7-9 Nm) 1 2

Crankcase (inner) 6mm 14-15 (19-21 Nm)

RH Crankcase - (Inside Stator Cover)

Crankshaft Slotted Nut 14mm 43 (58 Nm)

Balancer Shaft Slotted
14mm 43 (58 Nm) 1 5
Nut 8
Exhaust Nuts 6mm 7-8 (9-11 Nm) 6

Flywheel Nut 14mm 43 (58 Nm)

3
Cooling Fan 6mm 4-5 (5-7 Nm) 2

Oil Drain Bolt

14mm 18 (25 Nm)
(Crankcase) 9
4 7
Oil Pump
6mm 4-5 (5-7 Nm)
Screws RH Crankcase - Stator Cover

3.3
ENGINE
ENGINE INFORMATION
Engine Exploded Views
Crankcase Cylinder / Cylinder Head

Crankshaft and Piston Valve Train

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)

Capacity: Approximately 37 oz. (1.1 ltr.)

• Rocker Arms
• Carburetor
3
Drain Plug (Engine Oil): 18 ft. lbs. (23 Nm) • Transmission Components

Screen Fitting: 11 ft. lbs. (15 Nm) • Valves

Oil Pressure Specification: Not Applicable • Cylinder Head

• Cylinder
** For break-in period after engine top end service, use an SAE
40W mineral based oil to ensure complete piston ring seating to • Piston/Rings
cylinder wall. Change to above recommendation after 10 hours. • Camshaft

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
pistons from the top. The letters “IN” must always be toward the
intake side of the engine. The other numbers are used for
identification as to diameter, length and design. Four stroke
engine rings are rectangular profile. Any numbers or letters on
the rings (except oil control rings) must be positioned upward.
See text for oil control ring upper rail installation.
• Balancer/Bearings
NOTE: Cam chain service requires crankshaft
removal, as the chain is located on the pto side of
the engine.
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.

Engine Model Oversize Standard Piston

No. Available (mm) Identification
”IN” marking on
ES35C N/A top of piston
toward intake

3.5
ENGINE
Engine Service Data

Cylinder Head / Valvetrain ES35C

Rocker arm ID .3936 - .4007" (10.00 - 10.18 mm)
Rocker Arm/Shaft
Rocker shaft OD .3925 - .3931" (9.972 - 9.987 mm)
Std 1.1730" (29.795 mm)
In
Limit 1.1574" (29.40 mm)
Camshaft Cam lobe height
Std 1.1637" (29.56 mm)
Ex
Limit 1.1480" (29.16 mm)
Cylinder Head Surface warpage limit .002” (.05 mm)
In Std .003" (.07 mm)
Valve Clearance
Ex Std .003" (.07 mm)
Std .039" (1.0 mm)
In
Limit .063" (1.6 mm)
Valve Seat Angle Contacting width
Std .039" (1.0 mm)
Ex
Limit .063" (1.6 mm)
In .1958 - .1960" (4.975 - 4.980 mm)
Valve Stem diameter Ex .1950 - .1956" (4.955 - 4.970 mm)
Limit .1921" (4.9 mm)
In .1968 - .1973" (5.0 - 5.012 mm)
Valve Guide Inner Diameter Ex .1968 - .1973" (5.0 - 5.012 mm)
Limit .1980" (5.03 mm)
Inner 1.275" (32.4 mm)
Free Length
Valve Spring Outer 1.385" (35.2 mm)
Squareness 0.075” (1.9 mm)
Cam Chain Install new as a part of any crankshaft removal

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off

3.6
 ENGINE
Engine Service Data

Cylinder / Piston / Connecting Rod ES35C

Surface warpage limit (mating with cylinder head) .002” (0.05 mm)

Cylinder bore Std 2.4015 - 2.4019" (61 - 61.01 mm)

Taper limit .002” (0.05 mm)
Cylinder Out of round limit .002” (0.05 mm)
Std .00039 - .0015" (0.01 - 0.04 mm)
Piston to cylinder clearance
Limit .0039" (0.1 mm) 3
Boring Limit Not Applicable

Std 2.4003 - 2.4011" (60.97 - 60.99 mm)

Outer diameter 1st O.S. Not Applicable
Piston
2nd O.S. Not Applicable
Pin Bore - Inner Diameter .5906 - .5908" (15.002 - 15.008 mm)
Pin outer diameter clearance in piston .00015 - .00047” (.004 - .012 mm)
Piston Pin
Degree of fit Piston Pin must be a push (by hand) fit at 68! F (20! C)

Std .0059 - .013" (.15 - .35 mm)

Top ring
Limit .0196" (0.5 mm)
Second Std .0059 - .013" (.15 - .35 mm)
Piston Ring Piston Ring Installed gap
ring Limit .0196" (0.5mm)
Std .0079 - .0314" (0.2 - 0.8 mm)
Oil ring
Limit .059" (1.5 mm)
Std .00078 - .0023" (0.02. - 06 mm)
Top ring
Standard clearance - Limit .0035" (0.09 mm)
Piston Ring
piston ring to ring groove Std .00078 - .0023" (0.02 - 0.06 mm)
Second
ring Limit .0035" (0.09 mm)
Connecting rod small end ID .5903 - .5916” (15.01 - 15.028 mm)

Connecting Rod Connecting rod big end axial clearance Std .0039 - .011" (0.1 - 0.3 mm)

Connecting rod big end radial clearance Std Not Applicable

Crankshaft end runout 0.0015" (0.04 mm)

Crankshaft
Crankshaft end runout - limit 0.0039" (0.1 mm)

Oil pump chain Install new as a part of any oil pump replacement

Cam Shaft Chain Install new as a part of any crankshaft 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.

7-8 ft. lbs. (9-11 Nm)

7-8 ft. lbs. (9-11 Nm)

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.

7-8 ft. lbs. (9-11 Nm)

C
A Air In

16 ft. lbs. (22 Nm)

To Intake (impulse)

Air To Cylinder Head Exhaust Passage

7-8 ft. lbs. (9-11 Nm)

7-8 ft. lbs. (9-11 Nm)

3.10
 ENGINE
Cooling Shroud Removal/Installation
The cooling shroud directs air generated by the fan around the cylinder and casing for cooling.

REMOVAL:

1. Remove the carburetor and intake.

2. Remove the exhaust pipe.

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

B. Air Horn Assembly

C. Housing

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.

• Use only Polaris Youth (40w) Oil, or API certified

“SH” oil equivalent.

• Use fuel with a minimum octane of 87 (R+M)/2

method.

• Change break-in oil at 10 hours or 100 miles, whichever

comes first.

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.

Finding Top Dead Center (TDC)

1. Remove the cooling shroud.

2. Remove the inspection cap from the stator housing.

3. Remove the valve cover and emissions pipe assembly. 3

To position the crankshaft at Top Dead Center (TDC) on the
compression stroke:
4. Rotate the engine slowly in the direction of rotation while
watching the intake valve open and start to close.

5. Continue to rotate slowly while watching the camshaft

sprocket marks and timing mark in the inspection hole.
2. Allow the cam chain tensioner plunger to extend outward
Single TDC Mark Aligned to the end of its travel. Inspect tensioner and plunger (A)
for wear or damage.
TDC Mark

Rotation
A

6. The engine is at Top Dead Center when the single (TDC)

mark on flywheel is visible within the inspection hole and
the cam sprocket hole is facing upward. NOTE: The
sprocket marks should align with the gasket surface, the
cam lobes must be pointed downward and the rockers 3. Using a small flat blade screwdriver, turn the tensioner
must have valve clearance at this point. clockwise to retract the plunger. The plunger should move
smoothly in and out of the tensioner body.

4. Tap lightly on tensioner body with a soft face hammer to

loosen and remove tensioner if required.

5. Replace tensioner assembly if any part is worn or damaged.

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.

1. Remove the valve cover and secondary air injection pipe

as an assembly.

2. Loosen each of the four cylinder head nuts evenly 1/4 turn
each time in a cross pattern until loose.

6. Measure O.D. of rocker shafts for out-of-round. Inspect for

wear or damage. Replace if excessive wear is evident.
NOTE: Orientation of the rocker shafts is important for
C reassembly. Place only the exhaust rocker shaft into the
exhaust side of the cam support.

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.

8. Inspect the lash adjusters for wear, pitting, or damage to

4. If not removing the cylinder for other service, secure the
threads of the adjuster or locknut. Replace all worn or
cam chain with a wire to prevent it from falling into the
damaged parts. NOTE: The end of the lash adjuster is
crankcase.
hardened and cannot be ground or re-surfaced.
Camshaft Inspection
Camshaft Removal
1. Inspect cam sprocket teeth for wear or damage. Replace if
NOTE: Cam chain tensioner must be removed
necessary.
before performing this procedure.

1. Verify the valve cover and cam chain tensioner have been
removed.

2. Remove the 4 cylinder head bolts evenly by loosening each

one 1/4 turn at a time until loose. Tap the rocker assembly
with a non-marring hammer to loosen and remove the
assembly.
Inspect for Areas of
Tooth Wear or Damage

2. Inspect the compression release mechanism. This is a one-

way rotating shoulder that lifts the exhaust valve slightly
during start-up. If the one-way mechanism is not
functioning, replace the cam. Verify the stop bracket and
spring is functioning correctly. Replace if excessive wear
of components is found.
Compression Release
One-Way Operation

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.

1. Verify the valve cover and tensioner are removed.

2. Remove the two 6mm cylinder/head base screws.

3. Loosen each of the four cylinder head nuts evenly 1/4 turn
each time in a cross pattern until loose.
Lobe Height

Compression Release-One-way stop

4. Remove the nuts and tap the rocker assembly with a plastic
hammer until loose. Remove.

5. After removing the camshaft and securing the cam chain,

tap the cylinder head lightly with a plastic hammer until
= In. / mm. loose. CAUTION: Tap only in reinforced areas or on
thick parts of cylinder head casting to avoid damaging
casting.
Cam Lobe Height:
6. Remove cylinder head (A) and head gasket (B).
Intake
Std: 1.1730” (29.795 mm)
Limit: 1.1574” (29.40 mm)
Exhaust
Std: 1.1637” (29.56 mm)
Limit: 1.1480” (29.16 mm)

4. Thoroughly clean the cam shaft.

5. Measure height of each cam lobe using a micrometer.

Replace cam if worn below minimum height.

Replace camshaft if damaged or if any part is worn excessively. A

B

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

CAUTION Wear eye protection or a face shield during

Use care not to damage sealing surface.
If there is damage found on the cylinder head
combustion chamber, it is recommended the
component be replaced.
Cylinder Head Warp Inspection
1. Lay a straight edge across the surface of the head at several
different points and measure warpage by inserting a feeler
gauge between the straight edge and the cylinder head
surface. If warpage exceeds the service limit, replace the
cylinder head.Milling the
cylinder head disassembly and reassembly.
NOTE: Keep all parts in order with respect to their
location in the cylinder head.
NOTE: Valves have inner and outer springs.
3
1. Using a valve spring compressor, compress the valve
springs and remove the split keeper. NOTE: To prevent
loss of tension, do not compress the valve spring more than
necessary.

2. Remove spring retainer and spring.

A

= In. / mm.

Cylinder Head Warp Limit: .002” (.05 mm)

Combustion Chamber Inspection

Clean all accumulated carbon deposits from combustion
chamber and valve seat area with a soft wire brush. Inspect the
combustion chamber for cracks and/or damage from foreign
debris.
NOTE: The valve springs should be positioned with
the tightly wound coils against the cylinder head on
progressively wound springs (A).

3. Push valve out, keeping it in order for reassembly in the

same guide.

3.17
ENGINE
4. Measure free length of the inner and outer springs with a
Vernier caliper, Ill.1. Check spring for squareness as
shown in Ill.2. Replace spring if measurements are out of
specification.
Valve Inspection
1. Remove all carbon from valve with a soft wire wheel.
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

3. Check end of valve stem for flaring, pitting, wear or damage

(A).

Coil Fatigue / Squareness

III.2
5. Remove valve seals. NOTE: Replace seals whenever the
cylinder head is disassembled. Hardened, cracked or worn
valve seals will cause excessive oil consumption and
carbon buildup.
4. Inspect split keeper groove for wear or flaring of the keeper
seat area (B). NOTE: The valves cannot be re-faced or end
ground. Valves must be replaced if worn, bent, or damaged.

5. Measure diameter of valve stem with a micrometer in three

places and in two different directions (six measurements
total). Replace if excessive wear is evident.
Measure valve stem in
several places

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

Wear eye protection when

performing cylinder head service.

Follow the manufacturers instructions provided with the valve 3

cutting kit (commercially available). Abrasive stone seat
reconditioning equipment can also be used. Keep valves in order
with their respective seat.

NOTE: Valve seat width and point of contact on the

7. Subtract valve stem measurement to obtain stem to guide valve face is very important for proper sealing. The
clearance. NOTE: Be sure to measure each guide and valve valve must contact the valve seat over the entire
combination individually. circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
8. Replace valve and/or guide if clearance is excessive. uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
NOTE: If valve guides are replaced, valve seats must carbon accumulation and possible compression
be reconditioned. Refer to Valve Seat loss. If the seat is too narrow, heat transfer from
Reconditioning for procedure. valve to seat is reduced and the valve may overheat
and warp, resulting in burned valves.
Valve Seat Reconditioning
1. Install pilot into valve guide.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt spots,
roughness, and uneven surface. If any of the above conditions
exist, the valve seat must be reconditioned. If the valve seat is
cracked the cylinder head must be replaced.

Too Uneven Good Too

Wide Narrow

2. Apply cutting oil to valve seat and cutter.

3.19
ENGINE
3. Place 46! cutter on the pilot and make a light cut.
4. Inspect the cut area of the seat.
• If the contact area is less than 75% of the circumference
of the seat, rotate the pilot 180! and make another light
cut.
• If the cutter now contacts the uncut portion of the seat,
check the pilot. Look for burrs, nicks, or runout. If the
pilot is bent it must be replaced.
• If the contact area of the cutter is in the same place, the
valve guide is distorted from improper installation and
must be replaced. Be sure the cylinder head is at the
proper temperature and replace the guide.
• If the contact area of the initial cut is greater than 75%,
continue to cut the seat until all pits are removed and a
new seat surface is evident. NOTE: Remove only the
amount of material necessary to repair the seat surface.
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46!)apply black marker to the
entire valve face (A).
(A)
6. Insert valve into guide and tap valve lightly into place a few
times.
3.20
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)
Proper Seat Contact On Valve Face
• If the indicated seat contact is at the top edge of the
valve face and contacts the margin area(B) it is too high
on the valve face. Use the 30! cutter to lower the valve
seat.
• If too low use the 60!or 75! cutter to raise the seat.
When contact area is centered on the valve face,
measure seat width.
• If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
• If the seat is too narrow, widen using the 45! cutter and
re-check contact point on the valve face and seat width
after each cut.
Top 30o
o o
Seat 45 or 46
Bottom 60o or 75o
 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.

1. Install new valve seals on valve guides.

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.

4. Install valve carefully with a rotating motion to avoid

damaging valve seal.

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.

1. Remove cam chain guide at front of cylinder.

Closely spaced 2. Tap cylinder lightly with a soft-faced hammer in reinforced

coils toward areas only until loose. NOTE: Orientation of the dowels
cylinder head (arrows) is important for oil flow. Note their position for
reassembly.

6. Place retainer on springs and install valve spring

compressor. Compress spring only enough to allow split
keeper installation and prevent loss of spring tension.
Install split keepers with the gap even on both sides.

3. Rock cylinder back and forth while lifting it from the

crankcase, piston and connecting rod. Support piston with
Piston Support Block (PN 2870390).

Cam Chain Follower / Tensioner Guide

Removal
1. Remove bolt securing the tensioner guide to crankcase
(A). NOTE: CVT disassembly is required to gain access
to the tension guide bolt. Refer to Chapter 7.
7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the keepers.

Valve Sealing Test A

1. Clean and dry the combustion chamber area.

2. Pour a small amount of cleaning solvent into each port and

check for leakage around each valve. The valve seats
should hold fluid with no leaking.

2. Remove chain guides and inspect for cracks, wear or

damage. Replace assemblies as required.

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.

2. Inspect the top of the cylinder for warpage using a straight

edge and feeler gauge.

2. Push piston pin out of piston. If necessary, heat the crown

of the piston slightly with a propane torch. CAUTION: Do
not apply heat to the piston rings. The rings may lose radial
tension.

3. Remove the compression rings, starting with the top ring. = In. / mm.

Cylinder Warp:
.002” (.05 mm) MAX

3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a

telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2” down from top, in the middle, and
1/2” up from the bottom).
1/2” Down From Top of Cylinder

* 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

5. The oil control ring is a three piece design consisting of a

top and bottom steel rail and a center expander section. 1/2” Up From Bottom
Remove the top rail first followed by the bottom rail and
expander.

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.

If cylinder wear or damage is excessive, it will be necessary to

Cylinder Taper: replace the cylinder. Hone only enough to deglaze the outer
Limit: .002” (.05 mm) Max. layer of the cylinder bore.
Cylinder Out of Round:
Limit: .002” (.05 mm) Max.

Cylinder Hone Selection / Honing Procedure

CAUTION

A hone which will straighten as well as remove

material from the cylinder is very important.
Using a common spring loaded glaze breaker for
honing is not advised. Polaris recommends
using a rigid hone or arbor honing machine.
EXAMPLE OF CROSS HATCH PATTERN
Cylinders may be wet or dry honed depending upon the hone
manufacturer’s recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore. Piston Inspection
1. Measure piston outside diameter at a point 7 mm up from
Honing to Deglaze the bottom of the piston at a right angle to the direction of
A finished cylinder should have a cross-hatch pattern to ensure the piston pin.
piston ring seating and to aid in the retention of the fuel/oil
mixture during initial break in. Hone cylinder according to hone
manufacturer’s instructions, or these guidelines:

• Use a motor speed of approximately 300-500 RPM, run 7mm

the hone in and out of the cylinder rapidly until cutting
tension decreases. Remember to keep the hone drive
shaft centered (or cylinder centered on arbor) and to
bring the stones approximately 1/2” (1.3 cm) above and Piston
below the bore at the end of each stroke. Piston Pin

• Release the hone at regular intervals and inspect the

bore to determine if it has been sufficiently deglazed,
and to check for correct cross-hatch. NOTE: Do not 2. Subtract this measurement from the maximum cylinder
allow cylinder to heat up during honing. measurement obtained earlier.

• After honing has been completed, inspect cylinder for

thinning or peeling. = In. / mm.
IMPORTANT: Clean the Cylinder After Honing
Piston to Cylinder Clearance
Std: .00039- .0015” (0.01- 0.04 mm)
Limit: .0039” (.1 mm)

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.

Piston ring end gap installed

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.

Piston Ring Installed Gap:

Piston Pin Measurement Locations
Top Ring
Std: .0059- .013” (.15-.35 mm)
5. Measure connecting rod small end ID. Replace crankshaft Limit: .0196” (0.5 mm)
if out-of-round. Second Ring
Std: .0059- .013” (.15-.35 mm)
Limit: .196” (0.5 mm)
Oil Ring
Std: .0079-.0314” (0.2- 0.8 mm)
Limit: .059” (1.5 mm)

2. Measure the gap with a feeler gauge at both the top and
bottom of the cylinder.

NOTE: Measure at two points in the cylinder A

difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper
6. Measure piston ring to groove clearance by placing the ring and out of round.
in the ring land and measuring with a thickness gauge.
Replace piston and rings if ring-to-groove clearance 3. If the installed gap measurement exceeds the limit, replace
exceeds service limits. the rings. If using new rings and the measurement is too
small, file the ring ends to achieve the proper gap.
Piston
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
Ring re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust.
Feeler Gauge

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.

5. Measure the OD of the starter drive shaft on both ends for

out-of-round.

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. Remove stator housing bolts and remove housing.

7. Inspect gear teeth on starter drive. Replace starter drive if

gear teeth are cracked, worn, or broken.

8. Inspect the stator housing bearing. Replace if worn, rough

or damaged.

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

Avoid damage to the flywheel or crankshaft end.

Do not strike components or special tools with
hammers or heavy objects.

1. Before removing the flywheel, remove the shaft collar (A)

from the crankshaft. NOTE: Shaft collar installation is
important for proper loading of the flywheel upon
reassembly.
3

2. Install Flywheel Adapter PA-49936 and Puller PA-45153

and remove the flywheel.

NOTE: PA-45153 has left-hand threads which

correspond with the left-hand threads on PA-49936.
Use caution to avoid thread damage to flywheel or
tools.

PA-49
93 6

PA-45153

Flywheel Special Tools

Flywheel Adapter PA-49936
Flywheel Puller 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.

1. Remove the baffle plate.

4. Remove drive sprocket (D) and woodruff key from the

2. Using the Slotted Nut Socket PA-49935, remove the crankshaft.
crankshaft slotted nut (C) and washer (B) from the starter
drive one-way gear assembly (A). 5. Inspect sprocket teeth of both gears for wear or damage.

NOTE: Slotted nut is left-hand thread.

Removal

Inspect for Areas of

Tooth Wear or Damage

6. Inspect woodruff key for wear. Replace if damaged.

PA-49935
7. Replace any worn or damaged parts.

C Install

PA-49959
Remove

Slotted Nut Socket Tool

PA-49935

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

NOTE: One-way clutch components are not C

serviceable. Replace the component as an
assembly. B
3. Do not add specialized lubricants or greases to the bearing A Remove
or one-way components, as this may cause undesirable
operation.

PA-47344
Install

Slotted Nut Socket

PA - 47344

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.

2. Inspect the sprockets and chain for wear or damage. Inspect

chain for wear or damage. Replace chain anytime the oil
pump is replaced or if excessively worn.
Note: Install new chain as
part of oil pump repair.

4. Remove the oil pump gear nut.

3. Remove the oil pump retaining screws and pull the pump
from the engine case.

5. Remove drive sprocket (A), chain (B), pump sprocket (C)

and the woodruff key from the balance shaft.

6. Inspect sprockets and gear teeth for wear or damage.

7. Inspect woodruff key for wear.

8. Replace any worn or damaged parts.

3.30
 ENGINE
4. Thoroughly clean all oil passages with clean solvent.

5. Install a new pump with the oil galley pointed down as

shown.

Install with the oil galley pointing down

6. Torque screws to specification.

=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.

Crankcase Separation and

Cam Chain Removal
NOTE: Stator housing, flywheel and gears are
previously removed for this procedure. Use care
during the removal process to avoid damage to the
cam chain.

NOTE: Cylinder head and cylinder removal must be

performed prior to this procedure. 3. Watch the gap along the crankcase mating surface and
separate the crankcase evenly.
NOTE: Always replace the pto crankshaft seal after
performing this procedure. 4. Once the crankshaft bearing is free from the case, the
crankshaft and cam chain can be removed by hand for
1. Remove two case bolts (circled) from the magneto side replacement.
crankcase.

2. Separate crankcase using a press or by pressing on the pto Crankshaft Removal

end of the crankshaft using special tool (PA-46087). 1. Support the MAG side crankcase on blocks. Press the
crankshaft out using a press or special tool (PA-46087).
Use care not to damage the crankshaft oil passage on the
mag end crankshaft end.

NOTE: Tapping the pto end of the crankshaft with a

soft-face hammer may also separate the cases. Use
care not to damage the crankshaft end or cases.

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.

Crankcase / Bearing Inspection

NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
scoring or galling. Turn the outer race of each
bearing. The bearings should turn smoothly and
quietly. The inner race of each bearing should fit
tightly in the crankshaft. The outer race should be
firm with minimal side to side movement and no
detectable up and down movement.
2. Replace the crankshaft if the components fail visual
inspection.
3. The connecting rod utilizes a roller bearing. Clearance is
minimal and cannot be measured. Visually inspect bearing
journal for scoring, damage or excessive wear. Replace
crankshaft if it fails visual inspection.
NOTE: Removal and installation of new seals is
recommended anytime the crankcase is
disassembled.
1. Inspect the bearings in the crankcase.
NOTE: Due to extremely close tolerances and
minimal side wear, the bearing must be inspected
visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of bearing.
The bearing should turn smoothly and quietly. The
outer race should fit tightly in the crankcase. The
inner race should be firm with minimal side to side
movement and no detectable up and down
movement.
2. To remove crankcase bearings, use a blind hole bearing
puller.

NOTE: Bearings are damaged during the removal

procedure and should not be re-used.

3. Remove all traces of gasket material from the crankcase

mating surfaces. Inspect the surfaces closely for nicks,
burrs or damage.

Crankcase Oil Strainer Inspection

1. Remove drain plug.

2. Remove oil strainer and visually inspect for any damage or

obstructions in screen.
4. Check oil passages to make sure they are clear.
3. Replace oil strainer if it fails visual inspection.

3.33
ENGINE
ENGINE REASSEMBLY 2. Install the balance shaft into the mag side of the crankcase.

Bearing / Seal Installation

Mag-side
NOTE: To ease crankcase bearing installation, warm Crankcase
the crankcase until hot to the touch. Placing the
bearings in a freezer prior to installation will assist
the assembly process.

1. Install the bearings so the numbers are visible.

2. Drive or press the new bearings into the crankcase, using

the proper driver.

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.

NOTE: Tapping the mag end of the crankshaft with a

Crankcase Reassembly soft-face hammer may also install the crankshaft in
the PTO side. Use care not to damage the crankshaft
Crankshaft and Cam Chain Installation end.
Lubricate all bearings with clean engine oil before assembly.
1. Support the mag side crankcase cover on blocks high
enough to allow the crankshaft to drop. Install the
crankshaft using a hydraulic tool. Press on the pto end of
the crankshaft. Use care not to damage the crankshaft end.

NOTE: Tapping the end of the crankshaft with a soft-

face hammer may also install the crankshaft. Use
care not to damage the crankshaft end.

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

Chain Guide/Tensioner Installation

1. Install the chain guide and tighten the mounting bolt to
specified torque.

4. Using Slotted Nut Socket PA-47344, tighten the nut to the

specified torque.
B

=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.

6. Using Slotted Nut Socket PA-49935, tighten the crank shaft

nut to the specified torque. NOTE: Slotted nut is left hand
threaded.
=T
Baffle Plate Screw Torque:
5-7 ft. lbs. (7-9 Nm)

Oil Pump and Chain Installation

NOTE: Oil pump is not a serviceable assembly. Do
not disassemble pump. Replace entire component.

1. Inspect the oil pump sealing surface on the crankcase.

Install Apply a liberal amount of engine oil to the surfaces and
pump.

NOTE: Do not use gasket sealer on the pump

=T mating surfaces.

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

Install with the oil galley pointing down

=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.

1. Oil Control Ring: Place the oil control ring expander in

oil ring groove with the end gap facing forward. The
expander has no up or down marking and can be installed
D
either way. The ends should butt squarely together and
must not overlap.
3
2. Install the oil ring top rail with the end gap at least 30! from
4. Loop the chain around the oil pump drive sprocket (C) and the end of the expander.
install the sprocket onto the oil pump shaft. NOTE: The oil 3. Install the bottom rail with the gap at least 30! from the end
pump sprocket and shaft have a “D” configuration for of the expander on the side opposite the top rail gap.
alignment.
Top
5. Install the pump gear washer and nut. Torque to Ring Profile
specification.

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.

6. Install the oil baffle plate (Item D -See illustration) and

torque screws to specification.

=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

Do not re-use circlips. Circlips become

deformed during the removal process. Do not
compress the new clip more than necessary to
prevent loss of radial tension. Severe engine
damage may result if circlips are re-used or
deformed during installation.

1. Install a new circlip on one side of the piston with the end
gap facing up or down.

2. Apply clean engine oil all components before assembly.

Generously lubricate the connecting rod (both ends) and
6. Lubricate the piston and rings with assembly lube and
crankshaft main bearing area.
install a ring compressor on the piston assembly. Verify
3. Install the wrist pin and piston onto the connecting rod. that the ring gaps are 120 degrees apart from each other
IMPORTANT: Install the piston on the connecting rod before installation.
with the ’IN” casting mark facing the intake side of engine.
The piston pin should be a push fit into the piston.

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

Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase
and cylinder. Remove all traces of old gasket
material and apply a new base gasket
ENGINE
Cylinder Head and Camshaft Installation
NOTE: Verify the gasket surfaces on the cylinder
head and cylinder are clean. Remove all traces of old
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.

NOTE: Route cam chain through the cylinder chain

room and secure it, holding it up while rotating the 3
engine to avoid damage to the chain, drive sprocket
teeth or tensioner blade.

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.

3. Place the cylinder head onto the cylinder.

4. Install the two 6 mm base bolts, but do not tighten at this

time.

5. Install the cam according to the “Cam Shaft Timing”

procedure. Verify the cam chain is in place around the
crankshaft gear.

NOTE: Verify camshaft timing is accurate before

installing the rocker and tensioner assemblies.
4. Push the rings into the cylinder taper using a non-metallic,
blunt-edge tool while pushing the cylinder down. This will
help push the piston past the ring taper into the cylinder.

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

Serious engine damage will result if the

camshaft is not properly timed to the crankshaft.

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.

1. Install the cam chain over the crankshaft.

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.

Camshaft Installation - Timing Method 1

Reference Illustration Page 3.41

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

Method 1 - Camshaft Timing with Stator Housing Removed

Sprocket marks aligned with gasket surface at TDC on

compression stroke (cam lobes facing downward)

Crankshaft Keyway ‘UP’

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.

7. Install the tensioner. Torque fasteners to specification.

8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.

3.42