Polaris G21G4D99AW Service Manual Download Page 7

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9850067 R01 - 2020-2021

GENERAL

GENERAL XP

Service Manual

1.1

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

MODEL NUMBER DESIGNATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE AND ENGINE SERIAL NUMBER LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

SERVICE RULES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

PUBLICATION PART NUMBERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

REPLACEMENT KEYS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

SPECIAL TOOLS WEBSITE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

SPECIAL TOOLS INDEX

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

VEHICLE SPECIFICATIONS (MODEL YEAR 2021) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

MODEL SPECIFICATIONS - 2 SEAT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

MODEL SPECIFICATIONS - 4 SEAT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18

MODEL SPECIFICATIONS - INTL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22

MISC SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26

MASTER TORQUE TABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26

CONVERSION TABLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33

SAE TAP / DRILL SIZES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34

METRIC TAP / DRILL SIZES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34

DECIMAL EQUIVALENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35

GENERAL DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36

GENERAL DIAGNOSTICS INFORMATION OVERVIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36

GUIDED SYMPTOM DIAGNOSTIC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36

GUIDED SYMPTOM REFERENCES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37

ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38

ENGINE CRANKS BUT DOES NOT START

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41

NO CRANK NO START OR SLOW CRANK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43

OVER HEATING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44

WARNING LIGHTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45

ENGINE TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46

COOLING TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48

DIGITAL WRENCH® SOFTWARE OVERVIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.49

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.49

GUIDED DIAGNOSTICS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.49

DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50

DIGITAL WRENCH® COMMUNICATION ERRORS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.51

DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.51

DIGITAL WRENCH® SERIAL NUMBER LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52

DIGITAL WRENCH® FEATURE MAP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.53

ENGINE CONTROLLER REPROGRAMMING (REFLASH)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.55

POLARIS MOBILE DIGITAL WRENCH® (PMDW)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.55

Summary of Contents for G21G4D99AW

Page 1: ...authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this m...

Page 2: ...n which if not avoided WILL result in death or serious injury WARNING SAFETY ALERT WARNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION SAFETY A...

Page 3: ...G SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the nearest Po...

Page 4: ......

Page 5: ...TENANCE CHAPTER 3 ENGINE COOLING SYSTEM CHAPTER 4 ENGINE ELECTRICAL CHAPTER 5 FUEL SYSTEM CHAPTER 6 PVT SYSTEM CHAPTER 7 TRANSMISSION CHAPTER 8 FINAL DRIVE CHAPTER 9 STEERING SUSPENSION CHAPTER 10 BRA...

Page 6: ......

Page 7: ...CONVERSION TABLE 1 33 SAE TAP DRILL SIZES 1 34 METRIC TAP DRILL SIZES 1 34 DECIMAL EQUIVALENTS 1 35 GENERAL DIAGNOSTICS 1 36 GENERAL DIAGNOSTICS INFORMATION OVERVIEW 1 36 GUIDED SYMPTOM DIAGNOSTIC 1...

Page 8: ...E VIBRATION 1 78 CALIPER OVERHEATS BRAKES DRAG 1 79 POOR BRAKE PERFORMANCE 1 79 BRAKES LOCK 1 79 EPS TROUBLESHOOTING POWER STEERING NON FUNCTIONAL WITH MIL ON 1 80 EPS TROUBLESHOOTING POWER STEERING N...

Page 9: ...models not including the base First 3 digits and 10th digit are used in model number only They are not used with the 17 digit VIN Digits 1 through 8 determine Digital Wrench calibration VEHICLE IDENTI...

Page 10: ...on of the left rear frame q above the PVTcover INTL models have VIN stamped on front right upper side of the frame w The engine serial number can be found on a decal applied to the front of the engine...

Page 11: ...eath If a torquing sequence is indicated for nuts bolts or screws of a certain component start all fasteners and hand tighten Following the method and sequence indicated tighten evenly to the specifie...

Page 12: ...1GXD99BJ G21GXD99BZ G21GXH99AL G21GXH99BL G21GXJ99AJ G21GXJ99AZ G21GXJ99BJ G21GXJ99BZ 9939899 GENERAL XP 4 G21GMD99AJ G21GMD99AZ G21GMD99BJ G21GMD99BZ G21GMH99AL G21GMH99BL G21GMJ99AJ G21GMJ99AZ G21GM...

Page 13: ...ch series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number i e In this example the first two digits are 31 which would use key bl...

Page 14: ...d or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may ord...

Page 15: ...th 2 Bore Stand PU 50625 Engine Stand Sleeve Adapter Use With 2 375 Bore Stand PW 47054 Engine Stand 2 Bore PU 50624 Clutch Center Distance Tool PU 50658 A Valve Spring Compressor Adapter PV 43513 A C...

Page 16: ...allation Tool 2870341 Piston Pin Puller 2870386 Clutch Bushing Replacement Tool Kit 2871226 Bushing Replacement Tool PA 47336 Universal Clutch Compressor PU 50518 CHAPTER 6 TRANSMISSION Drive Clutch P...

Page 17: ...ock Rod Holding Tool PU 51024 Gas Shock Fill Tool PU 51039 CHAPTER 9 BRAKE SYSTEM Mityvac Pressure Test Tool 2870975 CHAPTER 10 BODY FRAME Multi Function Pliers 2876389 CHAPTER 11 ELECTRICAL Digital W...

Page 18: ...CHAPTER 11 ELECTRICAL PV 43568 Fluke 77 Digital Multimeter PF 51237 Static Timing Light Harness 2871745 Hall Effect Sensor Probe Harness 2460761 Battery Conductance Analyzer MDX 610P PU 50296 Connecto...

Page 19: ...HICLE SPECIFICATIONS MODEL YEAR 2021 MODEL SPECIFICATIONS 2 SEAT MODEL MODEL NUMBERS MODEL IMAGE GENERAL SPORT G21GAE99A4 GENERAL PREMIUM G21GAP99AM G21GAP99BM GENERAL DELUXE G21GAD99AC G21GAD99AW G21...

Page 20: ...162 5 cm Height 74 in 188 cm 75 in 190 5 cm Wheel Base 81 in 206 cm 83 in 211 cm Ground Clearance 12 in 30 5 cm 13 5 in 34 cm Dry Weight 1422 lb 645 kg Sport 1491 lb 676 kg Premium 1554 lb 705 kg Del...

Page 21: ...i 999 cc Number of Cylinders 2 Bore Stroke 93 x 73 5 mm Compression Ratio 10 5 1 Engine Idle Speed 1200 100 RPM Engine Max Speed 8750 RPM Valve Clearance Int 006 001 in 0 15 0 025 mm Valve Clearance E...

Page 22: ...ual Beam Halogen Dual Beam LED Taillights 0 28 Watt LED cluster Brake Lights 3 1 Watt LED cluster Ignition System ME17 ECU Spark Plug Gap NGK MR7F 0 7 0 8 mm Battery Amp Hr 12 V Flooded 575 CCA DC Out...

Page 23: ...t Aluminum 15 x 7 Rear Wheel Size Stamped Steel 12 x 8 Cast Aluminum 14 x 8 Cast Aluminum 15 x 7 Front Tire Size Model 27 x 9 12 Clincher 27 x 9 14 Maxxis Coronado 30 x 10 15 Crawler XG Rear Tire Size...

Page 24: ...ODEL SPECIFICATIONS 4 SEAT MODEL MODEL NUMBERS MODEL IMAGE GENERAL 4 PREMIUM G21G4P99AM G20G4P99BM GENERAL 4 DELUXE G21G4D99AW G21G4J99AW G21G4D99BW G21G4J99BW GENERAL XP 4 DELUXE G21GMD99AJ G21GMJ99A...

Page 25: ...x 109 x 28 cm Maximum Weight Capacity Payload 1280 lb 580 kg Includes riders cargo and accessories 1200 lb 544 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tong...

Page 26: ...eadlights Dual Beam LED Taillights 0 28 Watt LED cluster Brake Lights 3 1 Watt LED cluster Ignition System ME17 ECU Spark Plug Gap NGK MR7F 0 7 0 8 mm Battery Amp Hr 12 V Flooded 575 CCA DC Outlet Sta...

Page 27: ...uminum 15 x 7 Rear Wheel Size Cast Aluminum 14 x 8 Cast Aluminum 15 x 7 Front Tire Size Model 27 x 9 14 Dirt Commander 30 x 10 15 Crawler XG Rear Tire Size Model 27 x 11 14 Dirt Commander 30 x 10 15 C...

Page 28: ...2796 lb 1268 kg 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders...

Page 29: ...ice Manual Copyright Polaris Inc 1 23 GENERAL ABS TRACTOR GENERAL ABS ZUG GENERAL 4 EU Lubrication Wet Sump Oil Requirements PS 4 5W 50 Full Synthetic Oil Capacity 2 5 Qt 2 4 L Coolant Capacity 5 02 q...

Page 30: ...eadlights Dual Beam LED Taillights 0 28 Watt LED cluster Brake Lights 3 1 Watt LED cluster Ignition System ME17 ECU Spark Plug Gap NGK MR7F 0 7 0 8 mm Battery Amp Hr 12 V Flooded 575 CCA DC Outlet Sta...

Page 31: ...mander Rear Tire Size Model 27 x 11 14 E Mark 27 x 11 14 Dirt Commander Tire Air Pressure Front 12 psi 87 kPa Rear 14 psi 96 kPa Front 18 psi 124 kPa Rear 20 psi 137 kPa Brake System Front Rear Foot A...

Page 32: ...haft Sprocket Bolts 14 ft lbs 19 N m Connecting Rod Bolts Step 1 9 ft lbs 12 N m Step 2 22 ft lbs 30 N m Step 3 Tighten add n 90 Coolant Bleed Screw 89 in lbs 10 N m PART DESCRIPTION TORQUE SPECIFICAT...

Page 33: ...ft 10 Nm Valve Cover Bolts 7 lb ft 10 Nm CHAPTER 4 ENGINE ELECTRICAL PART DESCRIPTION TORQUE SPECIFICATION APS Mounting Fasteners 8 lb ft 11 Nm CPS Retaining Bolt 9 lb ft 12 Nm PART DESCRIPTION TORQU...

Page 34: ...s Step 4 7 44 lb ft 60 Nm Front Shifter Cable Jam Nut 18 lb ft 24 Nm Park Plate Fastener 9 ft lbs 12 Nm Rear Mount Bracket Fastener 20 ft lbs 27 Nm PART DESCRIPTION TORQUE SPECIFICATION Rear Shifter C...

Page 35: ...Nm Front Shock Mounting Fasteners 20 lb ft 27 Nm 90 Front Stabilizer Bar Link Fasteners 40 lb ft 54 Nm Front Stabilizer Bar Mount Fasteners 20 ft lbs 27 Nm PART DESCRIPTION TORQUE SPECIFICATION Rear I...

Page 36: ...m Brake Scraper Fasteners 7 lb ft 9 Nm Brake Switch 15 lb ft 20 Nm Caliper Bleeder Screw 4 lb ft 5 4 Nm Front Caliper Mounting Bolts 30 lb ft 41 Nm PART DESCRIPTION TORQUE SPECIFICATION Junction Block...

Page 37: ...5 Nm Front Outer Door Handle Fasteners 22 in lbs 2 5 Nm Front Outer Door Panel Fasteners T 40 42 in lbs 5 Nm Rear Door Hinge Fasteners 17 lb ft 23 Nm PART DESCRIPTION TORQUE SPECIFICATION Rear Door La...

Page 38: ...4 ft lbs 19 Nm AM FM Antenna Nut 25 in lbs 3 Nm Amp Fasteners 30 in lbs 4 Nm Audio Display Mounting Fasteners 30 in lbs 4 Nm Bumper Fasteners Front 30 lb ft 41 Nm Front Speaker Cover Fasteners 7 in lb...

Page 39: ...mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg kilogram kg...

Page 40: ...2 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4...

Page 41: ...mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625...

Page 42: ...plicated and compared to a like vehicle No If the concern has not been able to be duplicated gather more information about the concern After the concern has been duplicated please compare to a like ve...

Page 43: ...been selected Refer to the Transmission or Final Drive Chapters for further diagnostic information No Is the concern related to a Noise Yes Refer to necessary service information for pin pointing nois...

Page 44: ...rench Guided diagnosis Certain failures may not display a CEL MIL on the instrument cluster In this instance record CEL s from the instrument cluster and refer to the necessary section in the Service...

Page 45: ...oad test battery If battery fails the load test charge replace battery as needed Retest for concern before proceeding Check Ignition Switch and connections Concern may be caused by faulty Ignition Swi...

Page 46: ...s not moving concern may be within transmission Refer to the necessary section in the applicable service manual u Test drive vehicle for concern If the concern is related to the PVTsystem Transmission...

Page 47: ...ure that the fuel being used meets the correct octane rating specific to the vehicle If filled with fuel vehicle starts and gauge still is not reading test the fuel sending unit 6 Check fuses or fuel...

Page 48: ...oncern Check ECU for power and grounds to make sure that computer is turning on 12 If all previous checks pass concern may be caused by internal engine issue Refer to Cylinder Leakdown Test Previous t...

Page 49: ...ositive terminals at starter and solenoid for available voltage using DMM Readings should be 12 6 V With battery disconnected check cables for high resistance Reading should be less than 1 Ohm If resi...

Page 50: ...in need of changing may cause increase in engine temperature Too high of oil level may cause engine temperatures may cause increase in engine temperature Check level and correct as necessary Check mai...

Page 51: ...spect hoses and radiator for coolant leaks Repair as necessary Pressurize cooling system and look for pressure losses This indicates a leak in the cooling system Inspect for external leaks if none are...

Page 52: ...Injector Fuel pump inoperative restricted Tank vent plugged or pinched Engine flooded Injector control circuit failure Low compression high cylinder leakage No spark Spark plug fouled ignition compon...

Page 53: ...der Worn valve guides or seals Restricted breather Air filter dirty or contaminated LOW COMPRESSION Cylinder head gasket leak No valve clearance cam wear Valve not seating properly bent or carbon accu...

Page 54: ...cked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump Fuel pump output weak Cooling fan inoperative or turning too slowly perform current draw test Faulty hot light...

Page 55: ...refer to the Digital Wrench System Help To access the Digital Wrench System Help do one of the following Expand the Digital Wrench Help drop down on the left side of the main screen and click System H...

Page 56: ...drop down select Digital Wrench and then click Digital Wrench Updates 3 Select the Digital Wrench X X Updates link 4 Select the update you want to install on your PC IMPORTANT You must have the latest...

Page 57: ...and Troubleshooting Frequently Asked Questions FAQs Procedures and Solutions DIGITAL WRENCH DIAGNOSTIC CONNECTOR Located under the hood connected to a sealed plug q Follow these steps to connect the d...

Page 58: ...BER LOCATION To locate the Digital Wrench serial number do the following 1 Launch the Digital Wrench software 2 On the Digital Wrench main screen select the Configure the Diagnostic System Software me...

Page 59: ...hart format This is the most viewed screen Add and or update vehicle and customer information Also view ECU Identification View information from the main ECU sensors Access the Vehicle Home Page Set u...

Page 60: ...1 54 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc GENERAL INFORMATION...

Page 61: ...verview for information on how to access the System Help REPROGRAMMING REFLASH PROCEDURE 1 Verify the most current version of the Digital Wrench software is installed on your PC 2 Connect the SmartLin...

Page 62: ...products Dual core processor 2 GB internal memory external micro SD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video microphone a...

Page 63: ...e engine If the CHECK ENGINE lamp or the EPAS lamp illuminates retrieve the active error codes from the display 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button...

Page 64: ...Width Or Period P0501 9 Abnormal Update Rate P160A 10 Abnormal Rate Of Change C1068 C1705 12 Bad Intelligent Device Or Component P3503 19 Received Vehicle Speed Has Error P106B C1069 P306B 91 Accelera...

Page 65: ...Normal Or Shorted To Low Source P2228 10 Abnormal Rate Of Change P2230 110 Engine Temperature Sensor 0 Engine Overheat Shutdown P1217 2 Data Erratic Intermittent Or Incorrect P0116 3 Voltage Too High...

Page 66: ...omputation P121D 523 Gear Sensor Signal 2 Data Erratic Intermittent Or Incorrect P0914 3 Voltage Above Normal Or Shorted To High Source P0917 4 Voltage Too Low P0916 9 Abnormal Update Rate P1914 11 Ro...

Page 67: ...e Above Normal Or Shorted To High Source P0647 4 Voltage Below Normal Or Shorted To Low Source P0646 5 Current Below Normal Or Open Circuit P0645 905 Wheel Speed Sensor Front Left 2 Data Erratic Inter...

Page 68: ...ata Erratic Intermittent Or Incorrect P0236 3 Voltage Above Normal P0238 4 Voltage Below Normal P0237 31 Condition Exists P1234 1268 Ignition Coil Primary Driver 1 MAG 3 Voltage Above Normal P1353 4 V...

Page 69: ...Voltage Above Normal Or Shorted To High Source P0132 4 Voltage Below Normal Or Shorted To Low Source P0131 C1049 12 Bad Intelligent Device Or Component P113A 17 Data Valid But Below Normal Operating R...

Page 70: ...hrottle Release Signal 2 Data Erratic Intermittent Or Incorrect P1553 3 Voltage Above Normal Or Shorted To High Source P1555 4 Voltage Below Normal Or Shorted To Low Source P1554 7 Mechanical System N...

Page 71: ...ll Failure 31 Condition Exists C1053 520225 EPS Inverter Temperature 0 Data Valid But Above Normal Operational Range Most Severe Level C1055 12 Bad Intelligent Device Or Component C102F 16 Data Valid...

Page 72: ...rrent Below Normal Or Open Circuit P125A 520275 Accelerator Position Brake Position Interaction 31 Condition Exists P150A U1007 520276 Throttle Position Sensor 1 or 2 Indeterminable 2 Data Erratic Int...

Page 73: ...ition Exists C1681 520496 Intercooler Pump Driver Circuit 3 Voltage Above Normal Or Shorted To High Source P107D 4 Voltage Below Normal Or Shorted To Low Source P107C 5 Current Below Normal Or Open Ci...

Page 74: ...erating Range Least Severe Level P150F 524076 Engine Oil Pressure Sensor Switch 17 Data Valid But Below Normal Operating Range Least Severe Level P151F 524085 EPS Fault Lamp Driver Circuit 12 Bad Inte...

Page 75: ...the throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur The...

Page 76: ...low at this time clean and continue to monitor It is possible that the fluid is residual from manufacturing or previous repairs 2 Thoroughly clean the area using an appropriate cleaner Brake cleaner...

Page 77: ...uel injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts air box cover Faulty oxygen sensor RICH MIXTURE SYMPTOMS CAUSES Hard s...

Page 78: ...n warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector TMAP damaged check with...

Page 79: ...ed operating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift we...

Page 80: ...er s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Find leak and repair as necessary Operator error Instruct operator on guidelines for operation in wet terrain as outline...

Page 81: ...cle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may...

Page 82: ...damaged internal transmission components TRANSMISSION ISOLATION To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the transmission should...

Page 83: ...coil magnetized Rule out armature plate by putting it close to something metal to see if it tries to stick Drivetrain wedged Often caused by torsion spring coming out of place AWD Does not engage Rol...

Page 84: ...lled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake Adjust pad stop Set to proper level Cle...

Page 85: ...the throttle and brakes at the same time Excessive use of the brakes POOR BRAKE PERFORMANCE POOR BRAKE PERFORMANCE Air in system Water in system brake fluid contaminated Caliper or disc misaligned Cal...

Page 86: ...rocedure s available in Digital Wrench Power Steering Non Functional MIL is ON Cycle the ignition switch Is MIL on No There is no issue MIL on due to 5 minute timeout Verify code using Digital Wrench...

Page 87: ...onal MIL is OFF Is Battery Voltage 11 and 16VDC No Determine cause of incorrect battery voltage and repair Yes Is EPS Fuse OK No Replace EPS Fuse Yes 12 VDC and GND across 2 Pin EPS Connector with Key...

Page 88: ...igh EEPROM Failure These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit TABLE 2 EPS Inverter Temperature Test 1 Verify that the...

Page 89: ...cates the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body...

Page 90: ...M will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowled...

Page 91: ...upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the...

Page 92: ...to ground B so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There a...

Page 93: ...uit Testing Continuity Resistance page 1 86 4 Ensure you have checked for a short to ground Testing For A Short To Ground page 1 86 5 Ensure that neither end of the circuit is connected 6 Set your DMM...

Page 94: ...sulation damage Improper routing especially when it leads to chaffing or heat damage especially near exhaust You may need to use different techniques to duplicate these concerns These include but are...

Page 95: ...ep after switched power is removed 8 Maximum allowable is 10 milliamps If your meter is ranged to the 10 Amp scale this will appear as 0 010 Amps Current Draw Key Off Maximum of 01 DCA 10 mA 9 If over...

Page 96: ...1 90 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc For a video demonstration scan the QR code below or right click it and select open in new tab GENERAL INFORMATION...

Page 97: ...ABLE INSPECTION ADJUSTMENT 2 25 HEAT SHIELD INSPECTION 2 26 ENGINE MAINTENANCE 2 27 ENGINE OIL LEVEL 2 27 ENGINE OIL AND FILTER CHANGE 2 28 ENGINE CRANKCASE BREATHER HOSE INSPECTION 2 29 ENGINE CYLIND...

Page 98: ...RING ADJUSTMENT 2 46 SPRING ADJUSTMENT GENERAL 4 2 47 SHOCK COMPRESSION ADJUSTMENT 2 47 SUSPENSION MAINTENANCE GENERAL XP GENERAL XP 4 2 48 SPRING ADJUSTMENT GENERAL XP 2 48 SPRING ADJUSTMENT GENERAL...

Page 99: ...ways 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 ov...

Page 100: ...Tire Pressure General 1000 XP Front 10 psi 69 kPa Rear 14 psi 96 kPa Tire Pressure General 4 Front 18 psi 124 kPa Rear 20 psi 137 kPa Tire Pressure GENERAL XP 4 Front 16 psi 110 kPa Rear 22 psi 152 kP...

Page 101: ...10W 40 Extreme Duty Full Synthetic 2 5 Qt 2 4 L Engine Coolant 50 50 Extended Life Antifreeze 5 44 Qt 5 1 L Front Gearcase Fluid Demand Drive Fluid 8 5 oz 250 mL Transmission Fluid AGL Gearcase Lubri...

Page 102: ...ition 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 oi...

Page 103: ...n tire Verify there is adequate tread depth Wheels Lug Nuts Ensure rim is not cracked bent Verify proper lug nut torque Headlights Taillights Ensure all lights are operational Adjust headlight aim as...

Page 104: ...luid Demand Drive Initial fluid level inspection add lubricant if needed XU Transmission Fluid AGL Initial fluid level inspection add lubricant if needed XU E Engine Oil Filter Change Break In Perform...

Page 105: ...every 25 hours if subjected to extreme use XU Front Gearcase Fluid Demand Drive Fluid level inspection add lubricant if needed XU Transmission Fluid AGL Fluid level inspection add lubricant if needed...

Page 106: ...Shafts Remove and grease D E Spark Plug Inspect replace as needed XU Wiring Inspect for wear routing security inspect connectors subjected to water mud etc XU D Clutches Drive and Driven Inspect clean...

Page 107: ...izer Bars Lubricate and inspect bushings D Throttle Pedal Inspect for free movement replace pedal as needed Throttle Body Intake Ducts Flange Inspect duct for proper sealing air leaks Drive Belt Inspe...

Page 108: ...AGL Change fluid XU General Lubrication Lubricate all fittings pivots cables etc Shift Linkage Inspect lubricate adjust D Steering Lubricate XU Front Rear Stabilizer Bars Lubricate and inspect bushin...

Page 109: ...vel inspection add lubricant if needed XU Transmission Fluid AGL Fluid level inspection add lubricant if needed 250 HOUR 2500 MILES 4000 KM SERVICE XU PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES...

Page 110: ...and fittings for leaks and abrasion XU Front Gearcase Fluid Demand Drive Extreme Use Change fluid every 25 hours if subjected to extreme use XU Front Gearcase Fluid Demand Drive Fluid level inspectio...

Page 111: ...pect Exhaust Muffler Pipe Inspect Drive Shafts Remove and grease D E Spark Plug Inspect replace as needed XU Wiring Inspect for wear routing security inspect connectors subjected to water mud etc XU D...

Page 112: ...izer Bars Lubricate and inspect bushings D Throttle Pedal Inspect for free movement replace pedal as needed Throttle Body Intake Ducts Flange Inspect duct for proper sealing air leaks Drive Belt Inspe...

Page 113: ...d AGL Change fluid XU General Lubrication Lubricate all fittings pivots cables etc Shift Linkage Inspect lubricate adjust D Steering Lubricate XU Front Rear Stabilizer Bars Lubricate and inspect bushi...

Page 114: ...el inspection add lubricant if needed XU Transmission Fluid AGL Fluid level inspection add lubricant if needed 450 HOUR 4500 MILES 7200 KM SERVICE XU PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES S...

Page 115: ...luid Demand Drive Extreme Use Change fluid every 25 hours if subjected to extreme use XU Front Gearcase Fluid Demand Drive Fluid level inspection add lubricant if needed XU Transmission Fluid AGL Flui...

Page 116: ...an external surfaces XU Engine Oil Lines Fasteners Inspect for leaks and loose fittings D E Fuel System Cycle key to pressurize fuel pump check for leaks at fill cap fuel line rail and fuel pump repla...

Page 117: ...aris PS 4 or Polaris PS 4 Extreme Duty Add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereafter Engine Coolant Under Front Ho...

Page 118: ...g pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant until it is visible at the fill hole threads w 8 5 oz 250 mL Initial level check at 25 hours or 1 m...

Page 119: ...ilizer Bar Bushings Grease the fitting on each side of the vehicle q Premium All Season Grease Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing...

Page 120: ...Specialized Lubricants 2871322 Premium All Season Grease 3 oz 24 count 2871423 Premium All Season Grease 14 oz 10 count 2871515 Premium U Joint Lubricant 3 oz 24 count 2871551 Premium U Joint Lubrican...

Page 121: ...eat Shields ensure they are not damaged and are properly secured If any heat shields are found to be damaged or missing they must be replaced FRAME NUTS BOLTS AND FASTENERS Periodically inspect the to...

Page 122: ...ured A rattling sound while the engine or when the unit is moving is running is a good indication of an unsecured heat shield If any heat shields are found to be damaged loose or missing they must be...

Page 123: ...RH rear wheel opening Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTICE Make certain the dipstick is inserted all t...

Page 124: ...sh engine oil Check to make sure the O ring is in good condition Install the oil filter TORQUE Oil Filter Torque Turn by hand until filter O ring contacts sealing surface then turn an additional 3 4 t...

Page 125: ...orm a cylinder leak down test Never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Leakage Service Limit 20 If leakage exceeds service limit inspect the engine fo...

Page 126: ...mm Exhaust Valve Clearance cold 010 002 0 25 0 051 mm 10 Repeat steps 7 9 for inspecting all eight valves 11 If previously removed apply anti seize compound to the spark plug threads and reinstall th...

Page 127: ...he cam chain tensioner on the MAG side of the engine near the starter 2 Remove the plunger bolt q and the spring 3 Remove the two tensioner mounting bolts w 4 Push on the tensioner lock e and manually...

Page 128: ...er in the system Tap water contains minerals and impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat Recommended Coolant 50 50 Exten...

Page 129: ...engine and check for leaks Make sure radiator fins are clean to prevent overheating COOLING SYSTEM HOSES 1 Inspect all vehicle hoses for cracks deterioration abrasion or leaks Replace if necessary q...

Page 130: ...en the engine and radiator are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 2 Slowly remove the pressure cap to relieve any cooling system pressure 3 Place a suitab...

Page 131: ...re fuel lines are routed and retained properly NOTICE Make sure lines are not kinked or pinched FUEL PUMP FUEL FILTERS The fuel pump assembly q is located in the fuel tank under the passenger seat Thi...

Page 132: ...anel 2 Check the fuel tank vent line q for signs of wear deterioration or damage Replace line if necessary 3 Be sure the vent line is routed properly and secured with appropriate retention components...

Page 133: ...with fuel or oil it must be replaced 4 Inspect the air filter and replace if necessary NOTICE DO NOTattempt to clean the air filter 5 Place the air filter into the air box and reinstall the air box co...

Page 134: ...Reinstall the drain plug and O ring 5 Place the transmission in PARK apply the brake and start the engine 6 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clu...

Page 135: ...ricant as needed Do not overfill 5 Reinstall the fill plug and torque to specification TORQUE Transmission Fill Drain Plug Torque 14 lb ft 19 Nm TRANSMISSION LUBRICANT CHANGE 1 Remove the fill plug 2...

Page 136: ...ed Do not overfill 5 Reinstall the fill plug and torque to specification TORQUE Front Gearcase Fill Drain Plug Torque 10 lb ft 14 Nm FRONT GEARCASE FLUID CHANGE 1 Remove the fill plug 2 Place a drain...

Page 137: ...priate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION CAUTION If wheels are improperly installed it could affect vehicl...

Page 138: ...INTL 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...

Page 139: ...to be sure the steering mechanism is not restricted or limited NOTICE Check front end alignment whenever steering components are replaced WARNING Due to the critical nature of the procedures outlined...

Page 140: ...ovement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to Final Drive chapter for service procedures WHEEL TOE ALIGNMENT INSPECTION...

Page 141: ...ou which tie rod needs adjusting NOTICE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment IMPORTANT During tie rod adjustment it is very important that the fol...

Page 142: ...front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment collar q...

Page 143: ...NING DO NOT increase the spring adjustment q by more than one inch 25 4 mm over the factory setting Always return the spring adjuster to the factory setting after the load is removed from the vehicle...

Page 144: ...ng loads 1 Raise and safely support front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s too...

Page 145: ...afely support front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustm...

Page 146: ...k Damping adjustments can be made without using any tools Turn the adjuster knob clockwise to increase compression damping Turn the adjuster knob counter clockwise to decrease compression damping FACT...

Page 147: ...tion the vehicle on a level surface Place the transmission in PARK 2 View the brake fluid level in the reservoir q The level should be between the MAX and MIN level lines 3 If the fluid level is lower...

Page 148: ...excess heat in the parking brake system that can lead to premature pad and rotor wear along with driveability issues while in operation 1 Pull back on parking brake lever located in the center console...

Page 149: ...t the outer jam nut 1 1 2 turns 8 Hold the outer jam nut and turn in the inner jam nut e clockwise until the jam nut is tight against the bracket 9 Repeat Step 3 and Step 4 until the proper adjustment...

Page 150: ...h 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...

Page 151: ...et 3 5 lb ft 5 Nm 2 Coat the terminals with dielectric grease 3 Connect and tighten the red q cable first 4 Connect and tighten the black w cable last 5 Verify that cables are properly routed and rein...

Page 152: ...Torque fastener to specification TORQUE Battery Bracket 3 5 lb ft 5 Nm 2 Coat the terminals with dielectric grease 3 Connect and tighten the red q cable first 4 Connect and tighten the black w cable...

Page 153: ...et with an extension 6 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead...

Page 154: ...ROTTLE PEDAL INSPECTION This vehicle is equipped with Throttle Position Sensor q used to detect when the throttle pedal w is pushed or released The throttle pedal should move freely and always return...

Page 155: ...DISASSEMBLY INSPECTION BOTTOM END 3 30 PISTON TO CYLINDER CLEARANCE 3 43 ENGINE ASSEMBLY BOTTOM END 3 46 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 46 CONNECTING ROD BEARING SELECTION 3 47...

Page 156: ...GENERAL GENERAL XP Service Manual Copyright Polaris Inc COOLING SYSTEM HOSE REPLACEMENT 3 88 RADIATOR REPLACEMENT 3 89 THERMOSTAT REPLACEMENT 3 90 COOLING SYSTEM BLEEDING 3 91 WATER PUMP INSTALLATION...

Page 157: ...et or Chain Piston Rings SPECIAL TOOLS ENGINE COOLING SYSTEM TOOL DESCRIPTION PART NUMBER Engine Stand 2 Bore PU 50624 Engine Stand Adapter Mounts To The Engine PU 50562 Engine Stand Sleeve Adapter Us...

Page 158: ...ing temperature 2 Remove the spark plug from the cylinder being tested WARNING Use caution when removing the spark plug as the engine will be hot 3 Turn the engine over by hand until the piston in tha...

Page 159: ...on Piston Rings Cylinder Wall Intake Valve s Exhaust Valve s Valve Seat s Pay close attention during testing air that can be heard or felt is the best indication of where the leak is originating Sympt...

Page 160: ...he oil pressure adapter Torque the adapter to specification TORQUE Oil Pressure Gauge Adapter PU 52492 22 ft lbs 30 Nm 5 Start engine and allow it to reach operating temperature monitoring gauge indic...

Page 161: ...3 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 3 7 ENGINE OIL FLOW CHART ENGINE COOLING SYSTEM...

Page 162: ...te at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unleaded fue...

Page 163: ...Cylinder Out of Round Limit 001 0 025 mm Cylinder Taper Limit 001 0 025 mm Cylinder to Piston Clearance 0009 0019 0 025 0 050 mm Cylinder Head Cylinder Head Surface Warp Limit 0039 0 1 mm Cylinder Hea...

Page 164: ...I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D 1 6140 1 6143 40 996 41 004 mm 1 6129 40 970 mm G Marking Main Journal O D 1 6137 1 6140 40 988 40 995 mm 1 6129 40 970 mm Y Ma...

Page 165: ...REPLACEMENT Special Tool PU 52493 allows the replacement of the engine crankshaft PTO seal without splitting the engine case IMPORTANT PU 52493 does NOT work with 2017 and older models REMOVAL 1 Remov...

Page 166: ...the seal is critical Install the seal with the flat side of the seal facing out as shown 2 Tighten the drive bolt e until the cylinder r bottoms out against the crankcase 3 Once the seal is properly...

Page 167: ...seat and disconnect the negative battery cable from the battery 5 Remove the cargo box Refer to Cargo Box Removal page 11 62 procedure 6 Remove the air box assembly Refer to Intake Removal page 3 73...

Page 168: ...o to the muffler Remove exhaust head pipe towards the front of the vehicle Discard exhaust gaskets a 18 Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose g an...

Page 169: ...damage to vehicle components 23 Remove the starter motor bolts 2 and starter motor from the engine 24 Remove the six transmission joint bracket bolts 2 and transmission joint bracket 2 from the engin...

Page 170: ...cation in sequence TORQUE Starter Motor Bolts 7 lb ft 10 Nm Trans Joint Bracket Bolts 44 lb ft 60 Nm 4 Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the...

Page 171: ...hole number 4 on the Drive clutch side and hold number 4 on the Driven Clutch 8 Loosen the two bolts t retaining transmission joint bracket to the transmission on the right side 9 Align the front tra...

Page 172: ...er hose to the crankcase 21 Install the spark plug wires to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals NOTICE Ensure plug wires caps are pushed down all the way so...

Page 173: ...er complete engine disassembly Check level after filling and add oil as needed Refer to Engine Oil and Filter Change page 2 28 procedure 33 Bleed the cooling system Refer to Cooling System Bleeding pa...

Page 174: ...t anything from falling into the combustion chamber CAMSHAFT REMOVAL NOTICE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the PTO cylinder is at Top Dead...

Page 175: ...amshafts to allow each sprocket to be removed 8 Using a paperclip or other tool hold cam chain up to keep it from falling down into the crankcase NOTICE The crankcase has a built in lower guide to pre...

Page 176: ...part is worn past the service limit MEASUREMENT Camshaft Lobe Height Intake 1 5390 1 5429 39 09 39 19 mm Service Limit 1 5370 39 04 mm Exhaust 1 5142 1 5181 38 46 38 56 mm Service Limit 1 5122 38 41...

Page 177: ...1 mm CYLINDER HEAD REMOVAL NOTICE The cylinder head can be serviced with the engine installed in the chassis 1 Remove the two outer M6 bolts q that retain the cylinder head w to the cylinder 2 Loosen...

Page 178: ...and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head MEASUREMENT Cylinder Head Warp Limit 0...

Page 179: ...Lift up the cylinder head and push the valve i out keeping it in order for reassembly in the same valve guide 7 Repeat the previous steps to remove the remaining valves 8 Clean the combustion chamber...

Page 180: ...uide I D 2165 2171 5 500 5 515 mm 7 Be sure to measure each guide and valve combination individually NOTICE The valve guides cannot be replaced COMBUSTION CHAMBER CLEANING WARNING Wear eye protection...

Page 181: ...shield during cylinder head disassembly and reassembly Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions exi...

Page 182: ...ngle 46 apply black permanent marker to the entire valve face q 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Blue indicates seat c...

Page 183: ...h clean engine oil and apply oil or water based lapping compound to the face of the valve NOTICE Lapping is not required if an interference angle reconditioning method is used 10 Insert the valve into...

Page 184: ...eel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury c...

Page 185: ...d oil cooler Leave them all attached to the water pump housing 2 Remove the three long gold colored bolts q retaining the water pump housing to the engine 3 Remove the water pump assembly from the eng...

Page 186: ...rviced with the engine installed in the chassis 7 Remove the stator cover and flywheel see Chapter 3 Stator Cover Removal Inspection page 3 30 8 Place flywheel on a work bench with the one way clutch...

Page 187: ...way clutch component is worn or damaged replace the clutch and starter gear as an assembly CRANKCASE DISASSEMBLY INSPECTION 1 Remove the four screws retaining the oil cooler q to the crankcase 2 Remov...

Page 188: ...ee bolts o that retain the oil pump a to the crankcase 10 Use one of the oil pump retaining bolts or a pen magnet to extract the dowel pins s from the oil pump Doing so allows for oil pump removal wit...

Page 189: ...oil pump seal f during crankcase assembly NOTICE Oil pump assembly is non serviceable 13 Rotate the engine so the cylinder is facing up 14 Remove the eleven M6 g and two M8 h upper crankcase bolts 15...

Page 190: ...n assembly 3 Carefully rotate the balance shaft w and remove it from the crankcase 4 Inspect the balance shaft gear teeth for damage 5 Measure each bearing journal in two locations 90 degrees apart Re...

Page 191: ...he crankcase 6 Remove the cam chain e oil pump drive chain t and PTO main seal r from the crankshaft 7 Inspect the crankshaft gear u and auxiliary sprocket y for broken or worn teeth 8 If the cranksha...

Page 192: ...y CRANKSHAFT BEARING JOURNAL DIAMETERS B Main Bearing Standard 1 6140 1 6143 40 996 41 004 mm CRANKSHAFT BEARING JOURNAL DIAMETERS Service Limit 1 6129 40 970 mm Conn Rod Bearing Standard 1 6118 1 612...

Page 193: ...he crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case Refer to bearing selection procedures upon assembly NOTICE Always replace plain bearings when the crank...

Page 194: ...m CYLINDER PISTON REMOVAL IMPORTANT Pistons must be removed from the cylinders with the connecting rods attached DO NOTattempt to service the cylinder or pistons without disassembling the crankcase Al...

Page 195: ...be placed in either cylinder 1 Note location of the piston circlip gap q at the top 12 00 position or bottom 6 00 position 2 Remove piston circlip and push piston pin out of piston If necessary heat t...

Page 196: ...pand ring and lift it off the piston By hand Placing both thumbs on the ring ends spread the ring open and push up on opposite side Do not scratch ring lands 2 Repeat procedure for second compression...

Page 197: ...the rings MEASUREMENT Piston Ring Installed Gap Top Ring 010 014 0 25 0 35 mm Service Limit 1 6118 1 6122 40 942 40 950 mm Second Ring 1 6118 1 6122 40 942 40 950 mm Service Limit 028 0 70 mm Oil Cont...

Page 198: ...lling of surface or pitting 4 Measure small end I D in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service limit specification MEA...

Page 199: ...CTION CHART ROD BEARINGS CONNECTING ROD BIG END BORE DIAMETERS 1 2 3 1 7318 1 7321 43 989 43 996 mm 1 7321 1 7323 43 996 44 003 mm 1 7323 1 7326 44 003 44 010 mm 10 Whether using new connecting rods o...

Page 200: ...LETTERS AND NUMBERS q Connecting Rod Bearing Identification Number one number w Crankcase Bearing Identification Number six numbers Some engines may only have 4 digits The extra two digits will refer...

Page 201: ...ankshaft Rod Code B G Y 1 Blue Blue Green 2 Blue Green Yellow 3 Green Yellow Yellow CRANKSHAFT MAIN BEARING SELECTION In order to select the proper main bearings for the crankshaft you must reference...

Page 202: ...rough the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before ass...

Page 203: ...d ring with marking facing top of piston Rotate ring to position the end gap toward intake side of piston as shown below 5 Install top ring with mark facing top of piston Rotate ring to position the e...

Page 204: ...ods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is recommended they be i...

Page 205: ...Chapter 3 Piston Ring Installation page 3 48 3 Note the piston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side NOTICE Orientation arrow is also located...

Page 206: ...3 Crankshaft Main Bearing Selection page 3 47 and Connecting Rod Bearing Selection page 3 47 1 Rotate the engine so the cylinder is facing down 2 Clean the bearing bore surfaces of upper crankcase ma...

Page 207: ...Carefully lower the crankshaft into upper crankcase Guide connecting rods onto the rod journals of crankshaft as necessary 10 Adjust the PTO crankshaft seal so it rests properly in the upper crankcase...

Page 208: ...lace plain bearings when the crankcase or connecting rods have been disassembled Refer to bearing selection procedures 1 Remove all traces of crankcase sealant from the crankcase mating surfaces Inspe...

Page 209: ...any oil 5 Apply a thin continuous film of Crankcase Sealant PN 2871557 to upper crankcase mating surface e as shown Do not allow sealant to dry before assembly NOTICE DO NOT block oil passages r with...

Page 210: ...t lbs 12 N m 11 Rotate the engine so the cylinder is facing up 12 Install the eleven M6 o and two M8 i upper crankcase bolts Tighten all bolts lightly by hand 13 Torque the upper crankcase bolts in se...

Page 211: ...E Oil Pump Pick Up Retaining Screws 7 ft lbs 10 N m 20 Clean the gasket sealing surfaces on oil sump cover and crankcase to remove old gasket material and any oil NOTICE Gasket surfaces must be DRY an...

Page 212: ...ation page 3 59 and then Cylinder Head Installation page 3 61 STARTER ONE WAY CLUTCH ASSEMBLY 1 Install one way clutch in clutch hub with flange of clutch q engaged in recess 2 Clean screw threads in...

Page 213: ...lywheel seating it fully on taper 6 Install flywheel retaining bolt q Using a commercially available strap wrench hold flywheel w and torque the retaining bolt to specification NOTICE If the Cylinder...

Page 214: ...NT Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring e and retainer r in clean engine oil 6 Install the valve spring with widely spaced...

Page 215: ...olding Camshaft Timing Plate PU 50563 q from the cylinder NOTICE Once the cylinder head is removed nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holdin...

Page 216: ...op Dead Center TDC mark q is aligned or centered in the Crankshaft Position Sensor CPS mounting hole w This places the PTO cylinder at TDC for camshaft installation NOTICE DO NOT use the V mark locate...

Page 217: ...s engaged with the drive sprocket on the crankshaft 10 While lifting the cam chain up engage the cam sprockets into the chain with the I and E marks facing out 11 Install the sprockets onto the camsha...

Page 218: ...er Holding Camshaft Timing Plate PU 50563 from the end of the camshafts 16 Rotate the engine using the flywheel and install the remaining bolt in each camshaft sprocket Torque the sprocket bolts to sp...

Page 219: ...ONLY Install the cam chain tensioner s into the cylinder and torque to specification TORQUE Hydraulic Cam Chain Tensioner 15 ft lbs 20 N m 23 MECHANICAL TENSIONER ONLY Retract the plunger all the way...

Page 220: ...K REFERENCE q Intake Cam r Align marks with surface w Exhaust Cam t CPS Mounting Hole e Align marks with surface y Align Flywheel Mark in Mounting Hole IMPORTANT DO NOT use the V mark located on the f...

Page 221: ...rrier openings should face each other when installed properly 5 Install the four bolts r that retain each rear camshaft carrier t and tighten the bolts evenly to specification TORQUE Camshaft Carrier...

Page 222: ...et number 13 Refer to the appropriate tappet selection matrix Intake or Exhaust on the following pages and select the proper tappet 14 Install the proper tappet 15 Repeat steps 10 14 until all necessa...

Page 223: ...ecification and Measured Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3 dig...

Page 224: ...k plugs q and torque to specification 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Install valve cover seal w 5 Install the four valve cover shoulder bolts e a...

Page 225: ...ose Clamp 24 lb in 3 Nm s Plastic Push Rivet e Drain Plug d Intake Duct Hose r Engine Vent Hose f Front Intake Duct t Spring Band Clamp g Air Box In Intake Duct y Air Box Fastener 3 5 lb ft 4 7 Nm h A...

Page 226: ...ke Duct Hose e Drain Plug f Front Floor Intake Duct r Engine Vent Hose g Intake Duct Hose t Spring Band Clamp h Front Intake Duct y Air Box Fastener 3 5 lb ft 4 7 Nm j Air Box In Intake Duct u Air Box...

Page 227: ...pper close off panel and the frame of the vehicle 5 Remove the clamp holding the air box intake duct to the air box assembly Remove the air box and engine intake hose assembly from the vehicle 6 Eleva...

Page 228: ...rque to specification TORQUE Intake Duct Clamps 24 lb in 3 Nm 3 Install the hood onto the vehicle Refer to Hood Installation page 11 76 procedure 4 With the skid plate removed install the floor intake...

Page 229: ...5 lb ft 4 7 Nm 8 Install the clamp holding the engine crankcase breather hose to the engine Refer to Engine Crankcase Breather Hose Inspection page 2 29 procedure 9 Remove clean cloth in Electronic Th...

Page 230: ...i Silencer Asm w Headpipe Fasteners 18 lb ft 24 Nm o Outer Silencer Shield Fasteners 10 ft lbs Nm e Oxygen Sensor 13 lb ft 18 Nm a Washer r Spring s Outer Silencer Shield t Isolator Mount d Exhaust S...

Page 231: ...olding the silencer to the vehicle 6 Remove the exhaust assembly out the RH side of the vehicle EXHAUST INSTALLATION 1 Install the exhaust assembly in the RH side of the vehicle 2 Install the fastener...

Page 232: ...8 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 Install the spring holding the silencer to the vehicle 6 Lower the cargo box and secure in position ENGINE COOLING SYS...

Page 233: ...E COOLING SYSTEM ASSEMBLY VIEW q Thermostat housing y Filler Neck s Oil Cooler Inlet Hose w Water Pump u Radiator d Oil Cooler Outlet Hose e Engine Hoses i Pressure Cap f Bypass Hose r Lower Radiator...

Page 234: ...GENERAL GENERAL XP Service Manual Copyright Polaris Inc COOLANT HOSE ROUTING RETENTION 2 SEAT HOT SIDE Coolant hose is secured in location q as shown Coolant hose is secured in four locations q as sh...

Page 235: ...0067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 3 81 Coolant hose is secured in location q as shown COLD SIDE Coolant hose is secured in location q as shown ENGINE COOLING S...

Page 236: ...82 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc Coolant hose is secured in four locations q as shown Coolant hose is secured in location q as shown ENGINE COOLING SYST...

Page 237: ...NERAL GENERAL XP Service Manual Copyright Polaris Inc 3 83 COOLANT HOSE ROUTING RETENTION 4 SEAT HOT SIDE Coolant hose is secured in location q as shown Coolant hose is secured in six locations q as s...

Page 238: ...9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc Coolant hose is secured in location q as shown COLD SIDE Coolant hose is secured in location q as shown ENGINE COOLING SY...

Page 239: ...850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 3 85 Coolant hose is secured in six locations q as shown Coolant hose is secured in location q as shown ENGINE COOLING SYST...

Page 240: ...P Service Manual Copyright Polaris Inc COOLANT OVERFLOW LINE ROUTING RETENTION TOP VIEW Coolant overflow line is secured in two locations q as shown BOTTOM VIEW Coolant overflow line is secured in six...

Page 241: ...0 50 Extended Life Anti freeze 2880514 quart 2880513 gallon RECOMMENDED COOLANT Use only high quality antifreeze coolant mixed with distilled water in a 50 50 or 60 40 ratio depending on freeze protec...

Page 242: ...e cap tester commercially available 3 The pressure cap relief pressure is 13 psi Replace cap if it does not meet this specification COOLING SYSTEM HOSE REPLACEMENT 1 Inspect cooling system hoses for c...

Page 243: ...cool before servicing 4 Disconnect cooling fan electrical connector 5 Remove the upper radiator hose from the radiator 6 Remove the four upper radiator support fasteners w and disconnect the small ra...

Page 244: ...w retaining the thermostat cover 6 Remove the cargo box access panel 7 Using an 8 mm swivel socket and long extension remove the front bolt e retaining the thermostat cover 8 Lift the cover from the h...

Page 245: ...Polaris Premium Antifreeze to the radiator filler neck 5 Remove the seats engine service panel and divider panel heat shield to access the coolant bleed screw 6 Open the bleed screw e to allow any tr...

Page 246: ...hat are attached to the water pump Note location and routing for installation Be sure to catch and dispose of coolant properly 11 Remove the three bolts q w retaining water pump to engine block Note d...

Page 247: ...nstall the three water pump mounting bolts t y and torque to specification NOTICE Install different bolt lengths as shown TORQUE Water Pump Mounting Bolts 7 lb ft 10 Nm Apply Loctite 204 to bolt threa...

Page 248: ...shaft 6 Using an appropriate arbor press properly support the water pump housing and press out the water pump shaft from the impeller side 7 Extract the mechanical seal and the oil seal from the wate...

Page 249: ...4 to the threads of the impeller bolt Install washer and impeller bolt and torque to specification TORQUE Water Pump Impeller Bolt 7 lb ft 10 Nm Apply Loctite 204 to bolt threads 18 Clean cover q and...

Page 250: ...ENERAL XP Service Manual Copyright Polaris Inc WATER PUMP ASSEMBLY VIEW o Bolt f Washers k Oil Seal a Loctite 204 g Drive Tab l Impeller s Mechanical Seal h Water Pump Shaft 1 Washer d O Rings j Water...

Page 251: ...ERATION OVERVIEW 4 7 ETC TEST 4 7 ETC REPLACEMENT 4 7 ETC LEARN PROCEDURE 4 8 ACCELERATOR POSITION SENSOR APS 4 9 APS OPERATION OVERVIEW 4 9 APS TEST 4 9 APS REPLACEMENT 4 9 HEATED OXYGEN SENSOR O2 4...

Page 252: ...o prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit is exceeded the ECU suppresses the injection signals cutting off the fuel f...

Page 253: ...ift the connector locking lever and rotate it up until the connector is free from the ECU NOTICE Upon removing the ECU connector you should hear a click when the connector is fully open 5 To install r...

Page 254: ...e Speed Limiting Device ASLD function allows the rider to limit the maximum speed that the vehicle can achieve When a vehicle is operated past the set speed the ECU will limit the fuel supply to the e...

Page 255: ...ol of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected...

Page 256: ...the vehicle 2 Disconnect the CPS harness connector 3 Remove CPS retaining bolt q and remove the sensor w from the stator cover 4 Remove CPS wire lead from wire clip e 5 Install new sensor using a ligh...

Page 257: ...tampered with in any way All operating and control functions within the ETC are pre set No internal servicing or adjustments may be performed If a problem is encountered and you determine the ETC to...

Page 258: ...RTANT This procedure MUST be performed on the vehicle whenever the ECU is replaced or reflashed or the throttle body is replaced 1 After the reflash ECU replacement throttle body change leave the key...

Page 259: ...izing Digital Wrench by verifying that the throttle position readout varies as the pedal is pressed Reference the Data Display section and be sure Throttle Position is displayed Throttle Position shou...

Page 260: ...h First verify if there are any stored codes for the oxygen sensor NOTICE The ECU must first run though the O2 sensor time delay before a trouble code will be set This may take several minutes at idle...

Page 261: ...compared to its programming for determining the fuel and ignition requirements during engine operation The T MAP provides the ECU with engine load data T MAP TEST The T MAP is a non serviceable item...

Page 262: ...on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly 2 If not test resistance across sensor terminals ECT Resistance 77 F...

Page 263: ...t primary coil windings When the ECU commands the IC circuit OFF this will interrupt current flow through the primary coil windings The magnetic field created by the primary coil windings will collaps...

Page 264: ...ith an extension 6 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead spar...

Page 265: ...CARBON CANISTER REPLACEMENT 5 9 PURGE VALVE REPLACEMENT 5 10 PURGE VALVE OHM TEST 5 10 FUEL LINES 5 11 FUEL LINE ROUTING 5 11 FUEL LINE ROUTING GENERAL 4 5 13 FUEL LINE ROUTING EVAP MODELS 5 15 FUEL L...

Page 266: ...s a known good ECU from another POLARIS of the same model and year may be used without damaging system or engine components Never attempt to service any fuel system component while engine is running o...

Page 267: ...emains under high pressure even when the engine is not running Before attempting to service any part of the fuel system pressure should be relieved The Fuel Pressure Gauge Kit has an integrated pressu...

Page 268: ...MBLY VIEWS FUEL SYSTEM FUEL SYSTEM ASSEMBLY VIEW q Fuel Tank u Harness Clip w a PFA Nut 70 lb ft 95 Nm i Fuel Vent Line e Fuel Pump Assembly o Fuel Feed Line r Fuel Fill Neck and Fuel Cap a Routing Cl...

Page 269: ...ter 2 Vent Line Termination Fitting r PFA Nut 70 lb ft 95 Nm f Carbon Canister to Canister Filter Line 2 Purge Valve Fasteners 72 in lbs 8 Nm t Routing Clip g Carbon Canister Filter 2 Purge Valve Brac...

Page 270: ...0 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc FUEL PUMP ASSEMBLY VIEW q Fuel Pump r Fuel Level Sensor w Fuel Pressure Regulator t Float Arm Assembly e Wire Harness Connector y Pickup...

Page 271: ...to the charcoal canister and the ATM side is the end where air enters first If the air filter becomes plugged or restricted fuel vapors will not properly flow through the air filter to the charcoal ca...

Page 272: ...NOT trigger a trouble code but may cause a fuel odor Excessive hydrocarbon emissions may be caused by any of the following An ignition misfire Improper ignition timing Excessively lean or rich air fue...

Page 273: ...the removal procedure TORQUE Carbon Canister Filter Fasteners 72 in lbs 8 Nm 7 Reinstall rear lower close off panel and center council Reference page 11 63 8 Reinstall seats See page 11 76 CARBON CANI...

Page 274: ...e valve electrical connector w 5 Remove purge valve from the bracket 6 Install new purge valve onto its bracket 7 Installation is performed by reversing the removal procedure 8 Reinstall rear lower cl...

Page 275: ...01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 11 FUEL LINES FUEL LINE ROUTING FUEL FEED LINE ROUTING q Fuel Pump Assembly e Harness Clip Interlock w Routing Clip r Fuel Rail F...

Page 276: ...R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc FUEL VENT LINE ROUTING q Fuel Vent r Routing Clip Hinged w Routing Clip t Vent Line Termination Fitting e Harness Clip Interlock...

Page 277: ...5 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 13 FUEL LINE ROUTING GENERAL 4 FUEL FEED LINE ROUTING q Routing Clip w Harness Clip e Fuel Rail Fitting FUEL SYSTEM...

Page 278: ...5 14 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc FUEL VENT LINE ROUTING q Routing Clip w Harness Clip e Routing Clip Hinged r Vent Termination Fitting FUEL SYSTEM...

Page 279: ...R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 15 FUEL LINE ROUTING EVAP MODELS FUEL FEED LINE ROUTING q Fuel Pump Assembly e Panduit Strap w Routing Clip Hinged r Fuel Rail F...

Page 280: ...5 16 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc PURGE LINE ROUTING FUEL SYSTEM...

Page 281: ...0067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 17 q Fuel Vent t Purge Valve w Routing Clip Hinged y Panduit Strap e Carbon Canister u Throttle Body r Panduit Strap FUEL S...

Page 282: ...e Manual Copyright Polaris Inc FUEL VENT LINE ROUTING q Fuel Vent t Canister Filter w Routing Clip Hinged y Panduit Strap e Carbon Canister u Routing Clip Hinged r Carbon Canister to Canister Filter 5...

Page 283: ...020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 19 FUEL LINE ROUTING GENERAL 4 EVAP MODELS FUEL FEED LINE ROUTING q Fuel Pump Assembly e Panduit Strap w Routing Clip Hinged r Fuel R...

Page 284: ...5 20 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc PURGE LINE ROUTING FUEL SYSTEM...

Page 285: ...0067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 5 21 q Fuel Vent t Purge Valve w Routing Clip Hinged y Panduit Strap e Carbon Canister u Throttle Body r Panduit Strap FUEL S...

Page 286: ...e Manual Copyright Polaris Inc FUEL VENT LINE ROUTING q Fuel Vent t Canister Filter w Routing Clip Hinged y Panduit Strap e Carbon Canister u Routing Clip Hinged r Carbon Canister to Canister Filter 5...

Page 287: ...small straight blade screwdriver Screwdriver Method 1 Insert a 1 flat blade screw driver into the pry slot on the top of the retaining clip IMPORTANT To prevent damage to the retaining clip be sure t...

Page 288: ...essure 4 Quick connect has been twisted from its original inserted position or the connector has been damaged FUEL LINE REPLACEMENT WARNING Always wear safety goggles when working with high pressure o...

Page 289: ...NT LINE TERMINATION FITTING This fitting should be inspected and tested using a Mity Vac to ensure proper venting Connect the Mity Vac to the fitting and give it 5 pumps The gauge should return to 0 i...

Page 290: ...njected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length depending on the spe...

Page 291: ...ly 2 Be sure the engine has cooled enough to work on 3 Used compressed air to remove any debris from around fuel injectors WARNING Always wear safety glasses and proper shop clothing when performing t...

Page 292: ...to check if the injectors are operating With the engine running at idle feel for operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buz...

Page 293: ...ng the battery bracket and remove the battery from the vehicle 3 If equipped pull up the rubber fuel pump cover when disconnecting the fuel line and electrical connectors 4 While holding a shop towel...

Page 294: ...orque fasteners to specification TORQUE Close off Panel Fasteners 3 5 lb ft 5 Nm 5 Reinstall center console Connect the shift linkage to the shifter 6 Install RH and LH center console sides Torque fas...

Page 295: ...situations the check engine light will illuminate but turn off after 4 cranking revolutions if the system functions properly Once the engine is running the fuel pump remains on to maintain fuel pressu...

Page 296: ...he system pressure on the gauge If system pressure within specification is observed the ignition switch ECU fuel pump and pressure regulator are working properly Turn the key switch off and depress th...

Page 297: ...e to clean area around fuel pump may lead to debris entering the fuel tank during service Excessive debris in fuel tank may cause premature wear of fuel pump and or clogging of internal fuel filters 4...

Page 298: ...flashlight and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly NOTICE It is recommended to remove the fuel tank...

Page 299: ...uel tank 19 Torque nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench TORQUE Fuel Pump Nut 70 lb ft 95 Nm 20 Verify alignment of fuel pump orientation marks...

Page 300: ...5 36 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES FUEL SYSTEM...

Page 301: ...PVT SYSTEM 6 5 PVT COVERS DUCT ASSEMBLY VIEW GENERAL 6 5 PVT COVERS DUCT ASSEMBLY VIEW GENERAL 4 6 6 INNER CLUTCH COVER ASSEMBLY VIEW 6 7 PVT SYSTEM SERVICE 6 8 PVT DISASSEMBLY 6 8 PVT ASSEMBLY 6 9 D...

Page 302: ...ft During the development of the Polaris vehicle the PVTsystem is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or...

Page 303: ...Color Black Red Drive Clutch Spring Free Length 3 219 in 8 18 cm Drive Clutch Spring Part Number CREW 7044465 Drive Clutch Spring Color CREW Black Drive Clutch Spring Free Length CREW 3 75 in 9 52 cm...

Page 304: ...tional governor does the PVTsystem changes engine load requirements by either upshifting or backshifting PVT BREAK IN A proper break in of the clutches and drive belt will ensure a longer life and bet...

Page 305: ...ain Screw s Inner Clutch Cover e Intake Hose Bracket Fastener 3 5 lb ft 4 7 Nm d Slotted Hose Clamp 35 in lbs 8 Nm r Intake Hose Bracket f Outlet Hose t Outer Clutch Cover Fasteners 4 5 lb ft 6 Nm g B...

Page 306: ...h Cover e Intake Hose Bracket Fastener 3 5 lb ft 4 7 Nm d Slotted Hose Clamp 35 in lbs 8 Nm r Intake Hose Bracket f Outlet Hose t Outer Clutch Cover Fasteners 4 5 lb ft 6 Nm g Belt Screen Bracket y Ho...

Page 307: ...is Inc 6 7 INNER CLUTCH COVER ASSEMBLY VIEW q Inner Clutch Cover t Air Inlet Clutch Duct w Inner Cover Seal y Air Inlet Outlet Clutch Duct Fasteners 6 lb in 0 7 Nm e Clutch Cover Shield u Air Outlet C...

Page 308: ...ining bolt and driven clutch 8 Install the Drive Clutch Holding Tool on the drive clutch Drive Clutch Holding Tool 9314177 A 9 Remove the drive clutch retaining bolt and remove the drive clutch using...

Page 309: ...ll the protective cover and the fasteners that secure the cover to the top of the inner PVTcover 7 Install the four inner clutch cover bolts and washers that retain the cover to the transmission Torqu...

Page 310: ...belt rotation refer to Drive Belt Installation page 6 12 procedure If a new belt is installed install so numbers can be easily read 16 Install a new outer clutch cover seal with the colored stripe fac...

Page 311: ...luded with vehicle s tool kit NOTICE Make sure the tool is square with the moveable sheave surface of the driven clutch Clutch Spreader Tool 2878925 5 Rotate tool towards the clutch to open the sheave...

Page 312: ...er the drive clutch and over the driven clutch Clutch Spreader Tool 2878925 2 Rotate the driven clutch and walk the belt into the clutch 3 Remove the clutch spreader tool from driven clutch 4 Rotate s...

Page 313: ...ing Needle s Asm Roller and Bushing washer e Bearing d Nut Jam 250 ft lbs 339 N m Apply 0 1 mL Loctite 7088 Primer and 0 1 mL Loctite 620 r Spacer Clutch Short f Spring Clutch t Bolt Shoulder g Cover...

Page 314: ...bly IMPORTANT Upon reassembly if the reference marks created in step 2 are not in alignment the clutch will not be in balance and the assembly MUST be replaced 3 Remove cover bolts evenly in a cross p...

Page 315: ...components of the PVT system It is also one of the easiest to service Due to the severe relaxation the spring is subject to during operation it should always be inspected for tolerance limits during...

Page 316: ...ew bolts and nuts WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTICE A damaged shift weight is usually caused by a damaged...

Page 317: ...re PN 2871358 B 2 Loosen and remove the spider e counterclockwise using Clutch Spider Removal Installation Tool r Spider Removal Installation Tool 2870341 A ROLLER PIN AND THRUST WASHER INSPECTION 1 I...

Page 318: ...hers w off the shaft Replace as an assembly if worn damaged or if operational problems were noted prior to disassembly 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diam...

Page 319: ...LUTCH BUSHING TOOL KIT 2201379 ITEM QTY PART TOOL DESCRIPTION A B 1 5132027 EBS Puller Tool C 1 5132501 EBS Puller Nut D 1 5132029 EBS Main Adapter E 1 5132028 EBS Bushing Removal Tool Instructions 1...

Page 320: ...uller 2870386 3 Remove nut from puller rod and set aside 4 Install puller adapter a from kit PN 2871226 5 Install main adapter Item D onto puller 6 With towers pointing toward the vise slide sheave on...

Page 321: ...e tension as needed 27 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 28 Remove nut from puller rod and set aside 29 Remove bushing and bushing removal...

Page 322: ...nto the shaft threads Be sure all of the alignment marks i are in alignment t Moveable Sheave Asm y Jam Nut u Spider 6 Install clutch onto holding fixture and secure in a bench vise Tighten the spider...

Page 323: ...lutch assembly from the holding fixture and inspect the alignment marks made during disassembly NOTICE If the marks illustrated below are not in alignment upon assembly the clutch will not be in balan...

Page 324: ...right Polaris Inc DRIVEN CLUTCH SERVICE DRIVEN CLUTCH ASSEMBLY VIEW q Shoulder Sleeve i Spring w Bearing o Spider e Spring Pin a Roller r Slider s Washer t Slider Pin d E clip y Stationary Sheave f He...

Page 325: ...he screwdriver from the driven clutch Insert the driven clutch retaining bolt to keep the washers aligned during clutch installation 5 Reinstall the driven clutch and drive belt 6 Test the vehicle to...

Page 326: ...g a proper compressor may result in personal injury or damage to the clutch 5 Remove the universal clutch compressor 6 Note the alignment of the X s w on the spider and moveable sheave Remove the spid...

Page 327: ...fixed sheaves for reassembly 11 Inspect the clutch bushings for wear If there is heavy wear on the bushings replace the clutch assembly 12 Inspect the sheaves for excessive wear or damage DRIVEN CLUTC...

Page 328: ...utch and compress the helix cover CAUTION The helix cover is loaded by the spring Not using a proper compressor may result in personal injury or damage to the clutch 8 Align the marks previously made...

Page 329: ...ge measure the distance between the slider and the stationary sheave at the widest point q If the measurement is over the service limit the sliders or driven clutch will need to be replaced Also measu...

Page 330: ...6 30 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES PVT SYSTEM...

Page 331: ...EVER REPLACEMENT 7 9 SHIFT CABLE INSPECTION 7 9 SHIFT CABLE ADJUSTMENT 7 9 ASSEMBLY VIEWS TRANSMISSION 7 11 TRANSMISSION ASSEMBLY VIEW 7 11 TRANSMISSION MOUNTING TORQUE VALUES 7 12 TRANSMISSION VENT L...

Page 332: ...ial is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain SPECIAL TOOLS TRANSMISSION TOOL DESCRIPTION PART...

Page 333: ...s Inc 7 3 SHIFT CABLE SERVICE SHIFT LEVER CABLE ASSEMBLY VIEW GENERAL q Shift Lever t Shift Cable Nut 13 lb ft 18 Nm w Shifter Boot y Rear Shifter Cable Jam Nut 13 lb ft 18 Nm e Front Shifter Cable Ja...

Page 334: ...7 4 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc SHIFT CABLE ROUTING GENERAL TRANSMISSION...

Page 335: ...cure the jam nut w in the shifter mount bracket 2 Continue to route the shift cable rearward and secure the cable in the notch of the airbox intake duct e 3 Route the shift cable under the coolant hos...

Page 336: ...olaris Inc SHIFT LEVER CABLE ASSEMBLY VIEW GENERAL 4 q Shift Lever y Rear Shifter Cable Jam Nut 13 lb ft 18 Nm w Shifter Boot u Hose Clamp e Front Shifter Cable Jam Nut 18 lb ft 24 Nm i Bushing r Shif...

Page 337: ...7 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 7 7 SHIFT CABLE ROUTING GENERAL 4 TRANSMISSION...

Page 338: ...he shift cable rearward and secure the cable with a hose clamp e to the front seat base bracket in the notch of the airbox intake duct r 3 Route the shift cable rearward and secure in the notch of the...

Page 339: ...PECTION Shift cable adjustment may be necessary if symptoms include No gear position or incorrect gear position shown AWD light displayed on instrument cluster Ratcheting noise on deceleration Inabili...

Page 340: ...so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the lower jam nut to the bracket face as required to obtain proper cable adjustment NOTICE This proc...

Page 341: ...Bearing Cover Fastener QTY 3 9 ft lbs 12 Nm e Drain Plug Magnetic 12 ft lbs 16 Nm a Ring Gear Fastener QTY 8 28 ft lbs 38 Nm r Fork Retainer Fastener 9 ft lbs 12 Nm s Bellcrank Nut 14 ft lbs 19 Nm t T...

Page 342: ...7 12 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc TRANSMISSION MOUNTING TORQUE VALUES TRANSMISSION...

Page 343: ...Inc 7 13 TRANSMISSION VENT LINE TRANSMISSION VENT LINE ROUTING The transmission vent line runs up towards the passenger frame rail and through an open section of the frame to a vent line termination f...

Page 344: ...ted and tested using a Mity Vac to ensure proper venting Connect the Mity Vac to the fitting and give it 5 pumps The gauge should return to 0 immediately or there is an obstruction NOTICE If the vent...

Page 345: ...red drain the transmission lubricant Refer to Transmission Lubrication page 2 39 procedure 6 Remove the upper mounting bolt from the LH and RH rear shocks Swing shock outward 7 Remove the outer clutch...

Page 346: ...ss from the T MAP sensor fuel injectors oxygen sensor ETC and rear differential solenoid q T Map Sensor r ETC w Fuel Injectors t Rear Differential Solenoid e Oxygen Sensor 13 Remove the five plastic t...

Page 347: ...nnector gear position switch connector and crankshaft position sensor connector q Vehicle Speed Sensor e Crankshaft Position Sensor w Gear Position Switch 18 Remove the plastic tie straps retaining th...

Page 348: ...ion to the engine 24 Remove the rear transmission isolator fastener 25 Remove the two fasteners retaining the rear isolator to the frame bracket Remove the mount assembly from the vehicle 26 Slide tra...

Page 349: ...he shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly This unlocks the rear differen...

Page 350: ...r Fasteners 28 ft lbs 38 Nm d Differential Carrier e Ring Gear f Engagement Dog r Thrust Washer g Bearing t Output Gear h Shift Fork Retainer Fastener 9 ft lbs 12 Nm y Differential Pin j Torsion Sprin...

Page 351: ...k w 4 Remove E clip e that retains spring washer r flat washer t and gear switch y Remove the switch 5 Remove the sector cover bolts u and remove the sector cover i NOTICE Removal can be aided by usin...

Page 352: ...rings h from each shaft and discard Use new O rings upon assembly 11 If equipped with parking brake disc INTL models only remove the parking brake disc fastener washer and disc from the transmission 1...

Page 353: ...ferential assembly 2 by lifting underneath the gear or by tapping the shaft from the opposite side If use of a pry bar is necessary take care not to pry on sealing surfaces of case 17 Remove the idler...

Page 354: ...mbly 2 straight up to remove it from the housing 23 Inspect all gear and shaft assemblies for damage 24 Check the bearings for damage and that they are easy to turn Replace any questionable bearings 2...

Page 355: ...aring a and sprocket s from the reverse shaft 4 Tilt the two shafts towards each other and remove the silent chain from the two shafts 5 If necessary disassemble the other end of the reverse shaft Rem...

Page 356: ...on case 4 Remove the snap ring e and shim r from the snorkel shaft 5 Use an arbor press to remove the snorkel tube from the snorkel shaft 6 Remove the snap ring t and shim y retaining the bearing in t...

Page 357: ...r to mark the differential carrier and ring gear q prior to disassembly 2 Remove eight fasteners w retaining the ring gear 3 Remove ring gear e thrust washer r and output gear t 4 Remove dowel pin fro...

Page 358: ...er 3 Place the pinion gears e into the carrier and slide the differential pin r into the carrier NOTICE Align the hole of the differential pin with the dowel pin hole in the carrier 4 Insert the dowel...

Page 359: ...7 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 7 29 6 Install eight fasteners i securing ring gear TORQUE Ring Gear Fasteners 28 ft lbs 38 Nm TRANSMISSION...

Page 360: ...ce Manual Copyright Polaris Inc GEAR SHAFT BEARING INSPECTION Inspect all of the gears shafts and bearings shown for excessive wear or damage IMPORTANT If gear replacement is required also replace the...

Page 361: ...sed onto the snorkel shaft flush to the shoulder install the washer and new retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged o...

Page 362: ...y as shown below Leave the longer locking screw A out at this point IMPORTANT DO NOT install the longer screw Installing the longer screw will lock the snorkel tube and not allow for backlash setting...

Page 363: ...l the locking screw 2 to secure the snorkel tube 16 Torque the locking screw to specification TORQUE Snorkel Locking Screw 9 ft lbs 12 Nm TRANSMISSION ASSEMBLY NOTICE The snorkel shaft and pinion shaf...

Page 364: ...u Reverse Shaft j Gear i Sprocket k Bearing o Needle Bearing 6 Install the idler shaft assembly r reverse shaft assembly t and input shaft assembly y into the transmission housing all at the same time...

Page 365: ...ed into the engagement dogs NOTICE Shift fork pins should be offset towards the input shaft as shown above 10 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 11 Ins...

Page 366: ...age completely 13 Apply a continuous bead of Loctite 680 Sealant to the left hand transmission mating surface Loctite 680 Sealant PN 3233901 14 Install the transmission case cover and retaining bolts...

Page 367: ...ent star 2 onto the shift drum shaft Be sure to install the detent star with the raised edge facing outward and skip tooth aligned 20 Install the detent pawl 2 onto the shift shaft and carefully insta...

Page 368: ...TORQUE Bellcrank Nut 14 ft lbs 19 Nm 27 Refer to Transmission Installation page to complete the repair TRANSMISSION INSTALLATION 1 With the help of an assistant position the transmission into the vehi...

Page 369: ...HICLE DESCRIPTION 1 2012 RZR 570 2 2011 14 RZR 900 2014 15 RZR XP 1000 2013 RANGER 900 3 2014 16 ACE 2015 19 ACE 570 2015 16 RGR ETX 2013 19 RZR 570 2014 19 RANGER 500 570 2015 19 RANGER 570 Full Size...

Page 370: ...s to specification using the numbered sequence shown 9 Torque right side mounting bolts to specification using the numbered sequence shown TORQUE Engine Transmission Mounting Bolts Step 1 2 64 lb ft 8...

Page 371: ...Speed Sensor e Crankshaft Position Sensor w Gear Position Switch 15 Ensure harness is properly routed and install the plastic tie straps retaining the harness to the transmission 16 Install and proper...

Page 372: ...Connect the T MAP sensor fuel injectors oxygen sensor ETC and rear differential solenoid q T Map Sensor r ETC w Fuel Injectors t Rear Differential Solenoid e Oxygen Sensor 20 Ensure harness is properl...

Page 373: ...nd outer clutch cover Refer to PVT Assembly page 6 9 procedure 26 Rotate RH LH rear shocks into position and install NEW upper fasteners Torque fasteners to specification TORQUE GENERAL GENERAL 4 Shoc...

Page 374: ...7 44 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES TRANSMISSION...

Page 375: ...T 8 18 DRIVE SHAFT SERVICE GENERAL GENERAL 4 8 20 FRONT DRIVE SHAFT REMOVAL 8 20 FRONT DRIVE SHAFT INSTALLATION 8 21 REAR DRIVE SHAFT REMOVAL 8 22 REAR DRIVE SHAFT INSTALLATION 8 23 DRIVE SHAFT CV JOI...

Page 376: ...L INSPECTION 8 52 REAR BEARING REPLACEMENT 8 53 REAR BEARING CARRIER INSTALLATION 8 54 FRONT GEARCASE SERVICE 8 55 ALL WHEEL DRIVE OPERATION 8 55 FRONT GEARCASE REMOVAL 8 56 FRONT GEARCASE DISASSEMBLY...

Page 377: ...ft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest SPECIAL TOOLS FINAL DRIVE TOOL DESCRIPTION PART NUMBER Roll Pin Removal Tool 2872608 Axle Boot Clamp Tool...

Page 378: ...GENERAL XP Service Manual Copyright Polaris Inc ASSEMBLY VIEWS FINAL DRIVE PROPSHAFT ASSEMBLY VIEW 2 SEAT q Grease Fitting r Fastener 33 lb ft 45 Nm w Asm Prop Shaft Rear t Asm Prop Shaft Front e Asm...

Page 379: ...rvice Manual Copyright Polaris Inc 8 5 PROPSHAFT ASSEMBLY VIEW 4 SEAT q Grease Fitting y U Joint w Asm Propshaft Rear u Asm Propshaft Center e Asm Bearing Flex i Asm Propshaft Front r Fastener 33 lb f...

Page 380: ...T ASSEMBLY VIEW FRONT DRIVE SHAFT q Asm Front Drive Shaft t Boot w Circlip y Clamp Small e Kit Boot Plunging Joint u Circlip r Clamp Large i Circlip REAR DRIVE SHAFT q Asm Rear Drive Shaft y Boot w Ci...

Page 381: ...ENERAL XP Service Manual Copyright Polaris Inc 8 7 DRIVE SHAFT ASSEMBLY VIEW INTL ABS MODELS FRONT DRIVE SHAFT INTL ABS Models q Outer Race y Cage w Clamp Large u Ball e Kit Boot i ABS Ring r Clamp Sm...

Page 382: ...R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc REAR DRIVE SHAFT INTL ABS Models q Outer Race y Cage w Clamp Large u Ball e Kit Boot i ABS Ring r Clamp Small o Circlip t Shaft F...

Page 383: ...eal s Ring Gear w Cover Plate d Spring e AWD Coil f Output Hub r Backlash Spacer g Bearing t Nylon Spacer h Gearcase Housing y Armature Plate j Drain Plug 10 ft lbs 14 N m u Roller Cage k Fill Check P...

Page 384: ...GENERAL GENERAL XP Service Manual Copyright Polaris Inc GEARCASE VENT LINE The front gearcase vent line routs vertically and into an open section of the frame REF Description q Hose Clamp w Vent Hose...

Page 385: ...to remove the roll pin Discard roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft 4 Slide the front propshaft q off the rear propshaft w and remove it from th...

Page 386: ...Removal Tool 2872608 to remove the roll pin Discard roll pin Push the front propshaft rearward to remove it from the front gearcase input shaft 4 Slide the front propshaft q off the center propshaft w...

Page 387: ...t NOTICE If necessary separate the support bearing to gain clearance NOTICE The rear of the propshaft must be angled and guided backwards to aid in clearing the mount 10 Angle the front of the propsha...

Page 388: ...aining rings q from both sides of the yoke 2 Using a commercially available Ball Joint U Joint Press Set place a receiving cup adapter w with a larger ID than the U joint cap OD on one end 3 Place a r...

Page 389: ...during installation 2 Ensure yoke bores and ring grooves are clean before installing new U joint 3 Place U joint ends w without caps into yoke bores 4 Place caps e into yoke bores and align with U jo...

Page 390: ...joint 13 Verify the U joint moves freely and does not bind PROPSHAFT INSTALLATION 2 SEAT 1 Lubricate front gearcase shaft splines with Anti Seize 2 Lubricate the transmission output shaft splines wit...

Page 391: ...llow ridge of the bearing should be facing upwards 8 When installing the front prop shaft onto the front gearcase use a new roll pin 9 Align the front prop shaft paint mark with the front gearcase inp...

Page 392: ...output shaft NOTICE If necessary separate the support bearing to gain clearance IMPORTANT Use care not to damage brake lines when installing propshafts 5 Lubricate the support bushing with light oil t...

Page 393: ...t mark so the pin holes align Install a new roll pin IMPORTANT Always use a new roll pin when installing the front propshaft onto the front gearcase Do not reuse roll pins 10 Torque the center and rea...

Page 394: ...e nut and cone washer e from the front wheel hub assembly NOTICE Some models may feature two cone washers 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from th...

Page 395: ...n the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper and lower ball joint ends into the front bearing carrier 5 Install NEW pinch...

Page 396: ...120 lb ft 163 Nm NOTICE Do not lubricate the stud or the lug nut 11 Rotate wheel and check for smooth operation REAR DRIVE SHAFT REMOVAL 1 Raise and support the vehicle CAUTION Serious injury may res...

Page 397: ...d lower control arms 7 With a short sharp jerk remove drive shaft from the transmission splines REAR DRIVE SHAFT INSTALLATION 1 Install NEW spring ring on drive shaft Apply an anti seize compound to t...

Page 398: ...o specification TORQUE Rear Upper Bearing Carrier Mounting Fastener 42 lb ft 57 Nm Rear Lower Bearing Carrier Mounting Fastener 40 lb ft 54 Nm 180 4 Apply Anti Seize to drive shaft axle splines 5 Inst...

Page 399: ...instructions is very important to ensure proper shaft function and a normal service life The complete drive shaft and joint should be handled by getting hold of the interconnecting shaft to avoid dis...

Page 400: ...nt to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure circlip w is on the shaft and not left in the joint 6 Rem...

Page 401: ...joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush wi...

Page 402: ...t of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the shaft 20 Install and tighten the small clamp r on the boot using the appropriate cla...

Page 403: ...t with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 8 Visually inspect the joint for damage Replace if needed 9 Clean the splin...

Page 404: ...xcess grease in the boot 18 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and tighte...

Page 405: ...e front wheel hub castle nut Remove the nut and cone washer from the front wheel hub assembly 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc...

Page 406: ...i seize compound to the splines 2 Align splines of drive shaft with front gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Instal...

Page 407: ...liper mounting bolts and torque to specification TORQUE Front Caliper Mounting Bolts 30 lb ft 41 Nm IMPORTANT New bolts have a pre applied locking agent which is destroyed upon removal Always use new...

Page 408: ...nd cone washer from the rear wheel hub assembly 4 Remove and discard the brake caliper mounting bolts Remove the rear brake caliper assembly from the brake disc Refer to Rear Brake Caliper Removal pro...

Page 409: ...splines and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary NOTICE Grab the drive shaft joint near the transmission and give a brief tug to en...

Page 410: ...Care should be exercised during drive shaft removal or when servicing CV joints Drive shaft components are precision parts Cleanliness and following these instructions is very important to ensure prop...

Page 411: ...int to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure circlip w is on the shaft and not left in the joint 6 Re...

Page 412: ...oint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush wit...

Page 413: ...st of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the shaft 20 Install and tighten the small clamp r on the boot using the appropriate cl...

Page 414: ...with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 8 Visually inspect the joint for damage Replace if needed 9 Clean the spline...

Page 415: ...excess grease in the boot 18 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and tight...

Page 416: ...he front wheel 4 Remove the cotter pin q and loosen the front wheel hub castle nut w Remove the nut and cone washer e from the front wheel hub assembly NOTICE Some models may feature two cone washers...

Page 417: ...p on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so b...

Page 418: ...the front bearing carrier Torque the tie rod end fastener to specification TORQUE Tie Rod End Fastener 30 lb ft 41 Nm 90 5 Apply Anti Seize to drive shaft axle splines 6 Install front wheel hub assemb...

Page 419: ...all a NEW cotter pin u Tighten nut slightly if necessary to align cotter pin holes Bend both ends of cotter pin around end of spindle in different directions TORQUE Wheel Hub Castle Nut 180 lb ft 244...

Page 420: ...he brake caliper mounting bolts Remove the rear brake caliper assembly from the brake disc Refer to Brake Caliper Removal Rear page 10 61 procedure IMPORTANT Do not hang the caliper by the brake line...

Page 421: ...e Replace rear bearing carrier if damaged BEARING INSTALLATION 1 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed f...

Page 422: ...nd hand tighten the castle nut NOTICE Some models may feature two cone washers 5 Install rear brake caliper assembly and NEW mounting bolts Torque to specification TORQUE Rear Caliper Mounting Bolts 4...

Page 423: ...caliper from the brake disc Refer to Front Brake Caliper Removal procedure IMPORTANT Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove th...

Page 424: ...or scratches wear or damage Replace front bearing carrier if damaged BEARING INSTALLATION 1 Thoroughly clean the front bearing carrier housing and the outer race on the new bearing Be sure that all oi...

Page 425: ...r 30 lb ft 41 Nm 90 5 Apply Anti Seize to drive shaft axle splines 6 Install front wheel hub assembly and cone washer q Install washer with domed side out Hand tighten the castle nut 7 Install NEW bra...

Page 426: ...heel hub assembly 5 Remove and discard the brake caliper mounting bolts Remove the rear brake caliper assembly from the brake disc Refer to Rear Brake Caliper Removal procedure IMPORTANT Do not hang t...

Page 427: ...e Replace rear bearing carrier if damaged BEARING INSTALLATION 1 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed f...

Page 428: ...hten the castle nut 5 Install rear brake caliper assembly and NEW mounting bolts Torque to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm IMPORTANT New bolts have a pre applied lockin...

Page 429: ...If AWD is engaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input whic...

Page 430: ...oval prior to front gearcase removal If the vehicle does not have a winch skip to step 10 3 Disconnect battery 4 Remove four fasteners q securing winch to mounting plate 5 Disconnect electrical wires...

Page 431: ...14 Disconnect the wire harness for the front gearcase and remove the harness from the retaining dart 15 Remove the vent line from the front gearcase and plug vent line fitting 16 Remove the four faste...

Page 432: ...les from the drain plug magnet 2 Remove the seven cover screws q and remove the cover plate w assembly 3 Remove the LH output hub assembly e from the clutch housing or outer cover plate assembly IMPOR...

Page 433: ...from the gearcase housing 7 Remove the RH output hub assembly i from the gearcase housing 8 Remove pinion seal o internal retaining ring a and pinion gear assembly s from the gearcase housing Inspect...

Page 434: ...The rollers must slide up and down and in and out freely within the roll cage j sliding surfaces and H springs NOTICE Refer to the Electronic Parts Catalog for individual part availability Most parts...

Page 435: ...pinion shaft seal q into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub w in...

Page 436: ...ture plate u Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTICE Verify armature plate tabs are i...

Page 437: ...rcase housing Install the seven cover plate screws s and torque to specification TORQUE Cover Plate Screws 9 ft lbs 12 Nm FRONT GEARCASE INSTALLATION 1 Install the gearcase back into the vehicle throu...

Page 438: ...t Support Bearing 33 lb ft 45 Nm 8 Install skid plate and fasteners TORQUE Skid Plate 3 5 lb ft 4 7 Nm 9 Install both front drive shafts into the gearcase Refer to applicable Front Drive Shaft Install...

Page 439: ...ing plate TORQUE Winch Fasteners 16 lb ft 22 Nm 14 Reinstall lower fastener on passenger front shock TORQUE GENERAL GENERAL 4 Shock Mount Fasteners 20 lb ft 27 Nm 90 GENERAL XP GENERAL XP 4 Shock Moun...

Page 440: ...ASSEMBLY VIEW q Rim Cap u Wheel Hub w Wheel Nut Steel Wheels 60 lb ft 81 Nm Aluminum Wheels 120 lb ft 163 Nm i Brake Disc e Valve Stem o Brake Disc Fasteners 18 lb ft 24 Nm r Cotter Pin a Bearing Carr...

Page 441: ...q Rim Cap u Wheel Hub w Wheel Nut Steel Wheels 60 lb ft 81 Nm Aluminum Wheels 120 lb ft 163 Nm i Brake Disc e Valve Stem o Brake Disc Fasteners 18 lb ft 24 Nm r Cotter Pin a Snap Ring t Hub Castle Nut...

Page 442: ...BS GENERAL XP GENERAL XP 4 FRONT HUB ASSEMBLY VIEW q Rim Cap u Wheel Hub w Wheel Nut 120 lb ft 163 Nm i Brake Disc e Valve Stem o Wheel Studs r Cotter Pin a Bearing Carrier t Hub Castle Nut 180 lb ft...

Page 443: ...s Inc 8 69 REAR HUB ASSEMBLY VIEW q Rim Cap u Wheel Hub w Wheel Nut 120 lb ft 163 Nm i Brake Disc e Valve Stem o Wheel Studs r Cotter Pin a Snap Ring t Hub Castle Nut 180 lb ft 244 Nm s Wheel Bearing...

Page 444: ...8 70 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES FINAL DRIVE...

Page 445: ...MBLY VIEW 9 14 REAR SUSPENSION ASSEMBLY VIEW 9 15 REAR STABILIZER BAR ASSEMBLY VIEW 9 17 STEERING ASSEMBLY SERVICE 9 18 STEERING SHAFT REMOVAL UPPER 9 18 STEERING WHEEL REMOVAL 9 19 POWER STEERING UNI...

Page 446: ...CK SERVICE GENERAL GENERAL 4 9 53 SHOCK SPECIFICATIONS GENERAL 9 53 SHOCK SPECIFICATIONS GENERAL 4 9 55 SHOCK REMOVAL 9 57 SPRING REPLACEMENT 9 57 SPRING ADJUSTMENT 9 58 SPRING ADJUSTMENT GENERAL 4 9...

Page 447: ...CRIPTION PART NUMBER Shock Spanner Wrench 2877408 Gas Shock Recharging Kit 2200421 IFP Depth Tool 2871351 Shock Body Holding Tool PU 45281 A Seal Protector Sleeve PU 50939 Shock Rod Holding Tool PU 51...

Page 448: ...Bolt r Steering Bushing j Steering Rack t Tilt Steering Shock Mounting Fasteners k Steering Rack Fasteners 16 lb ft 20 Nm y Tilt Steering Shock l Nut 30 lb ft 41 Nm 90 u Steering Tilt Assembly Fasten...

Page 449: ...nt Shock i Bushing w Shock Mounting Fasteners o Pivot Shaft Short e Washer a Front Lower Control Arm Fastener r Nut 20 lb ft 27 Nm 90 s Front Upper Control Arm Fastener t LH Front Knuckle Asm d Front...

Page 450: ...Cap Asm w Bushing a Nut 42 lb ft 57 Nm e Pivot Cap Asm s Washer r Front Upper Control Arm Fastener d Spiral Ring t Front Lower Control Arm Fastener f LH Front Upper Control Arm y RH Front Upper Contro...

Page 451: ...R ASSEMBLY VIEW q Stabilizer Bar y Stabilizer Bar Mount Fastener w Stabilizer Bar Link Fasteners u Zerk Fitting e Stabilizer Bar Link i Stabilizer Bar Mounting Bracket r Nut 40 lb ft 54 Nm o Stabilize...

Page 452: ...EMBLY VIEW FRONT VIEW q RH Bearing Carrier Asm u Nut 42 lb ft 57 Nm w Rear Shock i LH Bearing Carrier Asm e Rear Inner Control Arm Fastener o Rear Upper Bearing Carrier Mounting Fastener r Washer a Pi...

Page 453: ...Pivot Cap Asm w Shock Mounting Fasteners a Washer e Washer s Nut 40 lb ft 54 Nm 90 r Nut 20 lb ft 27 Nm 90 d LH Rear Lower Control Arm t RH Rear Upper Control Arm f Nut 40 lb ft 54 Nm 180 y RH Rear L...

Page 454: ...REAR STABILIZER BAR ASSEMBLY VIEW q Stabilizer Bar y Stabilizer Bar Mount Fastener w Stabilizer Bar Link Fasteners u Zerk Fitting e Stabilizer Bar Link i Stabilizer Bar Bushing r Washer o Stabilizer...

Page 455: ...Pinch Bolt r Steering Bushing j Steering Rack t Tilt Steering Shock Mounting Fasteners k Steering Rack Fasteners 16 lb ft 20 Nm y Tilt Steering Shock l Nut 30 lb ft 41 Nm 90 u Steering Tilt Assembly F...

Page 456: ...Nut 51 lb ft 70 Nm s Front Lower Control Arm Fastener e Washer d Pivot Cap Asm r Shock Mounting Fasteners f Pivot Shaft Short t LH Front Knuckle Asm g Front Upper Control Arm Fastener y Nut 81 lb ft...

Page 457: ...sm w Bushing a Nut 81 lb ft 110 Nm e Pivot Cap Asm s Washer r Front Upper Inner Control Arm Fastener d Spiral Ring t Front Lower Inner Control Arm Fastener f LH Front Upper Control Arm y RH Front Uppe...

Page 458: ...olaris Inc FRONT STABILIZER BAR ASSEMBLY VIEW q Stabilizer Bar t Stabilizer Bar Mount Fasteners w Stabilizer Bar Link y Stabilizer Bar Mounting Bracket e Nut u Nut 22 lb ft 30 Nm r Stabilizer Bar Link...

Page 459: ...EMBLY VIEW FRONT VIEW q RH Bearing Carrier Asm i LH Bearing Carrier Asm w Rear Shock o Rear Bearing Carrier Fastener e Rear Inner Control Arm Fastener a Pivot Shaft Long r Pivot Cap Asm s Washer t Bus...

Page 460: ...Cap Asm w Shock Mounting Fasteners a Washer e Washer s Nut 81 lb ft 110 Nm r Nut 51 lb ft 70 Nm d Rear Inner Control Arm Fastener t RH Rear Upper Control Arm f LH Rear Lower Control Arm y RH Rear Low...

Page 461: ...7 REAR STABILIZER BAR ASSEMBLY VIEW q Stabilizer Bar y Stabilizer Bar Mount Fastener w Stabilizer Bar Link Fasteners u Zerk Fitting e Stabilizer Bar Link i Stabilizer Bar Bushing r Washer o Stabilizer...

Page 462: ...is readily available before proceeding Failure to replace fastener can result in injury or death 1 Remove the fasteners retaining the black plastic cover and remove the cover from the vehicle 2 Remove...

Page 463: ...se 5 Using a large bronze drift and hammer strike the steering shaft nut to pop the steering wheel off the shaft taper 6 Once the steering wheel pops loose completely remove the nut and lift the steer...

Page 464: ...teering EPAS units are programmed to be vehicle specific and are not interchangeable between product lines STEERING SHAFT REMOVAL LOWER 1 Use the steering wheel to position the front wheels so they po...

Page 465: ...ing Fault 2 Rotate the steering wheel to inspect bearing operation The wheel should spin smoothly and consistently 3 If the steering wheel has trouble turning the steering shaft bearings may need repl...

Page 466: ...vehicle and align the skip tooth spline on the power steering stub shaft with the opening in the lower steering shaft 3 Place the power steering mount bracket over the top of the brake pedal mount stu...

Page 467: ...aft NOTICE Striking the steering wheel or steering shaft can permanently damage the EPAS unit and cause a Power Steering Fault 1 Install the upper steering shaft and align the skip tooth spline on the...

Page 468: ...UE Silver 10 9 Upper Steering Shaft Pinch Bolt 30 lb ft 41 Nm NOTICE The upper steering shaft pinch bolt must be replaced with PN 7520943 which has a silver finish and is 10 9 grade Reference Figure 1...

Page 469: ...nt and rear Try to move the wheel and hub by pushing inward and pulling outward 4 If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose f...

Page 470: ...Steering Rack Fasteners 16 lb ft 20 Nm 3 Install the lower steering shaft to the steering rack gearbox Refer to Steering Shaft Installation Lower page 9 21 procedure 4 Install the fasteners securing t...

Page 471: ...equally positioned to get an accurate measurement 3 Measure the distance between the marks and record the measurement Call this measurement 2 4 Rotate the tires 180 by moving the vehicle forward Posit...

Page 472: ...rod end to keep it from rotating 2 Loosen jam nuts at both end of the tie rod 3 Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe specification IMPORTANT When ti...

Page 473: ...to loosen the upper control arm ball joint end while lifting upward on the upper control arm Completely remove the ball joint end from the bearing carrier 7 Loosen and remove the upper control arm thr...

Page 474: ...2018 models have M12 hardware 4 Remove ball joint from control arm Refer to Ball Joint Removal page 9 52 procedure 5 Examine control arm bushings and pivot tube Replace if worn Discard hardware 6 If...

Page 475: ...Ball Joint Pinch Bolts 42 lb ft 57 Nm 5 Install brake line mounting brackets y 6 Attach shock to control arm with fastener Torque lower shock bolt to specification TORQUE Shock Mount Fasteners 20 lb f...

Page 476: ...ation NOTICE 2019 models have M12 hardware 2016 2018 models have M10 hardware TORQUE Front Control Arm Fasteners 42 lb ft 57 Nm 3 Insert lower control arm ball joint end into the bearing carrier Insta...

Page 477: ...bilizer bar for straightness Inspect the pivot bushings and replace if needed FRONT STABILIZER BAR INSTALLATION 1 Carefully install stabilizer Align mounting brackets with marks from removal 2 Install...

Page 478: ...the upper control arm to the chassis 4 Examine control arm bushings and pivot tube Replace if worn Discard hardware WARNING The locking agent on the existing bolts was destroyed during removal DO NOT...

Page 479: ...tube Replace if worn Discard hardware 7 If not replacing the control arm thoroughly clean the control arm and pivot tube REAR CONTROL ARM INSTALLATION UPPER CONTROL ARM 1 Insert NEW pivot caps q contr...

Page 480: ...teners 42 lb ft 57 Nm LOWER CONTROL ARM 1 Insert NEW pivot caps q control arm bushings w and pivot tube e into new control arm A light press force may be needed 2 Install lower control arm assembly on...

Page 481: ...lding control arm to bearing carrier Torque fasteners to specification TORQUE Rear Outer Lower Control Arm Fasteners 40 lb ft 54 Nm 180 6 Attach stabilizer link to control arm with fastener u Torque t...

Page 482: ...m the vehicle 8 Inspect the stabilizer bar for straightness Inspect the pivot bushings and replace if needed REAR STABILIZER BAR INSTALLATION 1 Carefully install stabilizer bar through the wheel well...

Page 483: ...9 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 9 39 5 Install wheels and torque lugs to specification TORQUE Wheel Nuts 120 lb ft 163 Nm STEERING SUSPENSION...

Page 484: ...the brake line brackets w and routing clampe from the control arm 4 Remove upper ball joint pinch bolt e from bearing carrier 5 Remove Stabilizer link to control arm fastener t 6 Using a soft face ha...

Page 485: ...thoroughly clean the control arm and pivot tube LOWER CONTROL ARM 1 Remove lower ball joint pinch bolt from bearing carrier 2 Using a soft face hammer tap on bearing carrier to loosen the lower contr...

Page 486: ...be e into new control arm 3 Install upper control arm assembly onto vehicle frame Torque NEW fasteners r to specification TORQUE Front Inner Control Arm Fasteners 81 lb ft 110 Nm 4 Insert upper contro...

Page 487: ...o specification TORQUE Front Stabilizer Bar Link Fastener 81 lb ft 110 Nm 8 Install NEW ball joint into control arm Refer to Ball Joint Installation page 9 52 procedure LOWER CONTROL ARM 1 Insert NEW...

Page 488: ...m installation test vehicle at low speeds before putting into service FRONT STABILIZER BAR REMOVAL 1 Lift and support vehicle by main frame 2 Remove wheels 3 Identify mark top side of the stabilizer b...

Page 489: ...ation TORQUE Front Stabilizer Bar Mount Fasteners 22 lb ft 30 Nm 4 Install the fasteners w retaining the stabilizer bar to the linkage on each side of the vehicle Torque fasteners to specification TOR...

Page 490: ...on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 6 If not replacing the control arm thoroughl...

Page 491: ...6 If not replacing the control arm thoroughly clean the control arm and pivot tube REAR CONTROL ARM INSTALLATION UPPER CONTROL ARM 1 Insert NEW pivot caps q control arm bushings w and pivot tube e int...

Page 492: ...e fasteners to specification TORQUE Rear Bearing Carrier Fastener 81 lb ft 110 Nm LOWER CONTROL ARM 1 Insert NEW pivot caps q control arm bushings w and pivot tube e into new control arm A light press...

Page 493: ...y holding control arm to bearing carrier Torque fasteners to specification TORQUE Rear Bearing Carrier Fastener 81 lb ft 110 Nm 5 Attach stabilizer link to control arm with fastener u Torque to specif...

Page 494: ...m the vehicle 8 Inspect the stabilizer bar for straightness Inspect the pivot bushings and replace if needed REAR STABILIZER BAR INSTALLATION 1 Carefully install stabilizer bar through the wheel well...

Page 495: ...9 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 9 51 5 Install wheels and torque lugs to specification TORQUE Wheel Nuts 120 lb ft 163 Nm STEERING SUSPENSION...

Page 496: ...frame mounting bolts and remove the A arm from the chassis BALL JOINT REMOVAL 1 Remove the retaining ring q from the ball joint w 2 Place a proper sized driver on the ball joint and place the A arm in...

Page 497: ...ocked in a table vise eyelet down threaded end up SHOCKS Shocks LH Front 7044415 RH Front 7044416 LH Rear 7044417 RH Rear 7044418 Model Fox 2 0 Podium QS3 Fox 2 0 Podium QS3 Extended Length inches 22...

Page 498: ...1 425 x 012 0 800 x 006 1 425 x 008 1 425 x 008 1 425 x 008 1 230 x 0 082 Top Out 1 250 x 015 1 425 x 020 1 425 x 020 1 425 x 020 1 425 x 020 0 950 x 006 1 425 x 010 1 425 x 010 1 425 x 010 1 425 x 0...

Page 499: ...e vise eyelet down threaded end up SHOCKS Shocks LH Front 7044687 RH Front 7044688 LH Rear 7044689 RH Rear 7044690 Model Fox 2 0 Podium QS3 Fox 2 0 Podium QS3 Extended Length inches 22 52 22 47 Collap...

Page 500: ...R 1 425 x 008 875 x 100 Back Up 1 230 x 082 Top Out 1 250 x 010 1 350 x 010 1 425 x 010 0 850 x 006 0 850 x 008 1 425 x 006 1 425 x 006 1 425 x 006 1 425 x 006 1 250 x 006 1 425 x 015 R 1 425 x 008 Co...

Page 501: ...e 9 57 and Spring Adjustment procedures 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spring far enough to remove t...

Page 502: ...icle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment collar q to increase or decrease r...

Page 503: ...r of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment collar q to increase o...

Page 504: ...urn the adjuster knob clockwise to increase compression damping Turn the adjuster knob counter clockwise to decrease compression damping SETTING COMPRESSION DAMPING Softest Position 1 Factory Position...

Page 505: ...a clean towel can be used in the vice jaws to protect the body cap 2 Discharge nitrogen pressure from reservoir chamber 3 Once nitrogen pressure has been released depress reservoir cap and remove ret...

Page 506: ...ston IFP into the shock reservoir 9 Press the bearing assembly down with your fingers At the same time push the IFP tool upwards with your thumbs 10 Remove the bearing cap retaining ring with a valve...

Page 507: ...Remove the LSC using a 5 8 wrench 16 Remove the DSC using a DSC removal socket 17 Remove the reservoir with a rubber belted strap wrench 18 Before putting the body into the clamp blocks partially inse...

Page 508: ...body cap using a wire brush and pick 23 Remove both retaining rings in the body cap using a sharp pick 24 Press the bearing out of the body cap using a bearing press set or assorted sockets 25 Prep t...

Page 509: ...ents for assembly 30 Remove BOC post 31 Remove rebound valve stack Note order of valve stack for assembly NOTICE If you are not changing valve shims you can zip tie the shims together this will keep v...

Page 510: ...of the notches in the bleed shim align with the compression ports of the piston 34 Remove the piston bearing if it shows any signs of damage or wear 35 Remove piston O ring 36 Remove compression valve...

Page 511: ...N Eyelet will be Hot 41 Remove Loctite residue out from threads of the eyelet and shock shaft EYELET MOUNTED REBOUND ADJUSTER 1 For shocks with remove Jet Check Valve with Hex T handle wrench 2 Push n...

Page 512: ...Remove both retaining rings from the eyelet and press out bearing DX BUSHING AND SEAL STYLE EYELET NOTICE DX Bushing style eyelets have larger bore diameters than conventional eyelets 1 Remove both du...

Page 513: ...assembly Note the direction seal was installed for assembly 6 Remove external O ring from bearing assembly NOTICE If internal bearing is damaged replace with complete bearing assembly SHOCK ASSEMBLY F...

Page 514: ...Put the steel ball on the spring with a dab of shock oil 5 Install rebound knob into eyelet holding steel ball in place with fingers Ensure rebound knob threads into eyelet correctly and you can feel...

Page 515: ...shaft in clamp blocks and apply a thin layer of Slick Honey to metering rod ASSEMBLY CONTINUED 1 Apply specified Loctite two threads down and two threads wide completely around shock shaft threads 2 P...

Page 516: ...er of Slick Honey to seal 5 Install body cap NOTICE There are two different sides on the U Cup seal When seal is installed energizing side should be facing internal bearing 6 Install U Cup seal 7 Inst...

Page 517: ...n tool assembly on top of the piston and push down to install bearing NOTICE Bearing will be fully seated around piston when done correctly 13 Install compression side valve stack NOTICE When installi...

Page 518: ...d torque to specification TORQUE Piston Nut 22 lb ft 30 Nm 17 If applicable install BOC post valving NOTICE Ensure retaining ring is fully installed and secure 18 If applicable install BOC piston and...

Page 519: ...3 Place body in clamp blocks and install body cap Torque body cap to specification using body cap socket TORQUE Body Cap 100 lb ft 136 Nm 24 Place body in block clamps parallel to the ground 25 Replac...

Page 520: ...g and O ring on the IFP and apply a thin layer of shock oil to bearing and O ring 32 Install IFP assembly without bleed screw using the IFP installation tool IMPORTANT Push IFP into reservoir about 1...

Page 521: ...ush bearing assembly in with your finger tips 38 Install retaining ring 39 Use IFP tool to push down on IFP and fully extend the shock shaft assembly 40 Remove bleed screw and set IFP to the appropria...

Page 522: ...anual Copyright Polaris Inc 44 Ensure rebound and compression adjuster are fully functioning by hand actuating the shock absorber NOTICE Check for any leaks or faults in the shock absorber s functiona...

Page 523: ...rod is locked in a table vise eyelet down threaded end up SHOCKS Shocks LH Front 7045321 RH Front 7045322 Rear 7045306 Model Walker Evans 2 0 Velocity Walker Evans 2 5 Velocity Extended Length inches...

Page 524: ...1 00 X 012 1 10 X 012 1 20 X 012 1 30 X 008 1 50 X 008 1 50 X 008 Piston Bleed 0 0 0 0 Shaft Bleed 0 144 0 144 Compression 1 50 X 120 900 X 008 1 00 X 008 1 10 X 010 1 20 X 008 1 30 X 008 1 45 X 008 1...

Page 525: ...a table vise eyelet down threaded end up SHOCKS Shocks LH Front 7045311 RH Front 7045312 Rear 7045323 Model Walker Evans 2 0 Velocity Walker Evans 2 5 Velocity Extended Length inches 24 866 25 051 Col...

Page 526: ...12 1 30 X 012 1 45 X 012 1 50 X 012 1 20 X 008 1 50 X 010 Piston Bleed 0 0 0 0 Shaft Bleed 0 144 0 144 Compression 1 50 X 120 900 X 008 1 00 X 010 1 10 X 012 1 20 X 012 1 30 X 010 1 20 X 008 1 45 X 01...

Page 527: ...e 9 83 and Spring Adjustment procedures 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spring far enough to remove t...

Page 528: ...support front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment co...

Page 529: ...y support front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment...

Page 530: ...ockwise to decrease compression damping FACTORY COMPRESSION SETTINGS GENERAL XP Front Shock 8 clicks from full hard Rear Shock 8 clicks from full hard GENERAL XP 4 Front Shock 8 clicks from full hard...

Page 531: ...as possible 4 Remove needle from charge port 5 Remove the wire ring 6 Remove bleed screw from the seal head 7 Remove the shaft assembly 8 Dump all oil from the shock and let drain 9 Remove the piston...

Page 532: ...14 Remove the base valve 15 Remove the IFP from reservoir eyelet cap 16 Replace all o rings SHOCK ASSEMBLY WALKER EVANS 1 With the needle in the charge port push IFP until it bottoms out Then remove...

Page 533: ...t push the seal case down until it is 1 500 from top of the main body 8 Making sure oil is on top of the seal case pull up on the shaft until the piston stops against the seal case Ensure the seal cas...

Page 534: ...9 90 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES STEERING SUSPENSION...

Page 535: ...NERAL GENERAL 4 10 19 BRAKE LINE FITTING ORIENTATION GENERAL GENERAL 4 10 21 ASSEMBLY VIEWS BRAKE SYSTEM GENERAL XP GENERAL XP 4 10 23 BRAKE SYSTEM ASSEMBLY VIEW GENERAL XP 10 23 BRAKE LINE ROUTING GE...

Page 536: ...N 10 65 REAR CALIPER ASSEMBLY 10 66 REAR CALIPER INSTALLATION 10 66 DISC SERVICE 10 68 BRAKE DISC RUNOUT 10 68 BRAKE DISC INSPECTION 10 68 BRAKE DISC REPLACEMENT 10 69 BRAKE DISC REPLACEMENT 10 70 INT...

Page 537: ...ns freely and completely Adjust the caliper stop pin after pad service Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservoir is unobstructed...

Page 538: ...374 in 34 900 mm Front Caliper Piston O D 1 370 in 34 798 mm 1 368 in 34 760 mm REAR BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Rear Brake Pad Thickness 0 296 007 in 7 53 19 mm 0 180 in 4 6 mm Rear Bra...

Page 539: ...Bore 1 000 25 4 mm Front Caliper Piston O D Large 1 3685 1 3700 34 76 34 80 mm Medium 1 1860 1 1875 30 12 30 16 mm Small 9985 1 000 25 36 25 40 mm REAR BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Rear B...

Page 540: ...n 34 900 mm Front Caliper Piston O D 1 370 in 34 798 mm 1 368 in 34 760 mm REAR BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Rear Brake Pad Thickness 0 296 007 in 7 53 19 mm 0 180 in 4 6 mm Rear Brake Dis...

Page 541: ...e brakes to drag due to fluid expansion Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly As the temperature within the hydr...

Page 542: ...oir to prevent air from entering the master cylinder 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to specification TORQUE Caliper Bleeder Screw 4 lb ft 5 4 Nm 9 Repeat...

Page 543: ...OMPONENTS q LH Front Brake Caliper o Master Cylinder w Stat O Seals a RH Rear Brake Caliper e Banjo Bolt 15 lb ft 20 Nm s Rear Right Brake Line r Front Left Brake Line d Rear Left Brake Line t Front R...

Page 544: ...re Tube Clamp r Master Cylinder Fasteners 22 lb ft 30 Nm g Rivet t Outer Brake Line Clip h Brake Line Retention Fastener 35 in lbs 4 Nm y Front Scraper j Rear Caliper Fasteners 46 lb ft 62 Nm u Scrape...

Page 545: ...2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 11 BRAKE LINE ROUTING GENERAL FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Master Cyl...

Page 546: ...10 12 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Junction Block BRAKE SYSTEM...

Page 547: ...9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 13 JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block w Brake Line Retention Points e Rear Brake Calipers BRAKE SYS...

Page 548: ...ake Caliper o Master Cylinder w Stat O Seals a RH Rear Brake Caliper e Banjo Bolt 15 lb ft 20 Nm s Rear Right Brake Line r Front Left Brake Line d Rear Left Brake Line t Front Right Brake Line f LH Re...

Page 549: ...e Tube Clamp r Master Cylinder Fasteners 22 lb ft 30 Nm g Rivet t Outer Brake Line Clip h Brake Line Retention Fastener 35 in lbs 4 Nm y Front Scraper j Rear Caliper Fasteners 46 lb ft 62 Nm u Scraper...

Page 550: ...2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc BRAKE LINE ROUTING GENERAL 4 FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Master Cyl...

Page 551: ...10 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 17 MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Junction Block BRAKE SYSTEM...

Page 552: ...18 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block w Brake Line Retention Points e Rear Brake Calipers BRAKE SYSTE...

Page 553: ...LIPER ASSEMBLY VIEW GENERAL GENERAL 4 FRONT CALIPER q Asm Brake Pad y Square Ring Lubricate with DOT 4 Brake Fluid w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Cap Plug r Boot Pin Bushing o B...

Page 554: ...t Polaris Inc REAR CALIPER q Asm Brake Pad y Square Ring Lubricate with DOT 4 Brake Fluid w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Cap Plug r Boot Pin Bushing o Bleeder Screw 4 lb ft 5 4...

Page 555: ...der to Left Caliper Fitting 45 0 2 5 w Master Cylinder to Right Caliper Fitting 45 0 2 5 NOTICE The right w and left e front brake lines are stacked on top of each other and attach to the front port o...

Page 556: ...2 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc FRONT BRAKE CALIPER q Front Brake Line Fitting 10 0 2 5 REAR BRAKE CALIPER q Rear Brake Line Fitting 60 0 65 0 BRAKE SYS...

Page 557: ...TEM COMPONENTS q LH Front Brake Caliper o Master Cylinder w Stat O Seals a RH Rear Brake Caliper e Banjo Bolt 15 lb ft 20 Nm s Rear Right Brake Line r Front Left Brake Line d Rear Left Brake Line t Fr...

Page 558: ...her f Brake Line Retention Fastener 8 lb ft 11 Nm r Master Cylinder Fasteners 22 lb ft 30 Nm g Nut t Outer Brake Line Clip h Wire Tube Clamp y LH Front Scraper j Rivet u Scraper Fasteners 7 lb ft 9 Nm...

Page 559: ...Service Manual Copyright Polaris Inc 10 25 BRAKE LINE ROUTING GENERAL XP FRONT BRAKE LINES FROM MASTER CYL INDER TO CALIPERS ROUTING q Master Cylinder e LH Front Brake Caliper w Brake Line Retention P...

Page 560: ...lb ft 20 Nm 2 Right Brake Line From the master cylinder route the brake line q across the chassis and secure in the routing clip w and routing clamp e 3 Continue routing the brake line down the upper...

Page 561: ...2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 27 REAR BRAKE LINE FROM MASTER CYLIN DER TO JUNCTION BLOCK ROUTING q Master Cylinder e Junction Block w Brake Line Retention Point...

Page 562: ...he center brake line is attached to the rear port of the Master Cylinder TORQUE Banjo Bolt 15 lb ft 20 Nm 2 From the master cylinder route the brake line q down the chassis and secure in the routing c...

Page 563: ...GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 29 REAR BRAKE LINE FROM JUNCTION BLOCK TO CALIPERS ROUTING q RH Rear Brake Caliper e LH Rear Brake Caliper w Brake Line Retention Points r Ju...

Page 564: ...he chassis and secure in the routing clips w and routing clamps e Torque the fastener that secures the routing clamp to specification NOTICE The first routing clip secures both the right and left rear...

Page 565: ...ce Manual Copyright Polaris Inc 10 31 6 Route the brake line down the rear upper control arm and secure with the routing clamps e and wire tube clamp r 7 Install brake line onto rear caliper TORQUE Re...

Page 566: ...CALIPER ASSEMBLY VIEW GENERAL XP FRONT CALIPER q Asm Brake Pad y Square Ring Lubricate with DOT 4 Brake Fluid w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Cap Plug r Boot Pin Bushing o Bleede...

Page 567: ...Asm Brake Pad u Seal Caliper Inner Lubricate with DOT 4 Brake Fluid w Asm Caliper Mount i Caliper Brake e Boot Pin Seal o Cap Plug r Boot Pin Bushing a Bleeder Screw 4 lb ft 5 4 Nm t Piston Brake Lubr...

Page 568: ...rake Caliper o Master Cylinder w Stat O Seals a RH Rear Brake Caliper e Banjo Bolt 15 lb ft 20 Nm s Rear Right Brake Line r Front Left Brake Line d Rear Left Brake Line t Front Right Brake Line f LH R...

Page 569: ...er 8 lb ft 11 Nm e Washer g Nut r Master Cylinder Fasteners 22 lb ft 30 Nm h Wire Tube Clamp t Outer Brake Line Clip j Rivet y LH Front Scraper k Rear Caliper Fasteners 46 lb ft 62 Nm u Scraper Fasten...

Page 570: ...XP Service Manual Copyright Polaris Inc BRAKE LINE ROUTING GENERAL XP 4 FRONT BRAKE LINES FROM MASTER CYL INDER TO CALIPERS ROUTING q Master Cylinder e LH Front Brake Caliper w Brake Line Retention P...

Page 571: ...5 lb ft 20 Nm 2 Right Brake Line From the master cylinder route the brake line q across the chassis and secure in the routing clip w and routing clamp e 3 Continue routing the brake line down the uppe...

Page 572: ...R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc REAR BRAKE LINE FROM MASTER CYLIN DER TO JUNCTION BLOCK ROUTING q Master Cylinder e Junction Block w Brake Line Retention Points...

Page 573: ...port of the Master Cylinder TORQUE Banjo Bolt 15 lb ft 20 Nm 2 From the master cylinder route the brake line q down the chassis and secure in the routing clip w 3 Route the brake line rearward along t...

Page 574: ...021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc REAR BRAKE LINE FROM JUNCTION BLOCK TO CALIPERS ROUTING q RH Rear Brake Caliper e LH Rear Brake Caliper w Brake Line Retention Points r Junc...

Page 575: ...the chassis and secure in the routing clips w and routing clamps e Torque the fastener that secures the routing clamp to specification NOTICE The first routing clip secures both the right and left re...

Page 576: ...Service Manual Copyright Polaris Inc 6 Route the brake line down the rear upper control arm and secure with the routing clamps e and wire tube clamp r 7 Install brake line onto rear caliper TORQUE Rea...

Page 577: ...CALIPER ASSEMBLY VIEW GENERAL XP 4 FRONT CALIPER q Asm Brake Pad y Square Ring Lubricate with DOT 4 Brake Fluid w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Cap Plug r Boot Pin Bushing o Blee...

Page 578: ...t Polaris Inc REAR CALIPER q Asm Brake Pad y Square Ring Lubricate with DOT 4 Brake Fluid w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Cap Plug r Boot Pin Bushing o Bleeder Screw 4 lb ft 5 4...

Page 579: ...linder to Left Caliper Fitting 45 0 2 5 w Master Cylinder to Right Caliper Fitting 45 0 2 5 NOTICE The right w and left e front brake lines are stacked on top of each other and attach to the front por...

Page 580: ...46 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc FRONT BRAKE CALIPER q Front Brake Line Fitting 15 0 2 5 REAR BRAKE CALIPER q Rear Brake Line Fitting 15 0 2 5 BRAKE SYS...

Page 581: ...en the brake line banjo bolts and allow fluid to drain 5 Remove the two mounting fasteners that secure the master cylinder to the frame MASTER CYLINDER INSTALLATION 1 Install the master cylinder into...

Page 582: ...ke pedal lever 2 Remove the E clip from the pedal mount and remove the brake pedal lever from the vehicle BRAKE PEDAL INSTALLATION 1 Install the brake pedal onto pedal pivot shaft 2 Insert E Clip into...

Page 583: ...remove the caliper from the front hub WARNING When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 5 Push caliper piston into caliper bore sl...

Page 584: ...BRAKE PAD INSTALLATION 1 Lubricate mounting bracket pins q with a light film of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Ins...

Page 585: ...contacts disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reserv...

Page 586: ...the line q Remove brake line from caliper IMPORTANT Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 5 Loosen brake pad adjustment set scre...

Page 587: ...er pistons with a standard pliers The piston sealing surfaces will become damaged if a standard pliers is used 5 Once the pistons are removed use a pick to carefully remove the square O rings e from t...

Page 588: ...Inspect the brake disc and pads as outlined in this chapter FRONT CALIPER ASSEMBLY 1 Install new O rings w in the caliper body Be sure the grooves q are clean and free of residue or brakes may drag up...

Page 589: ...ion TORQUE Brake Line Banjo Bolts 15 lb ft 20 Nm 4 Install the adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 5 Bleed the brake syst...

Page 590: ...o catch brake fluid when removing the line q Remove brake line from caliper IMPORTANT Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 5 Loo...

Page 591: ...t with brake cleaner or alcohol NOTICE Be sure to clean all the seal grooves in the caliper body 6 Inspect caliper body for nicks scratches pitting or wear 7 Measure bore size and compare to specifica...

Page 592: ...g care not to allow any debris to enter the caliper 2 Install the caliper and torque the mounting bolts to specification TORQUE Front Caliper Mount Bolts 30 lb ft 41 Nm NOTICE If disc scraper was remo...

Page 593: ...olts and lift caliper off the brake disc WARNING When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 5 Push caliper piston into the caliper...

Page 594: ...r liquid soaked do not use the pads Use only new clean pads 3 Install the caliper and torque the new mounting bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 4 Slowly pump the...

Page 595: ...surfaces Do not allow brake fluid to come in contact with finished surfaces 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove the cali...

Page 596: ...ce Limit 1 192 in 30 277 mm 2 Inspect piston for nicks scratches pitting or wear Measure piston diameter and replace if damaged or worn beyond service limit MEASUREMENT Rear Caliper Piston O D Std 1 1...

Page 597: ...ounting bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 3 Torque the banjo bolt w to specification TORQUE Brake Line Banjo Bolts 15 lb ft 20 Nm 4 Install the adjustment set sc...

Page 598: ...fluid when removing the brake line Use a wrench to remove the brake line banjo bolt q 5 If necessary loosen brake pad adjustment set screw w 2 3 turns to allow brake pad removal after the caliper is...

Page 599: ...h brake cleaner or alcohol NOTICE Be sure to clean caliper body seal grooves REAR CALIPER INSPECTION 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications...

Page 600: ...ket and make sure the dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease REAR CALIPER INSTALLATIO...

Page 601: ...0 ft lbs 163 Nm 6 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake...

Page 602: ...ceeds specification Brake Disc Runout 0 010 0 254 mm BRAKE DISC INSPECTION 1 Visually inspect disc for scoring scratches or gouges Replace disc if deep scratches are evident 2 Use a 0 1 micrometer and...

Page 603: ...UE Brake Disc Mounting Bolts 18 lb ft 24 Nm IMPORTANT Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 Install wheel hub assembly w...

Page 604: ...surface and install the new disc on the wheel hub 5 Install new studsu 6 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin TORQUE Wheel...

Page 605: ...itors the vehicle wheel speed at via a tone ring that is fixed to the half shafts on both the front and rear gearcase The sensor outputs an analog signal while the tone ring spins with the wheel to ge...

Page 606: ...Brake Caliper Fasteners 30 lb ft 41 Nm e Banjo Bolt 15 lb ft 20 Nm o ABS Module Step 1 Pre torque all three fasteners to 1 8 lb ft 2 Nm Step 2 Torque all three fasteners to 3 lb ft 4 Nm Step 3 Torque...

Page 607: ...7 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 73 BRAKE LINE ROUTING AND RETENTION INTL ABS MASTER CYLINDER TO ABS MODULE q Master Cylinder w Routing Clips e ABS Module BRA...

Page 608: ...10 74 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc ABS MODULE TO FRONT BRAKE CALIPERS q ABS Module e Brake Clip w Routing Clip r Front Brake Calipers BRAKE SYSTEM...

Page 609: ...10 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 75 ABS MODULE TO JUNCTION BLOCK q ABS Module w Routing Clip e Junction Block BRAKE SYSTEM...

Page 610: ...6 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block r Hose Clamp w Routing Clip t Rear Brake Caliper e Clip BRAKE SYS...

Page 611: ...L GENERAL XP Service Manual Copyright Polaris Inc 10 77 BRAKE LINE FITTING ORIENTATION ABS MASTER CYLINDER ABS MODELS q Master Cylinder to ABS Rear Port Fitting 80 0 2 5 w Master Cylinder to ABS Front...

Page 612: ...al Copyright Polaris Inc ABS UNIT TOP OF ABS UNIT q Right Rear Caliper Brake Line Fitting 67 5 2 5 e Right Front Caliper Brake Line Fitting 50 0 2 5 w Left Rear Caliper Brake Line Fitting 75 0 2 5 r L...

Page 613: ...067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 79 ABS UNIT CONNECTOR SIDE q Master Cylinder Front Port Fitting 45 0 2 5 w Master Cylinder Rear Port Fitting 55 0 2 5 BRAKE...

Page 614: ...GENERAL GENERAL XP Service Manual Copyright Polaris Inc BRAKE LINE ROUTING AND RETENTION NON ABS INTL FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Ma...

Page 615: ...10 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 10 81 MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Master Cylinder BRAKE SYSTEM...

Page 616: ...0 82 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block w Brake Line Retention Points e Rear Brake Caliper BRAKE SYSTE...

Page 617: ...e pedal mount and remove the brake pedal lever from the vehicle with its bushings t BRAKE PEDAL INSTALLATION INTL 1 Install the brake pedal onto pedal pivot shaft 2 Insert E Clip q into end of pivot s...

Page 618: ...ly NOTICE Some models may have 2 pressure switches Pressure switches will use the same replacement procedure but may utilize a spacer between the switch and master cylinder If a spacer is used note th...

Page 619: ...item and requires the halfshaft to be replaced The new halfshaft will come with the tone ring installed 1 Remove drive shaft Refer to Front Drive Shaft Removal page 8 20 or Rear Drive Shaft Removal p...

Page 620: ...NTL ABS For the ABS system to work properly the gap between the tone ring and sensor must be set to a specific value Adjusting wheel speed must be done for all four sensors Two sensors are located on...

Page 621: ...nt of force 4 With the proper air gap attained torque the fasteners to specification TORQUE ABS Sensor Mount INTL 5 lb ft 7 Nm 5 Repeat the procedure on the adjacent side of the gearcase ABS HECU REMO...

Page 622: ...or the vehicle ABS HECU INSTALLATION INTL ABS 1 Install the HECU onto its bracket 2 Install three HECU fasteners q and torque to specification in sequence TORQUE ABS HECU Mounting Fasteners INTL Step...

Page 623: ...gs INTL 15 lb ft 20 Nm 5 Connect ABS HECU electrical connector r 6 Bleed Brake System ABS TROUBLESHOOTING INTL ABS Bent Wheel speed sensor bracket Damaged tone ring broken missing teeth Incorrect whee...

Page 624: ...ING BRAKE ASSEMBLY VIEW q Parking Brake Lever u Edge Clip w Pin Clip i Parking Brake Bracket e Pin Clevis o Parking Brake Caliper Fastener 37 lb ft 50 Nm r Parking Brake Lever Fastener 22 lb ft 30 Nm...

Page 625: ...excess heat in the parking brake system that can lead to premature pad and rotor wear along with driveability issues while in operation 1 Pull back on parking brake lever located in the center consol...

Page 626: ...ing brake 10 If additional adjustment is needed the cable can be adjust on the parking brake handle side jam nut r CALIPER REMOVAL CAUTION Do not get oil grease or fluid on the parking brake pads Dama...

Page 627: ...m 3 Install the cable pin and clip pin q Test the park brake for proper function DISC INSPECTION REPLACEMENT Measure the brake disc with a micrometer If the thickness of the disc is less than specifie...

Page 628: ...10 94 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES BRAKE SYSTEM...

Page 629: ...ENTER CONSOLE ASSEMBLY VIEW GENERAL 4 GENERAL XP 4 11 14 REAR CLOSEOFF FENDERS FLOOR ASSEMBLY VIEW GENERAL 4 11 16 REAR CLOSEOFF FENDERS FLOOR ASSEMBLY VIEW GENERAL XP 4 11 17 SEAT ASSEMBLY VIEW GENER...

Page 630: ...NT INSTALLATION 11 71 EXTERIOR BODY COMPONENT INSTALLATION GENERAL 4 11 73 HOOD INSTALLATION 11 76 SEAT INSTALLATION 11 76 DOOR INSTALLATION 11 77 DOOR INSTALLATION GENERAL 4 11 78 DOOR CABLE ADJUSTME...

Page 631: ...reated is clean and free of gasoline or flammable residue WARNING Do not flame treat components that are installed on the vehicle Remove the component from the vehicle before flame treating The body c...

Page 632: ...Y VIEW q Lower Front Fascia y Front Radiator Shroud w Front Fascia Fasteners 3 5 lb ft 4 7 Nm u Radiator Shroud Fasteners 22 in lbs 2 5 Nm e Upper Front Fascia i LH Lower Front Fascia Bracket r Lower...

Page 633: ...Inner Hood a Trim Clip w 1 4 Turn Latch s RH Front Fender e Washer d Hood Liner r Latch Grommet f LH Front Fender t Outer Hood g LH Fender Flair y RH Hood Vent h LH Hood Vent u Plastic Push Rivet j Fr...

Page 634: ...q Inner Hood a Trim Clip w 1 4 Turn Latch s RH Front Fender e Washer d Hood Liner r Latch Grommet f LH Front Fender t Outer Hood g LH Fender Flair y RH Hood Vent h LH Hood Vent u Plastic Push Rivet j...

Page 635: ...H ASSEMBLY VIEW q Main Dash Carrier o LH Dash Tray w Body Fasteners 3 5 lb ft 4 7 Nm a Center Dash Storage e Trim Clip s RH Dash Tray r Upper Dash d Tube Plug t Plastic Push Rivet f Glovebox Door y Tr...

Page 636: ...ce Manual Copyright Polaris Inc BODY GENERAL GENERAL XP FLOOR ROCKER ASSEMBLY VIEW GENERAL q RH Floor Clip t Body Fastener 3 5 lb ft 4 7 Nm w U Nut y Floor Drain Plug e LH Floor Clip u Plastic Push Ri...

Page 637: ...P Service Manual Copyright Polaris Inc 11 9 FLOOR ROCKER ASSEMBLY VIEW GENERAL XP q RH Floor Clip t Body Fastener 3 5 lb ft 4 7 Nm w U Nut y Floor Drain Plug e LH Floor Clip u Plastic Push Rivet r LH...

Page 638: ...onsole w Plastic Push Rivet a Cup Holder e Passenger Grab Handle s Rubber Grommet r Passenger Grab Handle Fasteners 6 lb ft 8 Nm d Compartment Plug t Console Service Panel f Center Console Cover y Bod...

Page 639: ...lastic Push Rivet i Service Panel w RH Fender Flair o LH Rear Fender e Trim Clip a LH Fender Flair r RH Rear Fender s Rear Fender Intake Fastener 22 in lbs 2 5 Nm t Body Fastener 3 5 lb ft 4 7 Nm d Cl...

Page 640: ...lastic Push Rivet i Service Panel w RH Fender Flair o LH Rear Fender e Trim Clip a LH Fender Flair r RH Rear Fender s Rear Fender Intake Fastener 22 in lbs 2 5 Nm t Body Fastener 3 5 lb ft 4 7 Nm d Cl...

Page 641: ...FLOOR ASSEMBLY VIEW GENERAL 4 GENERAL XP 4 q Front Closeoff Panel i U Nut w Service Panel o RH Floor Clip e Plastic Push Rivet a LH Floor Clip r RH Upper Center Fender s Floor Drain Plug t Body Fasten...

Page 642: ...LH Center Console w Plastic Push Rivet a Cup Holder e Passenger Grab Handle s Rubber Grommet r Passenger Grab Handle Fasteners 6 lb ft 8 Nm d Compartment Plug t Console Service Panel f Center Console...

Page 643: ...15 REAR CENTER CONSOLE q Center Console Top u Compartment Plug w Plastic Push Rivet i Center Console Cover Fastener 22 in lbs 2 5 Nm e Rear Center Console o Center Console Cover r Storage Bin a Inner...

Page 644: ...f LH Fender Flair e Trim Clip g Rear Fender Intake Fastener 22 in lbs 2 5 Nm r RH Rear Fender h Clutch Intake Filter t Body Fastener 3 5 lb ft 4 7 Nm j Rear Fender Intake y RH Rocker Panel k Service...

Page 645: ...air f LH Fender Flair e Trim Clip g Rear Fender Intake Fastener 22 in lbs 2 5 Nm r RH Rear Fender h Clutch Intake Filter t Body Fastener 3 5 lb ft 4 7 Nm j Rear Fender Intake y RH Rocker Panel k Servi...

Page 646: ...s Inc SEATS SEAT ASSEMBLY VIEW GENERAL SEAT ASSEMBLY q Seat Back Asm y Seat Slider Asm w Seat Bottom Asm u Seat Slider Base Asm e Seat Back Bottom Mounting Fasteners 6 ft lbs 8 Nm i Tube Spacer r Seat...

Page 647: ...OUNTING q Seat Belt Asm u Nut w Nut i T Rail Bracket Mount Fasteners 3 5 ft lbs 5 Nm e Seat Belt Buckle Fasteners 40 lb ft 54 Nm o T Rail Bracket Mount r Seat Belt Buckle a LH T Rail Bracket t Seat Be...

Page 648: ...ASSEMBLY VIEW GENERAL 4 SEAT ASSEMBLY q Seat Back Asm u Tube Spacer w Seat Bottom Asm i Seat Frame e Seat Slider Asm o Seat Base Pad r Seat Back Bottom Mounting Fasteners 6 ft lbs 8 Nm a Sleeve t Seat...

Page 649: ...l Copyright Polaris Inc 11 21 SEAT BELT MOUNTING q Front Seat Belt Asm y Rear Seat Belt Asm w Nut u Nut e Seat Belt Buckle Fasteners 40 lb ft 54 Nm i Washer r Seat Belt Buckle o Seat Belt Adjuster Mou...

Page 650: ...yright Polaris Inc CARGO BOX CARGO BOX ASSEMBLY VIEW GENERAL CARGO BOX MOUNTING q Cargo Box Assembly t Nut w Cargo Box Body Fasteners 3 5 ft lbs 5 Nm y Tailgate Support Mounting Fasteners 8 ft lbs 11...

Page 651: ...q Box Support i Dump Box Shock w Cargo Box Mounting Fasteners 5 ft lbs 7 Nm o Clevis Pin e Nut a Nut 60 in lbs 7 Nm r Lower Front Fender Flair Fastener 3 5 lb ft 4 7 Nm s Box Latch Bushing t Latch Sp...

Page 652: ...gate Latch Hook Fasteners 7 ft lbs 10 Nm r Side Fender Flair Fasteners 3 5 lb ft 4 7 Nm f Tailgate Cable Fasteners 7 ft lbs 10 Nm t LH Box Panel g Tailgate Support to Fender Flair Fasteners 22 in lbs...

Page 653: ...bs 2 5 Nm i Trim Clip w Inner Tailgate Panel o Hitch Pin e Tailgate Cable a Tailgate Latch Spring r Tailgate Rod s Inner Tailgate Pivot Bracket Fasteners 22 in lbs 2 5 Nm t Outer Tailgate Panel d Tail...

Page 654: ...Copyright Polaris Inc CARGO BOX ASSEMBLY VIEW GENERAL XP CARGO BOX MOUNTING q Cargo Box Assembly t Nut w Cargo Box Body Fasteners 3 5 ft lbs 5 Nm y Tailgate Support Mounting Fasteners 8 ft lbs 11 Nm...

Page 655: ...q Box Support i Dump Box Shock w Cargo Box Mounting Fasteners 5 ft lbs 7 Nm o Clevis Pin e Nut a Nut 60 in lbs 7 Nm r Lower Front Fender Flair Fastener 3 5 lb ft 4 7 Nm s Box Latch Bushing t Rubber B...

Page 656: ...ok r 1 4 Turn Clip g Tailgate Latch Hook Fasteners 7 ft lbs 10 Nm t Side Fender Flair Fasteners 3 5 lb ft 4 7 Nm h Tailgate Cable Fasteners 7 ft lbs 10 Nm y 1 4 Turn Retainer j Tailgate Support to Fen...

Page 657: ...bs 2 5 Nm i Trim Clip w Inner Tailgate Panel o Hitch Pin e Tailgate Cable a Tailgate Latch Spring r Tailgate Rod s Inner Tailgate Pivot Bracket Fasteners 22 in lbs 2 5 Nm t Outer Tailgate Panel d Tail...

Page 658: ...nual Copyright Polaris Inc DOORS DOOR ASSEMBLY VIEW FRONT FRONT DOOR MOUNTING q Door Hinge Pivot Fastener t Washer w Door Pivot Bushing y Striker Mount e Nut 8 lb ft 11 Nm u Striker Mount Fasteners 5...

Page 659: ...t Inner Door Panel Fasteners T 40 42 in lbs 5 Nm e Inner Door Panel Fasteners T 25 22 in lbs 2 5 Nm y Inner Door Trim q RH Inner Front Door Panel t Inner Door Panel Fasteners T 40 42 in lbs 5 Nm w Doo...

Page 660: ...Door Handle Fasteners 22 in lbs 2 5 Nm y 90 Deg Cable Retention Bracket Fasteners 3 5 ft lbs 4 7 Nm 1 Door Latch u Nut 2 Door Latch Clip i Inner Door Handle Fasteners 3 5 ft lbs 4 7 Nm 2 Door Latch F...

Page 661: ...L GENERAL XP Service Manual Copyright Polaris Inc 11 33 FRONT OUTER DOOR ASSEMBLY q Outer Front Door Panel e Outer Door Panel Fasteners 42 in lbs 5 Nm w U Nut NOTICE LH outer door panel shown RH outer...

Page 662: ...are only applicable to GENERAL 4 models REAR DOOR MOUNTING q Door Hinge Pivot Fastener y Nut w Door Pivot Bushing u Upper Rear Bolster Fasteners 17 lb ft 23 Nm e Nut 8 lb ft 11 Nm i RH Rear Bolster r...

Page 663: ...NERAL XP Service Manual Copyright Polaris Inc 11 35 REAR INNER DOOR ASSEMBLY q LH Inner Front Door Panel e Inner Door Panel Fasteners 22 in lbs 2 5 Nm w Door Seal NOTICE LH inner door panel shown RH i...

Page 664: ...Door Frame u Door Latch Fasteners7 ft lbs 10 Nm w Door Hinge Fasteners 17 lb ft 23 Nm i Nut e Rear Door Hinge o Rear Door Handle r Adjustable Rear Door Cable a Door Handle Fasteners 16 in lbs 2 Nm t...

Page 665: ...e Manual Copyright Polaris Inc 11 37 REAR OUTER DOOR ASSEMBLY q Outer Front Door Panel e Bolster Bar Cover w U Nut r Outer Door Panel Bolster Bar Cover Fasteners 22 in lbs 2 5 Nm NOTICE LH outer door...

Page 666: ...Copyright Polaris Inc ROPS ROPS ASSEMBLY VIEW GENERAL q ROPS Fasteners 40 lb ft 54 Nm y ROPS LH w Nut u ROPS Rear e Front Support Fasteners 40 lb ft 54 Nm i ROPS RH r ROPS Front Support o Visor Panel...

Page 667: ...PS ASSEMBLY VIEW GENERAL 4 q ROPS Fasteners 40 lb ft 54 Nm i ROPS Rear LH w Nut o ROPS Rear e Front Support Fasteners 40 lb ft 54 Nm a ROPS Rear RH r ROPS Front Support s ROPS Front RH t U Nut d Visor...

Page 668: ...W GENERAL q Seat Base Frame y Top Frame Fasteners 22 ft lbs 30 Nm w Front Seat Base Frame M8 Fasteners 10 ft lbs 14 Nm u Nut e Front Seat Base Frame M10 Fasteners 30 ft lbs 41 Nm i Front Frame r Top F...

Page 669: ...9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 11 41 SKID PLATE q Main Skid Plate e Skid Plate Washer w Rear Skid Plate r Skid Plate Fasteners 3 5 lb ft 4 7 Nm BODY FRA...

Page 670: ...AL GENERAL XP Service Manual Copyright Polaris Inc FRAME MOUNTING TORQUE SEQUENCE q Upper Frame Fasteners e Lower Frame Fasteners w Nut Step 1 35 ft lbs 47 Nm Step 2 40 ft lbs 54 Nm Shaded callouts in...

Page 671: ...steners 22 ft lbs 30 Nm e Seat Support Bracket s Nut r Lower Seat Support Bracket M10 Fasteners 30 ft lbs 41 Nm d Upper Seat Support Bracket M10 Fasteners 30 ft lbs 41 Nm t Rear Seat Base Frame M8 Fas...

Page 672: ...ERAL GENERAL XP Service Manual Copyright Polaris Inc SKID PLATE q Front Skid Plate e Skid Plate Washer w Center Skid Plate r Skid Plate Fasteners 3 5 lb ft 4 7 Nm e Rear Skid Plate y Skid Plate Fasten...

Page 673: ...anual Copyright Polaris Inc 11 45 FRAME MOUNTING TORQUE SEQUENCE q Upper Outer Frame Fasteners e Lower Outer Frame Fasteners w Nut Step 1 35 ft lbs 47 Nm Step 2 40 ft lbs 54 Nm Shaded callouts indicat...

Page 674: ...l Copyright Polaris Inc FRAME ASSEMBLY VIEW GENERAL XP q Seat Base Frame t Top Frame Fasteners 22 ft lbs 30 Nm w Front Seat Base Frame M8 Fasteners 10 ft lbs 14 Nm y Nut e Front Seat Base Frame M10 Fa...

Page 675: ...9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 11 47 SKID PLATE q Main Skid Plate e Skid Plate Washer w Rear Skid Plate r Skid Plate Fasteners 3 5 lb ft 4 7 Nm BODY FRA...

Page 676: ...Frame M8 Fasteners 10 ft lbs 14 Nm o Top Frame Fasteners 22 ft lbs 30 Nm e Seat Support Bracket a Nut r Lower Seat Support Bracket Fasteners 30 ft lbs 41 Nm s Upper Seat Support Bracket Fasteners 30...

Page 677: ...GENERAL XP Service Manual Copyright Polaris Inc 11 49 SKID PLATE q Front Skid Plate e Skid Plate Washer w Center Skid Plate r Skid Plate Fasteners 3 5 lb ft 4 7 Nm e Rear Skid Plate y Skid Plate Faste...

Page 678: ...r to expose door hinge 2 Remove door hinge fasteners 3 Remove door from vehicle DOOR REMOVAL GENERAL 4 FRONT DOOR REMOVAL 1 Open door to expose door hinge 2 Remove door hinge fasteners 3 Remove door f...

Page 679: ...ove from the vehicle EXTERIOR BODY COMPONENT REMOVAL 1 Remove the hood from the vehicle Refer to Hood Removal page 11 51 procedure 2 Remove the front bumper from the vehicle Refer to Front Bumper Remo...

Page 680: ...REMOVAL 1 Remove the fasteners holding the rear fender to the vehicle and rocker panel Pull the rear fender from the tabs holding it to the vehicle NOTICE Remove the clutch intake hose from the LH re...

Page 681: ...holding the hood liner to the vehicle and remove the hood liner EXTERIOR BODY COMPONENT REMOVAL GENERAL 4 1 Remove the hood from the vehicle Refer to Hood Removal page 11 51 procedure 2 Remove the fr...

Page 682: ...Pull the fender tabs up out of the rocker panel REAR FENDER FLAIR REMOVAL 1 Pull the cargo box handle and lift the cargo box out of the way 2 Remove the fasteners holding the rear fender flair to the...

Page 683: ...fasteners holding the lower front fascia to the vehicle Remove the lower front fascia from the vehicle 2 To remove the hood liner remove the fasteners and clamps securing the pulse bar mounting brack...

Page 684: ...e vehicle 2 Remove the upper dash panel UPPER FLOOR PANEL REMOVAL 1 Remove the fasteners holding the upper floor panel to the main floor panels CONTROLS CONSOLE PANEL REMOVAL 1 Pull the controls conso...

Page 685: ...he vehicle 4 Remove the shift boot from the center console top and remove the remaining fasteners holding center console top to the vehicle Disconnect the 12 V power connectors and remove the center c...

Page 686: ...rake Pedal Removal page 10 48 procedure 2 Remove the remaining fasteners holding the RH and LH main floors to the vehicle INTERIOR BODY COMPONENT REMOVAL GENERAL 4 NOTICE ROPS shown removed for illust...

Page 687: ...console panel and behind the speedometer display holding the main dash to the vehicle Disconnect the rest of the interior controls from the wire harness and remove the main dash from the vehicle NOTI...

Page 688: ...Disconnect the accessory power outlet and remove the rear center console and top from the vehicle UPPER REAR CLOSEOFF PANEL REMOVAL 1 Remove the fasteners holding the rear upper close off panel to the...

Page 689: ...LOOR REMOVAL 1 Remove the fasteners holding the front seat base frame to the vehicle 2 Remove the remaining fasteners holding the rear RH and LH floors to the vehicle MAIN FLOOR REMOVAL 1 Remove the b...

Page 690: ...he cargo box handle and lift the cargo box up 2 Remove the pin holding the shock to the cargo box 3 Disconnect the cargo box wire harness from the main wire harness 4 Remove the fasteners holding the...

Page 691: ...box and secure in position INTERIOR BODY COMPONENT INSTALLATION NOTICE ROPS shown removed for illustration purposes only It is not necessary to remove the ROPS to remove the interior body components...

Page 692: ...RQUE Rear Upper Close off Panel Fasteners 3 5 lb ft 4 7 Nm 2 Install the ECU Refer to ECU Replacement page 4 2 procedure CENTER CONSOLE INSTALLATION 1 Install the center console top into the vehicle a...

Page 693: ...in floor panels DASH INSTALLATION 1 Connect the interior controls to the wiring harness and install the main dash into the vehicle Install the fasteners in the glovebox behind the controls console pan...

Page 694: ...COMPONENT INSTALLATION GENERAL 4 NOTICE ROPS shown removed for illustration purposes only It is not necessary to remove the ROPS to remove the interior body components MAIN FLOOR INSTALLATION 1 Instal...

Page 695: ...t 14 Nm Front Seat Base Frame M10 Fasteners 40 lb ft 54 Nm FRONT CLOSEOFF PANEL INSTALLATION 1 Install the fasteners holding the front close of panel to the vehicle Torque fasteners to specification T...

Page 696: ...Install the ECU Refer to ECU Replacement page 4 2 procedure REAR CENTER CONSOLE INSTALLATION 1 Install the fasteners holding the rear center console to the vehicle 2 Install the fasteners holding the...

Page 697: ...ole Panel Fasteners 3 5 lb ft 4 7 Nm 3 Install the center tunnel access cover and fasteners securing it to the RH and LH center console panels 4 Install the fasteners holding the passenger grab handle...

Page 698: ...the main dash to the vehicle Torque fasteners to specification TORQUE Main Dash Fasteners 3 5 lb ft 4 7 Nm CONTROLS CONSOLE PANEL INSTALLATION 1 Install the wiring harness connectors to the controls...

Page 699: ...ue fasteners to specification TORQUE Pulse Bar Fasteners 3 lb ft 4 Nm Intake Duct Hose Clamp 3 lb ft 4 Nm Coolant Surge Tank Fasteners 2 lb ft 2 7 Nm FRONT FASCIA INSTALLATION 1 Install the front fasc...

Page 700: ...hose clamp until taught do NOTovertighten hose clamp Install the fasteners holding the rear fender to the vehicle and rocker panel Torque the fasteners to specification TORQUE Rear Fender Fasteners 3...

Page 701: ...all the hood onto the vehicle Refer to Hood Installation page 11 76 procedure EXTERIOR BODY COMPONENT INSTALLATION GENERAL 4 HOOD LINER INSTALLATION 1 If removed install fasteners holding the hood lin...

Page 702: ...4 7 Nm 2 Install the fasteners holding the lower front fascia to the vehicle ROCKER PANEL INSTALLATION 1 Install the fasteners holding the rocker panel to the vehicle TORQUE Rocker Panel Fasteners 3...

Page 703: ...lower fender tabs into of the rocker panel Install the fasteners holding the center lower fender to the vehicle Torque fasteners to specification TORQUE Center Lower Fender Fasteners 3 5 lb ft 4 7 Nm...

Page 704: ...5 lb ft 4 7 Nm 2 Install the hood onto the vehicle Refer to Hood Installation page 11 76 procedure HOOD INSTALLATION 1 Install the hood on the vehicle and align the latches 2 Rotate the latches 90 to...

Page 705: ...stic covers off of door panel 2 Loosen 13mm door hinge fasteners q 3 With the help of an assistant align the Driver door hinges with door hinge mounting brackets 4 Place door pivot bushings in door hi...

Page 706: ...m 9 Check the front door gap on its leading edge NOTICE If door gap adjustment is needed make a small adjustment to the striker pin vertical position and redo steps 2 7 and 8 10 Verify the door proper...

Page 707: ...ith the help of an assistant align the Driver side front door hinges with door hinge mounting brackets 5 Install the door hinge pivot bolts and nuts into the door hinges using a 13 mm socket and wrenc...

Page 708: ...Hinge Fasteners 27 lb ft 37 Nm 9 Check the front door gap on its leading edge NOTICE If door gap adjustment is needed make a small adjustment to the striker pin vertical position and redo steps 2 7 an...

Page 709: ...Check the door gap on its leading edge NOTICE If door gap adjustment is needed make a small adjustment to the striker pin vertical position and redo steps 1 4 7 Verify that the door properly opens cl...

Page 710: ...3 Remove inner door panel by removing its fasteners e 4 Push door latch into double lock position 5 Locate exterior handle cable adjuster 6 Loosen the door cable lock collar and adjuster until no thre...

Page 711: ...the paint mark 11 Push door latch into double lock position 12 Open exterior door handle slowly NOTICE The exterior door handle should be about 3 4 of the way through its throw when it releases the la...

Page 712: ...Push door latch into double lock position 23 Open interior door handle slowly NOTICE The interior door handle should be about 3 4 of the way through its throw when it releases the latch Adjust cable...

Page 713: ...handle in the full open position turn the adjuster until the door latch opens 6 Mark the adjuster with a paint pen 7 Turn the adjuster an additional 3 4 turns NOTICE The door handle should be about 3...

Page 714: ...e RH and LH ROPS to the vehicle frame and rear ROPS 4 Pull the cargo box handle and lift the cargo box out of the way 5 Remove the fasteners that hold the rear ROPS to the vehicle frame ROPS INSTALLAT...

Page 715: ...to specification in order of installation TORQUE Rear ROPS Fasteners 40 lb ft 54 Nm Side ROPS Fasteners 40 lb ft 54 Nm Front Cross Fasteners 40 lb ft 54 Nm 6 Install the fasteners that hold the visor...

Page 716: ...he seat belt shoulder strap assemblies to the center and rear ROPS 7 Remove the fasteners that hold the rear ROPS to the vehicle frame 8 Remove the fasteners that hold the center ROPS to the vehicle f...

Page 717: ...ll the fasteners that hold the front cross to the front RH and LH ROPS Torque the ROPS fasteners to specification in order of installation TORQUE Center ROPS Fasteners 40 lb ft 54 Nm Rear ROPS Fastene...

Page 718: ...orque fasteners to specification TORQUE Skid Plate Fasteners 3 5 lb ft 4 7 Nm SKID PLATE REPLACEMENT GENERAL 4 1 Remove the fasteners that hold the front skid plate to the frame and remove the front s...

Page 719: ...BOX HARNESS COMPONENT LOCATIONS INTL 12 24 CARGO BOX HARNESS ROUTING RETENTION INTL 12 25 INSTRUMENT CLUSTER SERVICE 12 26 INSTRUMENT CLUSTER OVERVIEW 12 26 INSTRUMENT CLUSTER REPLACEMENT 12 26 INSTR...

Page 720: ...NTL ABS 12 52 CHARGING SYSTEM SERVICE 12 55 CHARGING SYSTEM OPERATION OVERVIEW 12 55 CHARGING SYSTEM BREAK EVEN TEST 12 55 CHARGING SYSTEM STATOR ALTERNATOR TESTS 12 55 STATOR ALTERNATOR REPLACEMENT 1...

Page 721: ...LIGHTS HORN SWITCH INT L TRACTOR 12 72 HORN 12 72 TURN LIGHTS 12 72 FLASHER MODULE 12 73 BRAKE ALARM 12 73 PARKING BRAKE SWITCH 12 73 FOG LIGHT SWITCH 12 74 VEHICLE SPEED SENSOR VSS 12 75 VSS OPERATI...

Page 722: ...der 10 Ohms remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead res...

Page 723: ...er PV 43568 Static Timing Light Harness 2871745 Hall Effect Sensor Probe Harness 2460761 Battery Conductance Analyzer MDX 610P PU 50296 Connector Test Kit PV 43526 Timing Light 2870630 Relay Bypass PU...

Page 724: ...Voltage Regulator AC Input j AWD 2WD TURF Switch r Voltage Regulator DC Out k Speedometer t Video Front l Key Switch y Winch Contactor 1 12V Receptacle HI Dash u Engine Coolant Fan 2 Winch Switch i A...

Page 725: ...Sensor t ECM Code 13 2 MAG Fuel Injector y Purge Solenoid 2 T Map u Ground Ignition Coil 2 PTO Fuel Injector i Ignition Coil 2 Stator AC o Coolant Temp Sensor 2 Fuel Pump Sender a Oxygen Sensor 2 12V...

Page 726: ...Inc HARNESS ROUTING RETENTION 2 SEAT FRONT VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point w Edge Clip NOTICE If harness replacement is required no...

Page 727: ...olaris Inc 12 9 REAR VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point e Cable Clip w Edge Clip NOTICE If harness replacement is required note the ro...

Page 728: ...r Voltage Regulator DC Out 1 12V Receptacle HI Dash t Video Front 2 Winch Switch y Winch Contactor 2 12V Receptacle LO Dash u Engine Coolant Fan 2 Seatbelt Switch i AWD Coil 2 12V Receptacle HI Consol...

Page 729: ...tion Sensor t ECM Code 13 2 MAG Fuel Injector y Purge Solenoid 2 T Map u Ground Ignition Coil 2 PTO Fuel Injector i Ignition Coil 2 Stator AC o Coolant Temp Sensor 2 Fuel Pump Sender a Oxygen Sensor 2...

Page 730: ...Inc HARNESS ROUTING RETENTION 4 SEAT FRONT VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point w Edge Clip NOTICE If harness replacement is required no...

Page 731: ...laris Inc 12 13 REAR VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point e Cable Clip w Edge Clip NOTICE If harness replacement is required note the ro...

Page 732: ...12 14 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc CARGO BOX HARNESS COMPONENT LOCATIONS q Chassis Harness e RH Taillight w LH Taillight CHASSIS BODY ELECTRICAL...

Page 733: ...laris Inc 12 15 CARGO BOX HARNESS ROUTING RETENTION q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point NOTICE If harness replacement is required note the r...

Page 734: ...Input h Brake Pedal Switch 2 Hazard Switch r Voltage Regulator DC Out j Operator Alarm Signal 2 12V Receptacle LO Dash t Winch Contactor k Operator Alarm B 2 Fog Light Switch y Fan l LED Light 1 3 LE...

Page 735: ...le LO Console r Start Solenoid B 2 g Trailer Jumper 2 12V Receptacle HI Console t ECM Code 4 h Vehicle Speed Sensor 2 Park Brake y ECM Code 13 j Transmission Switch 2 Seatbelt Switch u Ignition Coil k...

Page 736: ...HARNESS ROUTING RETENTION INTL NON ABS FRONT VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point w Edge Clip NOTICE If harness replacement is required...

Page 737: ...laris Inc 12 19 REAR VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point e Cable Clip w Edge Clip NOTICE If harness replacement is required note the ro...

Page 738: ...Receptacle LO Dash r Voltage Regulator DC Out k Operator Alarm Signal 3 Fog Light Switch t Winch Contactor l Operator Alarm B 3 LED Light 5 y LF ABS Sensor 1 LED Light 1 3 Infotainment u Fan 2 Winch S...

Page 739: ...h Trailer Jumper 2 12V Receptacle LO Console t Start Solenoid B 3 j LR ABS Sensor 2 12V Receptacle HI Console y ECM Code 4 k Vehicle Speed Sensor 2 Park Brake u ECM Code 13 l Transmission Switch 2 Se...

Page 740: ...nc HARNESS ROUTING RETENTION INTL ABS FRONT VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point w Edge Clip NOTICE If harness replacement is required n...

Page 741: ...laris Inc 12 23 REAR VIEW q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point e Cable Clip w Edge Clip NOTICE If harness replacement is required note the ro...

Page 742: ...1 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc CARGO BOX HARNESS COMPONENT LOCATIONS INTL q Chassis Harness r License Plate Lamp w Fog Light t RH Taillight e LH Taillight CHASSIS...

Page 743: ...is Inc 12 25 CARGO BOX HARNESS ROUTING RETENTION INTL q Zip Tie Retention Locations The white tape on the harness signifies a zip tie retention point NOTICE If harness replacement is required note the...

Page 744: ...r to Interior Body Component Removal page 11 56 procedure 2 Disconnect the wire harness connector from the back side of the instrument cluster 3 Remove the fasteners holding the instrument cluster mou...

Page 745: ...al Input 7 High Beam Input 8 Trailer Turn Sign Input 10 Fuel Level Sensor 11 Blackout Mode Input 12 Accy Air Temp Input 15 INSTRUMENT CLUSTER PINOUTS INTL FUNCTION PIN CAN HIGH 1 CAN LOW 2 SWITCHED PO...

Page 746: ...s Whenever removing the battery disconnect the black negative cable first When reinstalling the battery install the black negative cable last 3 Disconnect the red positive battery cable 4 Remove the b...

Page 747: ...he chance of sparks Whenever removing the battery disconnect the black negative cable first When reinstalling the battery install the black negative cable last 3 Disconnect the red positive battery ca...

Page 748: ...atteries are Lead Acid Conventional Dry Shipped Absorbed Glass Mat AGM Lead Acid Low Maintenance AGM Low Maintenance To identify which type of battery the vehicle has refer to the examples below and f...

Page 749: ...attention IMPORTANT Do not activate the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a b...

Page 750: ...ring charging see Battery Removal 2 Charge the battery with a charging output no larger than 10 of the battery s amp hour rating Charge as needed to raise the specific gravity to 1 270 or greater 3 In...

Page 751: ...the battery IMPORTANT Do not remove the sealing strip until ready to activate the battery 4 Remove the top strip of caps on the electrolyte package NOTICE Retain this strip of caps for battery sealin...

Page 752: ...tap on the top of the container to aid the flow of electrolytes into the battery 8 Remove the empty electrolyte container from the battery and immediately install the previously removed strip of seali...

Page 753: ...plied during charging NOTICE Battery voltage may reach more than 16 volts during initial charging session 2 Allow battery to stand for 1 2 hours before checking voltage 3 Check open circuit voltage Co...

Page 754: ...pilled acid during charging see Battery Removal 2 Charge the battery with a charging output no larger than 10 of the battery s amp hour rating Charge as needed to raise the specific gravity to 1 270 o...

Page 755: ...eries AGM BATTERY CHARGING LOW CHARGE The nominal voltage for an AGM battery is 12 8 Volts when fully charged The battery will self discharge when disconnected from a vehicle and will discharge at a f...

Page 756: ...atteries to full capacity Listed in the table below are the approximate charging times for deeply discharged batteries Always use the recommended automatic battery charger and wait for the charger to...

Page 757: ...ove the battery from the vehicle and store the battery in a cool dry location Continue to maintain the battery with the BatteryMINDer 2012 AGM 2 AMP charger and inspect the battery every 60 days BATTE...

Page 758: ...ry in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seco...

Page 759: ...again in 3 months None Required 75 100 12 6 12 8 May need slight charge 3 6 hrs 50 75 12 3 12 6 Needs Charge 5 11 hrs 25 50 12 0 12 3 Needs Charge At least 13 hrs 0 25 12 0 or less Needs Charge At lea...

Page 760: ...er steering A circuit breaker protects the fan motor circuit Relay Operation The relays assist with component operation like the cooling fan fuel pump EFI system and electronic power assisted steering...

Page 761: ...B SPLICE EFI B 2 RELAY FUSE BLOCK EFI B FAN COIL HI 10 OG BK RELAY FUSE BLOCK RELAY FUSE BLOCK FAN B FUSED RELAY IN 13 OG BK RELAY FUSE BLOCK ENGINE COOLANT FAN FAN B RELAY OUT 14 OG BK ECM CODE 4 REL...

Page 762: ...ERM FUSE OUT 40 BN RELAY FUSE BLOCK SPLICE COIL GND GROUND TERM RELAY COIL FUSE DETAILS FUSE RELAY PIN WIRE COLOR FROM COMPONENT TO COMPONENT FUNCTION EFI 10A Fuse 17 RD SPLICE EFI RELAY FUSE BLOCK EF...

Page 763: ...G SPLICE DRIVE RELAY FUSE BLOCK SWITCHED B DRIVE FUSE OUT Key 10A Fuse 43 RD RELAY FUSE BLOCK START SOLENOID B UNSWITCHED B KEY FUSE IN 47 RD WH RELAY FUSE BLOCK KEY SWITCH KEY FUSE OUT CIRCUIT BREAKE...

Page 764: ...SPLICE EFI B 2 RELAY FUSE BLOCK EFI B FAN COIL HI 10 OG BK RELAY FUSE BLOCK RELAY FUSE BLOCK FAN B FUSED RELAY IN 13 OG BK RELAY FUSE BLOCK ENGINE COOLANT FAN FAN B RELAY OUT 14 OG BK ECM CODE 4 RELA...

Page 765: ...TERM FUSE OUT 40 BN RELAY FUSE BLOCK SPLICE COIL GND GROUND TERM RELAY COIL FUSE DETAILS FUSE RELAY PIN WIRE COLOR FROM COMPONENT TO COMPONENT FUNCTION EFI 10A Fuse 17 RD SPLICE EFI RELAY FUSE BLOCK...

Page 766: ...SPLICE DRIVE RELAY FUSE BLOCK SWITCHED B DRIVE FUSE OUT Key 10A Fuse 43 RD RELAY FUSE BLOCK START SOLENOID B UNSWITCHED B KEY FUSE IN 47 RD WH RELAY FUSE BLOCK KEY SWITCH KEY FUSE OUT CIRCUIT BREAKER...

Page 767: ...RT RELAY COIL Fuel Pump Relay 25 RD DB RELAY FUSE BLOCK SPLICE EFI B 2 EFI B FUEL PUMP COIL HI 26 OG RELAY FUSE BLOCK SPLICE R S B 2 KEY SWITCH B FUEL PUMP RELAY IN 31 RD BU RELAY FUSE BLOCK FUEL PUMP...

Page 768: ...1 UNSWITCHED FUSED B EFI RELAY COIL HI 30 RD RELAY FUSE BLOCK RELAY FUSE BLOCK UNSWITCHED FUSED B EFI RELAY IN 35 RD DB RELAY FUSE BLOCK SPLICE EFI B EFI B EFI RELAY OUT 36 DG YE ECM CODE 4 RELAY FUS...

Page 769: ...BLOCK RELAY FUSE BLOCK UNSWITCHED FUSED B EFI RELAY IN Lights 20A Fuse 42 RD DG SPLICE CHASSIS RELAY FUSE BLOCK CHASSIS RELAY OUT LIGHTS INPUT 48 RD YE RELAY FUSE BLOCK SPLICE FUSED LIGHTS B LIGHTS B...

Page 770: ...RELAY COIL Fuel Pump Relay 25 RD DB RELAY FUSE BLOCK SPLICE EFI B 2 EFI B FUEL PUMP COIL HI 26 OG RELAY FUSE BLOCK SPLICE R S B 2 KEY SWITCH B FUEL PUMP RELAY IN 31 RD BU RELAY FUSE BLOCK FUEL PUMP SE...

Page 771: ...NSWITCHED FUSED 1 UNSWITCHED FUSED B EFI RELAY COIL HI 30 RD RELAY FUSE BLOCK RELAY FUSE BLOCK UNSWITCHED FUSED B EFI RELAY IN 35 RD DB RELAY FUSE BLOCK SPLICE EFI B EFI B EFI RELAY OUT 36 DG YE ECM C...

Page 772: ...EY FUSE OUT EPS 30A Fuse 18 RD RELAY FUSE BLOCK START SOLENOID B 1 UNFUSED B EPS 24 RD EPS POWER RELAY FUSE BLOCK EPS FUSE POWER OUT EFI 15A Fuse 41 RD SPLICE EFI RELAY FUSE BLOCK EFI B FUSE IN 47 RD...

Page 773: ...en point may vary slightly The battery should be fully charged before performing this test WARNING Never start the engine with an ammeter connected in series Damage to the meter or meter fuse will res...

Page 774: ...tage readings according to RPM Test each leg at the specified RPM in the table 5 Example The alternator current output reading should be approximately 21 VAC 25 at 1300 RPM between each leg 6 If one o...

Page 775: ...TESTING PROCEDURE 1 Remove the negative cable from the battery 2 Connect a jumper from the negative battery cable terminal to the negative battery post 3 Ensure your meter leads and selector dial are...

Page 776: ...s The battery will continually discharge if operated below the Break Even RPM Continued problems would call for battery inspection No Ohm stator wires if bad replace stator if good continue with alter...

Page 777: ...through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 0 1 VDC per connection or component To...

Page 778: ...ter solenoid Starter Solenoid Terminal Resistance 77 F 0 0 5 Starter Solenoid Operation To energize the Starter Solenoid the following must occur The brake must be applied to provide a ground path via...

Page 779: ...operate for up to five minutes After the five minutes you will need to cycle the key switch and restart the engine to regain power steering operation NOTICE To conserve battery power the EPS unit will...

Page 780: ...hile performing this procedure 5 Adjust the beam to the desired position by loosening or tightening the three adjustment screws q and moving the lamp to the appropriate height 6 Adjust the beam to the...

Page 781: ...headlight assembly from the bumper HEADLIGHT INSTALLATION 1 Install the headlight adjustment springsw onto the front bumper mounting bosses 2 Insert the three headlight mounting screws q into the hea...

Page 782: ...olding the cargo box trim panel to the cargo box and remove the panel 3 Reaching through the access hole on the outside of the cargo box remove the fasteners holding the tail light to the cargo box 4...

Page 783: ...s greater than 0 5 ohms clean the switch terminals Re test and replace switch if necessary SWITCH POSITION CONTINUITY BETWEEN Brake Pedal Released No continuity between pins Brake Pedal Pressed Contin...

Page 784: ...Headlight Switch Light TESTING 1 Disconnect the headlight switch harness on the back side of the dash by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test b...

Page 785: ...no continuity between any of the pins Turn the key to ACCY position There should be contunity between switch pins A and B Turn the key to ON position There should be continuity between switch pins A...

Page 786: ...RF There should be continuity between switch pins 1 and 2 NOTICE Pins 7 and 2 provide power and ground to light the switch lamp TRANSMISSION GEAR POSITION SWITCH The transmission gear position switch...

Page 787: ...ckle undone vehicle speed will be limited to 15 mph If the circuit is closed buckle inserted the vehicle will function normally TESTING 1 Disconnect the harness q running to the driver s seat belt lat...

Page 788: ...ntil it is below the MINIMUM level mark The meter should read OPEN CIRCUIT FLUID LEVEL CONTINUITY BETWEEN Proper Brake Fluid Level Continuity between pins Low Brake Fluid Level No continuity between p...

Page 789: ...GHTS There should be continuity between switch pins A E and F C and D Turn the ignition key to ON There should be continuity between pins C and D E and F Turn the ignition key to START There should be...

Page 790: ...ch pins 2 and 6 Turn on the Left Turn Signal There should be continuity between switch pins 1 and 8 Turn on the Right Turn Signal There should be continuity between switch pins 1 and 7 Depress the Hor...

Page 791: ...a NOTICE If the parking brake is applied the ECU will rev limit the engine at 1500 RPM until the parking brake is released This feature has been added to prevent drive away with the parking brake appl...

Page 792: ...CTION PIN FUNCTION 1 2 Fog Light Fuse Out 3 Fog Light 4 5 6 7 Ground Fog Light 8 TESTING 1 Disconnect the harness from the hazard switch 2 Test outputs in both the ON and OFF positions If any of the t...

Page 793: ...input to the ECU The ECU then interprets this switching into the speed the output gear is rotating VSS TEST 1 Disconnect the three wire harness from the speed sensor and remove the sensor from the tr...

Page 794: ...ct the electrical harness leads to the 12V receptacle and remove from the center console s AWD COIL OPERATION OVERVIEW When the key switch is ON 12 VDC power is present at the hub coil When the AWD sw...

Page 795: ...the new pulse bar to the pulse bar bracket and secure with fasteners TORQUE Pulse Bar Fasteners Torque Until Fastener Is Fully Seated 7 Reinstall positive and negative cables and secure with nuts TOR...

Page 796: ...12 78 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES CHASSIS BODY ELECTRICAL...

Page 797: ...DE MIRROR REMOVAL INTL 13 13 SIDE MIRROR INSTALLATION INTL 13 13 LIGHT BAR SERVICE 13 14 LIGHT BAR ASSEMBLY VIEW 13 14 LIGHT BAR REMOVAL 13 15 LIGHT BAR INSTALLATION 13 16 LIGHT BAR SWITCH 13 16 FRONT...

Page 798: ...ERVICE 13 45 FRONT SPEAKER SERVICE 13 46 SUBWOOFER SERVICE 13 48 SUBWOOFER PINOUT 13 52 AMPLIFIER SERVICE 13 53 AMPLIFIER PINOUT 13 54 REAR SPEAKER ASSEMBLY SERVICE 13 54 REAR SPEAKER SERVICE 13 56 FR...

Page 799: ...on what options are installed on the vehicle being serviced Always inspect the vehicle to ensure there are not additional accessories such as electrical components that would need to be removed to all...

Page 800: ...1 GENERAL GENERAL XP Service Manual Copyright Polaris Inc ROOF SERVICE GENERAL ROOF ASSEMBLY VIEW q Front Roof Fasteners 3 5 lb ft 4 7 Nm e Rear Roof Fasteners 5 lb ft 7 Nm w Roof r Rear Roof Bracket...

Page 801: ...o either Scan the QR Code with a mobile device From a computer right click HERE and open link in a new window 1 Ensure the ROPS Visor Trim Panel has been installed 2 With the help of an assistant plac...

Page 802: ...50067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 6 Install upper rear fasteners into the roof and ROPS visor TORQUE Front Roof Fasteners 3 5 lb ft 4 7 Nm FACTORY INSTALLED O...

Page 803: ...ight Polaris Inc 13 7 ROOF SERVICE GENERAL 4 ROOF ASSEMBLY VIEW GENERAL 4 q Front Roof Fasteners 3 5 lb ft 4 7 Nm r Rear Roof Fasteners 5 lb ft 7 Nm w Front Roof Panel t Rear Roof Bracket e Rear Roof...

Page 804: ...OPS visor ROOF INSTALLATION GENERAL 4 1 Ensure the ROPS Visor Trim Panel has been installed 2 With the help of an assistant place the roof onto the top of the ROPS 3 Engage the front hooks into the RO...

Page 805: ...67 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc 13 9 6 Install upper rear fasteners into the roof and ROPS visor TORQUE Front Roof Fasteners 3 5 lb ft 4 7 Nm FACTORY INSTALLED...

Page 806: ...GENERAL GENERAL XP Service Manual Copyright Polaris Inc REAR VIEW MIRROR SERVICE REAR VIEW MIRROR ASSEMBLY VIEW q Mirror e Upper Mirror Arm w Lower Mirror Arm r Mirror Mounting Fasteners 5 lb ft 7 Nm...

Page 807: ...l the foam pads on the inside surface of the lower and upper mirror arms to help secure mirror to the tube 2 Install the rear view mirror onto the front support ROPS and align with audio system mounti...

Page 808: ...Service Manual Copyright Polaris Inc SIDE MIRROR SERVICE INTL SIDE MIRROR ASSEMBLY VIEW INTL q Mirror Set r LH Mirror Bracket w RH Mirror Bracket t LH Mirror Bracket Cover e RH Mirror Bracket Cover y...

Page 809: ...move the mirror bracket cover 3 Remove the two ROPS fasteners securing the mirror bracket and ROPS to the vehicle frame Remove the mirror bracket SIDE MIRROR INSTALLATION INTL 1 If removed the mirror...

Page 810: ...he mirror onto the mirror bracket and secure with mounting nut Torque nut to specification TORQUE Side Mirror Mounting Nut lb ft Nm LIGHT BAR SERVICE LIGHT BAR ASSEMBLY VIEW q Nut M8X1 25 18 lb ft 25N...

Page 811: ...d 1 Remove light bar assembly mounting hardware q 2 Cut cable tie w securing wire lead to front bumper 3 Remove bumper screen e to gain access to the light bar electrical connector 4 Disconnect light...

Page 812: ...stall cable tie w to secure wire lead to front bumper 4 Install light bar assembly mounting hardware q Torque to specification TORQUE Light Bar Mounting Hardware 35 lb in 3 92 Nm NOTICE Light bar shou...

Page 813: ...itch harness on the back side of the connector by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the single set of outputs ON OFF If the test belo...

Page 814: ...nual Copyright Polaris Inc FRONT BUMPER SERVICE FRONT BUMPER ASSEMBLY VIEW q Front Bumper t Lower Backer Plate w Upper Front Bumper Fasteners 30 lb ft 41 Nm y Bumper Cap e End Cap u Nut r Lower Front...

Page 815: ...inch hook 2 Remove the end caps from the front bumper 3 Remove the front bumper upper mounting fasteners NOTICE On International models disconnect the turn indicators in the bumper before removing fro...

Page 816: ...all the front bumper lower mounting fasteners and torque to specification TORQUE Front Bumper Fasteners 30 lb ft 41 Nm 2 Install the front bumper upper mounting fasteners and torque to specification T...

Page 817: ...Nut 30 lb ft 41 Nm f Winch Contactor Cable r Winch Contactor Mount Bracket g Winch Mount Bracket t Winch Contactor Fasteners 6 ft lbs 8 Nm h Winch Cable y Winch Contactor j Nut 30 lb ft 41 Nm u Nut 24...

Page 818: ...1 Route the two winch cables from the winch contactor up to the upper front shock bracket and secure with attachment clip q 2 Pass the two winch cables through the grommet w in the hood liner 3 Route...

Page 819: ...or connector 5 Remove the lower fastener on the passenger front shock 6 Remove winch from passenger side NOTICE If required remove winch mounting plate 7 Remove four 15mm nuts w retaining mounting pla...

Page 820: ...ate TORQUE Winch Fasteners 16 lb ft 22 Nm 4 Reinstall lower fastener on passenger front shock TORQUE GENERAL GENERAL 4 Shock Mount Fasteners 20 lb ft 27 Nm 90 GENERAL XP GENERAL XP 4 Shock Mount Faste...

Page 821: ...Switch B Winch Switch Light TESTING 1 Disconnect the winch switch harness on the back side of the center console by depressing the connector locks and pulling on the connector Do not pull on the wirin...

Page 822: ...in lbs 4 Nm w Routing Clip d USB Harness e AM FM Antenna Ground Strap Fastener 14 ft lbs 19 Nm f Panduit Strap r AM FM Antenna g Audio Display Bracket t Antenna Mount h Audio Display y Washer j Audio...

Page 823: ...p of the dash support tube The white tape on the harness signifies a routing retention point w Double Cable Tie The LH branch of audio harness is secured to the main chassis harness The white tape on...

Page 824: ...y from the vehicle INSTALLATION 1 Install the speaker assembly into the vehicle and align the mounting holes NOTICE Ensure speaker connector is oriented upward and not pinched between speaker and floo...

Page 825: ...is Inc 13 29 FRONT SPEAKER SERVICE NOTICE Passenger side speaker shown REMOVAL 1 Remove the four fasteners q securing the front speaker cover 2 Remove the front speaker cover 3 Remove the four fastene...

Page 826: ...rom the harness 5 Disconnect the speaker connectors e and remove the speaker INSTALLATION 1 Connect the speaker connectors e and carefully install the speaker back into the speaker housing 2 Install t...

Page 827: ...er fasteners q Torque fasteners to specification TORQUE Speaker Cover Fasteners 7 in lbs 75 Nm BASE AUDIO DISPLAY PINOUT PIN FUNCTION 1 2 3 LEFT FRONT 4 LEFT FRONT 5 6 7 8 9 USB 5V 10 USB DATA 11 USB...

Page 828: ...Amp Bracket d Washer r Subwoofer Amp Bracket Fasteners 30 in lbs 4 Nm f Washer t Subwoofer Amp Bracket Fasteners 30 in lbs 4 Nm g Nut 25 in lbs 3 Nm y Amplifier h AM FM Antenna Ground Strap u Amp Fast...

Page 829: ...er Mount Bracket w Inner Rear Speaker Mount Bracket Fasteners 30 in lbs 4 Nm i Edge Clip e Inner Front Speaker Mount Bracket o Inner Rear Speaker Mount Bracket r LH Rear Speaker Asm a Rear Audio Y Har...

Page 830: ...nt Harness o Temp Sensor Harness w Routing Clip a Panduit Strap e GPS Antenna s USB Harness r Front Camera d Display Fasteners 40 in lbs 4 5 Nm t Front Camera Mount f Display Mounting Bracket y Edge C...

Page 831: ...Inc 13 35 REAR VIEW 2 SEAT q V2V Antenna Bracket u Rear Camera w V2V Antenna i Rear Camera Mount e V2V Mount Bracket o Washer r V2V Mount Bracket Fastener 40 in lbs 4 5 Nm a Rear Camera Mount Fastener...

Page 832: ...ht Polaris Inc REAR VIEW 4 SEAT q V2V Antenna Bracket y Washer w V2V Antenna u Rear Camera Mount Fasteners 5 ft lbs 7 Nm e V2V Mounting Fastener 40 in lbs 4 5 Nm i Edge Clip r Panduit Strap o Rear Cam...

Page 833: ...on point w Double Cable Tie The LH branch of audio harness is secured to the main chassis harness The white tape on the harness signifies a cable tie retention point e Routing Clip The LH speaker sign...

Page 834: ...ess The rear audio harness is routed up through the ROPS r Edge Clip w V2V Antenna Harness Lead from Infotainment Harness The V2V Antenna Harness Lead is routed up through the ROPS t V2V Antenna e Edg...

Page 835: ...rear audio harness is routed up through the ROPS t V2V Antenna w V2V Antenna Harness Lead from Infotainment Harness The V2V Antenna Harness Lead is routed up through the ROPS y Edge Clip e Edge Clip...

Page 836: ...e display setting and user information See page RIDE COMMAND DISPLAY REMOVAL INSTALLATION 1 Remove Hood by turning 1 4 turn fasteners 2 Remove seven push pins q retaining upper dash panel 3 Disconnect...

Page 837: ...DISPLAY 16 PIN PIN FUNCTION 1 2 3 SUB LINEOUT 4 SUB LINEOUT 5 6 7 8 VIDEO TURN ON 9 10 11 GROUND VIDEO FRONT 12 VIDEO FRONT P 13 14 PIN FUNCTION 15 16 DISPLAY 32 PIN PIN FUNCTION 1 AUDIO 2 LINE OUT R...

Page 838: ...2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc PIN FUNCTION 22 GROUND VIDEO REAR 23 VIDEO REAR P 24 25 26 27 28 29 CAN HI DISPLAY 30 CAN LO DISPLAY 31 SW B DISPLAY 32 UNSW B DISPLAY FAC...

Page 839: ...p 5 5 Refer to the wiring schematic and check circuits without voltage for continuity and proper operation Did you find any problems in the circuit Go to Step 7 Go to Step 1 and repeat diagnosis 6 Rep...

Page 840: ...you find and repair the condition Go to Step 2 Repeat Diagnosis GPS Antenna Troubleshooting 1 Unplug connector from GPS antenna and verify all contacts are securely seated in the connector 2 Turn ign...

Page 841: ...bly from the vehicle INSTALLATION 1 Install the speaker assembly into the vehicle and align the mounting holes NOTICE Ensure speaker connector is oriented upward and not pinched between speaker and fl...

Page 842: ...olaris Inc FRONT SPEAKER SERVICE NOTICE Passenger side speaker shown REMOVAL 1 Remove the four fasteners q securing the front speaker cover 2 Remove the front speaker cover 3 Remove the four fasteners...

Page 843: ...from the harness 5 Disconnect the speaker connectors e and remove the speaker INSTALLATION 1 Connect the speaker connectors e and carefully install the speaker back into the speaker housing 2 Install...

Page 844: ...asteners 7 in lbs 75 Nm SUBWOOFER SERVICE REMOVAL 1 Remove hood 2 If windshield is installed then open or remove it as required to gain access to upper dash 3 Remove five push pin rivets q from front...

Page 845: ...9 Remove two screws t then lift instrument cluster assembly out of dash and set aside 10 Remove the following fasteners One push pin rivet y and screw u from each side of dash Two screws u in glove bo...

Page 846: ...ofer 15 Remove the four fasteners securing the amp s to bracket and remove amp NOTICE Note the location of the amp connector 16 Remove two fasteners d securing the subwoofer to the dash support bracke...

Page 847: ...upport structure using four fasteners f Torque fasteners to specification TORQUE Subwoofer Amp Bracket Fasteners 30 in lbs 4 Nm 3 Install two fasteners d through dash support brackets into subwoofer T...

Page 848: ...ugh the hole in the glove box and secure with grommet 9 Connect Ride Command Display electrical connectors 10 Install the instrument cluster and two fasteners Torque fasteners to specification TORQUE...

Page 849: ...isconnect the connector from the amplifier 6 Remove the four fasteners q securing the amplifier to the subwoofer bracket 7 Lift the amplifier straight out of the dash INSTALLATION 1 Carefully install...

Page 850: ...T L 17 AUDIO 1 LINE OUT L 18 AUDIO 1 LINE OUT R 19 AUDIO 1 LINE OUT R 20 SUB LINE OUT L 21 SUB LINE OUT L 22 SUB LINE OUT R 23 SUB LINE OUT R REAR SPEAKER ASSEMBLY SERVICE NOTICE Driver side rear spea...

Page 851: ...sembly into corner of ROPS so inner bracket is nested into ROPS crossmember Slide outer speaker bracket assembly along ROPS tubing until nuts in bracket align with slots in speaker 4 If required tempo...

Page 852: ...side rear speaker shown REMOVAL 1 Remove the four fasteners q securing the rear speaker cover and speaker NOTICE Use care when removing the four fasteners as they secure both the speaker cover and sp...

Page 853: ...emove the speaker INSTALLATION 1 Connect the speaker connectors w and carefully install the speaker back into the speaker housing 2 Install the speaker cover and align mounting holes 3 Install the fou...

Page 854: ...n tip forward 2 Holding grille near vehicle disconnect the main chassis connector q from front camera connector w 3 Remove the edge clip e securing the harness to grille and remove grille 4 Depress fo...

Page 855: ...ng attached to front camera rearward through grille then carefully push front camera mount into grille until all four tabs lock in place Ensure the following Camera mount is positioned as high as poss...

Page 856: ...emove the two edge clips q securing the main harness 2 Remove the edge clip w securing the camera harness connector 3 Disconnect main chassis connector e from rear camera connector r 4 Remove the fast...

Page 857: ...s y Do not overtighten screws TORQUE Rear Camera Mount Fasteners 5 ft lbs 7 Nm NOTICE RH fastener secures the outer edge of the rear box shield One washer is used as spacer on LH side of bracket 3 Joi...

Page 858: ...TICE Front fascia hidden for clarity Chassis structure may vary slightly from that shown 4 Carefully cut the ziptie portion of the edge clip e securing the ambient air temperature sensor harness 5 Car...

Page 859: ...as long as sensor is exposed to ambient air flow 3 Holding grille near vehicle connect the main harness connector to front camera connector 4 Install the front grille GPS ANTENNA SERVICE REMOVAL 1 Rem...

Page 860: ...on under hood liner NOTICE Ensure harness is routed to prevent contact with hot components sharp edges or moving parts 3 Use cable tie to coil and secure excess harness length in upper dash compartme...

Page 861: ...ing two roof bracket fasteners 4 To remove the V2V antenna from the antenna bracket open the clamshell cover Loosen slotted nut and carefully remove antenna by pulling upward and routing antenna cable...

Page 862: ...le and threaded fitting on antenna through hole in bracket rubber washer and top of clamshell cover Route antenna cable through hole in back of cover slide slotted washer and slotted nut over cable th...

Page 863: ...VEHICLE TO VEHICLE V2V ANTENNA SERVICE 4 SEAT REMOVAL 1 Disconnect the V2V antenna connector from RIDE COMMAND harness 2 Cut and remove the panduit strap securing antenna harness to the ROPS 3 Open th...

Page 864: ...Nut e Rubber Washer NOTICE Antenna cable not shown for clarity INSTALLATION 1 If V2V antenna was removed from the V2V antenna bracket open clamshell cover Insert cable and threaded fitting on antenna...

Page 865: ...B pillar bracket then install clamshell cover to bracket using two mounting fasteners Torque fasteners then close cover TORQUE V2V Mounting Fastener 40 in lbs 4 5 Nm 3 Join connector from antenna to...

Page 866: ...13 70 9850067 R01 2020 2021 GENERAL GENERAL XP Service Manual Copyright Polaris Inc NOTES FACTORY INSTALLED OPTIONS...

Page 867: ...Headlights GENERAL Base LH Headlight Jumper Harness GENERAL Base RH Headlight Jumper Harness 4 Seat Models GENERAL 4 GENERAL 4 XP 1000 2414815 Cargo Box Harness Cargo Box Harness 2413051 Factory Inst...

Page 868: ......

Page 869: ...ce 2 54 Off Season Storage 12 41 Open Circuit Voltage OCV 12 40 Removal 2 54 12 28 Specific Gravity Test 12 40 Specifications 12 28 Specifications INTL 12 29 Battery Maintenance AGM Dry Shipped 12 35...

Page 870: ...ss Component Locations Domestic Models 12 14 INTL 12 24 Routing Retention Domestic Models 12 15 INTL Models 12 25 Center Console Assembly View GENERAL GENERAL XP 11 10 Assembly View GENERAL 4 GENERAL...

Page 871: ...t Half Shaft Diagnostics 1 77 Dynamic Testing 1 84 E ECU Diagnostic Trouble Codes Overview 1 57 ETC Learn Procedure 4 8 Operation Overview 4 2 Replacement 4 2 Service 4 2 Electrical Connector Probing...

Page 872: ...em Assembly View 3 76 Exterior Body Component Removal 11 51 Component Removal GENERAL 4 11 53 F Feedback Form 3 Final Drive Service Notes 8 3 Service Specifications 8 3 Special Tools 8 3 Floor Rocker...

Page 873: ...erview 5 31 Replacement 5 33 Test 5 32 Fuel Sender Test 5 31 Fuel System Assembly View 5 4 EVAP Assembly View 5 5 Fuel Line Replacement 5 24 Fuel Lines 2 35 Fuel Tank Vent Line 2 36 Pump Filters Maint...

Page 874: ...ake Caliper Installation INT L 10 93 Parking Brake Adjustment INT L 2 52 10 91 Parking Brake Inspection INT L 2 52 10 91 Periodic Maintenance Overview 2 6 Piston Disassembly Inspection 1000 3 41 Insta...

Page 875: ...4 9 50 Removal General General 4 9 38 General XP General XP 4 9 50 Rear Suspension Assembly View General General 4 9 8 General XP General XP 4 9 15 Rear View Mirror Assembly View 13 10 Regulator Recti...

Page 876: ...Cover Installation 3 59 Stator Cover 3 30 Steering Assembly View General General 4 9 4 General XP General XP 4 9 11 Steering System Inspection 2 43 Power Steering Unit Installation 9 22 Power Steering...

Page 877: ...9 PVT System 1 73 Turn Lights Horn Switch 12 72 Horn 12 72 Turn Lights 12 72 U U Joint Assembly 8 15 Disassembly 8 14 V Valve Clearance Adjustment 3 67 Inspection 3 25 Sealing Test 3 27 Seat Reconditi...

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Summary of Contents for G21G4D99AW

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Polaris G21G4D99AW, Service Manual, Page: 7 / 877

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