Polaris G21GXJ99AJ Manuals

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Polaris G21GXJ99AJ Service Manual

Polaris G21GXJ99AJ Service Manual (877 pages)

full manual

Brand: Polaris | Category: Offroad Vehicle | Size: 47.87 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Model Number Designation
  9
- Vehicle Identification
  9
- Vehicle Identification Number (Vin) Designation
  9
- Vehicle and Engine Serial Number Location
  10
- Reference Information
  11
  - Service Rules
    11
  - Publication Part Numbers
    12
  - Replacement Keys
    13
  - Special Tools Website
    14
  - Special Tools Index
    15
- Vehicle Specifications (Model Year 2021)
  19
- Misc Specifications and Charts
  32
  - Master Torque Table
    32
  - Conversion Table
    39
  - Sae Tap / Drill Sizes
    40
  - Metric Tap / Drill Sizes
    40
  - Decimal Equivalents
    41
- General Diagnostics
  42
- Fluid Inspection
  76
- Fluid Leaks
  76
Maintenance Chapter 2 Maintenance 2

97
- Chapter 2
  99
- General Information - Maintenance
  99
- Maintenance
  99
- Service Notes - Maintenance
  99
- Special Tools - Maintenance
  99
- Service Specifications - Maintenance
  100
- Periodic Maintenance
  102
  - Periodic Maintenance Overview
    102
  - Break-In Period
    102
  - Pre-Ride Inspection
    103
  - Maintenance Interval Chart
    104
  - Maintenance Quick Reference
    117
  - Grease Lubrication Points
    119
  - Maintenance Lubricants
    120
- General Vehicle Inspection and Maintenance
  121
  - Pre-Ride / Daily Inspection
    121
  - Frame, Nuts, Bolts, and Fasteners
    121
  - Shift Cable Inspection / Adjustment
    121
  - Heat Shield Inspection
    122
- Engine Maintenance
  123
  - Engine Oil Level
    123
  - Engine Oil and Filter Change
    124
  - Engine Crankcase Breather Hose Inspection
    125
  - Engine Cylinder Leakdown Test
    125
  - Valve Clearance Inspection
    125
  - Cam Chain Tensioner Inspection
    127
- Cooling System Maintenance
  128
  - Cooling System Overview
    128
  - Coolant Strength
    128
  - Coolant Level Inspection
    128
  - Coolant Drain / Fill
    130
- Fuel System and Air Intake Maintenance
  131
  - Fuel Pump / Fuel Filters
    131
  - Fuel Tank Vent Line
    132
  - Vent Line Termination Fitting
    132
  - Air Filter Service
    133
  - Intake Duct Drain Inspection
    133
- Pvt System Maintenance
  134
  - Pvt Drying
    134
- Transmission and Front Gearcase Maintenance
  135
  - Transmission Lubrication
    135
  - Front Gearcase Lubrication
    136
- Final Drive Maintenance
  137
- Maintenance
  137
  - Drive Shaft Boot Inspection
    137
  - Wheel Removal
    137
  - Wheel Installation
    137
  - Tire Inspection
    138
  - Tire Inspection (Intl)
    138
- Steering Maintenance
  139
  - Steering Inspection
    139
  - Steering Wheel Free-Play
    139
  - Tie Rod End / Wheel Hub Inspection
    140
  - Wheel Toe Alignment Inspection
    140
  - Wheel Toe Adjustment
    141
- Suspension Maintenance - General / General 4
  142
  - Spring Adjustment
    142
  - Shock Compression Adjustment
    143
  - Spring Adjustment - General 4
    143
  - Spring Adjustment - General Xp 4
    145
  - Shock Compression Adjustment
    146
- Brake System Maintenance
  147
  - Brake Hose and Fitting Inspection
    147
  - Brake Fluid Inspection
    147
  - Brake Pad / Disc Inspection
    147
- Electrical Maintenance
  150
  - Battery Maintenance
    150
  - Battery Removal
    150
  - Battery Installation
    151
  - Battery Removal (Intl)
    151
  - Battery Installation (Intl)
    152
  - Engine / Chassis Electrical Ground
    152
  - Spark Plug Service
    153
  - Throttle Pedal Inspection
    154
Chapter 3 Engine / Cooling System

155
- General Information - Engine
  157
- Service Notes - Engine / Cooling System
  157
- Special Tools - Engine / Cooling System
  157
- Engine Cylinder Leakdown Test
  158
- Oil Pressure Test
  160
- Engine Oil Flow Chart
  161
- Engine Break-In Period
  162
- Engine Service Specifications
  163
  - Service Specifications - Engine / Cooling System
    163
- Engine Service
  165
  - Top End Service (Engine in Chassis)
    165
  - Crankshaft Pto Seal Replacement
    165
  - Engine Removal
    167
  - Engine Installation
    170
- Engine Disassembly / Inspection - Top End
  174
  - Camshaft Sprocket Inspection
    175
- Engine Disassembly / Inspection - Bottom End
  184
  - Piston-To-Cylinder Clearance
    197
- Engine Assembly - Bottom End
  200
- Engine Assembly - Top End
  214
  - Camshaft Timing - Quick Reference
    220
  - Valve Lash - Tappet Selection
    223
- Intake Service
  225
  - Intake Assembly View - General / General
    225
  - Intake Assembly View - General 4 / General
    226
  - Intake Removal
    227
  - Intake Installation
    228
- Exhaust Service
  230
  - Exhaust System Assembly View
    230
  - Exhaust Removal
    231
  - Exhaust Installation
    231
- Cooling System Service
  233
- Cooling System Hose Replacement
  242
- Radiator Replacement
  243
- Thermostat Replacement
  244
- Cooling System Bleeding
  245
- Water Pump Installation
  246
Chapter 4 Engine Electrical

251
- Ecu Operation Overview
  252
- Ecu Replacement
  252
- Ecu Service
  252
- Electronic Control Unit (Ecu)
  252
- Adjustable Speed Limiting Device (Asld) - Abs Models
  254
  - Asld Overview - Abs Models
    254
- Crankshaft Position Sensor (Cps)
  255
  - Cps Operation Overview
    255
  - Cps Test
    255
  - Cps Replacement
    256
- Electronic Throttle Control (Etc)
  257
  - Etc Operation Overview
    257
  - Etc Test
    257
  - Etc Replacement
    257
  - Etc Learn Procedure
    258
- Accelerator Position Sensor (Aps)
  259
  - Aps Operation Overview
    259
  - Aps Test
    259
  - Aps Replacement
    259
- Heated Oxygen Sensor (O2)
  260
  - O2 Operation Overview
    260
  - O2 Test
    260
  - O2 Replacement
    260
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  261
  - T-Map Operation Overview
    261
  - T-Map Test
    261
  - T-Map Replacement
    261
- Engine Coolant Temperature (Ect) Sensor
  262
  - Ect Operation Overview
    262
  - Ect Test
    262
  - Ect Replacement
    262
- Ignition System Service
  263
  - Ignition Coil / Ht Lead Replacement
    263
  - Ignition Coil Tests
    263
  - Spark Plug Service
    264
Chapter 5 Fuel System

265
- General Information - Fuel System
  266
- Service Notes - Fuel System
  266
- Service Specifications - Fuel System
  267
- Special Tools - Fuel System
  267
- Assembly Views - Fuel System
  268
  - Fuel System Assembly View
    268
  - Evap Fuel System Assembly View
    269
  - Fuel Pump Assembly View
    270
- Evap System
  271
  - Evap System Overview
    271
  - Evap Conditions and Symptoms
    272
  - Carbon Canister Filter Replacement
    273
  - Carbon Canister Replacement
    273
  - Purge Valve Replacement
    274
  - Purge Valve Ohm Test
    274
- Fuel Lines
  275
  - Fuel Line Routing
    275
  - Fuel Line Routing - General 4
    277
  - Fuel Line Routing (Evap Models)
    279
  - Fuel Line Routing - General 4 (Evap Models)
    283
  - Fuel Line Quick Connect Removal
    287
  - Fuel Line Replacement
    288
  - Vent Line Termination Fitting
    289
- Fuel Injector
  290
  - Fuel Injector Operation Overview
    290
  - Fuel Injector O-Rings
    290
  - Fuel Injector Test
    291
  - Fuel Injector Replacement
    291
  - Fuel Injector Troubleshooting
    292
- Fuel Tank Service
  293
  - Fuel Tank Removal
    293
  - Fuel Tank Installation
    294
- Fuel Pump Service
  295
  - Fuel Pump Operation Overview
    295
  - Fuel Pump Test
    296
  - Fuel Pump Replacement
    297
Chapter 6 Pvt System

301
- General Information - Pvt System
  302
- Service Notes - Pvt System
  302
- Special Tools - Pvt System
  302
- Service Specifications - Pvt System
  303
- Pvt System Overview
  304
  - Drive Clutch Operation
    304
  - Driven Clutch Operation
    304
  - Pvt Break-In
    304
  - Pvt System Maintenance / Inspection
    304
- Assembly Views - Pvt System
  305
  - Pvt Covers / Duct Assembly View - General 4
    306
  - Inner Clutch Cover Assembly View
    307
- Pvt System Service
  308
  - Pvt Disassembly
    308
  - Pvt Assembly
    309
- Drive Belt Service
  311
  - Drive Belt Removal
    311
  - Drive Belt Inspection
    311
  - Drive Belt Installation
    312
- Drive Clutch Service
  313
  - Drive Clutch Assembly View
    313
  - Moveable Sheave Bushing Inspection
    319
- Driven Clutch Service
  324
  - Driven Clutch Assembly View
    324
  - Driven Clutch Alignment Procedure
    325
  - Driven Clutch Disassembly
    325
  - Driven Clutch Assembly
    327
  - Driven Clutch Slider Inspection
    329
Chapter 7 Transmission

331
- General Information - Transmission
  332
- Service Notes - Transmission
  332
- Service Specifications - Transmission
  332
- Special Tools - Transmission
  332
- Shift Cable Service
  333
  - Shift Lever / Cable Assembly View - General
    333
  - Shift Cable Routing - General
    334
  - Shift Lever / Cable Assembly View - General 4
    336
  - Shift Cable Routing - General 4
    337
  - Shift Lever Replacement
    339
  - Shift Cable Inspection
    339
  - Shift Cable Adjustment
    339
- Assembly Views - Transmission
  341
  - Transmission Assembly View
    341
  - Transmission Mounting Torque Values
    342
- Transmission Vent Line
  343
  - Transmission Vent Line Routing
    343
  - Vent Line Termination Fitting
    344
- Transmission Service
  345
  - Transmission Removal
    345
  - Differential Operation
    349
  - Transmission Disassembly
    351
    
    Gear Cluster Disassembly
    355
    
    Snorkel Shaft Removal / Disassembly
    355
    
    Bevel Differential Disassembly
    357
    
    Bevel Differential Assembly
    358
  - Gear / Shaft / Bearing Inspection
    360
  - Transmission Assembly
    363
  - Transmission Installation
    368
Chapter 8 Final Drive

375
- General Information - Final Drive
  377
- Service Notes - Final Drive
  377
- Service Specifications - Final Drive
  377
- Special Tools - Final Drive
  377
- Assembly Views - Final Drive
  378
  - Propshaft Assembly View - 2 Seat
    378
  - Propshaft Assembly View - 4 Seat
    379
  - Drive Shaft Assembly View
    380
  - Drive Shaft Assembly View (Intl Abs Models)
    381
  - Front Gearcase Assembly View
    383
  - Gearcase Vent Line
    384
- Propshaft Service
  385
  - Propshaft Removal - 2 Seat
    385
  - Propshaft Removal - 4 Seat
    386
  - U-Joint Disassembly
    388
  - U-Joint Assembly
    389
  - Propshaft Installation - 2 Seat
    390
  - Propshaft Installation - 4 Seat
    392
  - Front Drive Shaft Removal
    394
  - Front Drive Shaft Installation
    395
  - Rear Drive Shaft Removal
    396
  - Rear Drive Shaft Installation
    397
  - Drive Shaft / CV Joint Handling Tips
    399
  - Outer CV Joint / Boot Replacement
    400
  - Inner Plunging Joint / Boot Replacement
    402
  - Front Drive Shaft Removal
    405
  - Front Drive Shaft Installation
    406
  - Rear Drive Shaft Removal
    408
  - Rear Drive Shaft Installation
    409
  - Drive Shaft / CV Joint Handling Tips
    410
  - Outer CV Joint / Boot Replacement
    411
  - Inner Plunging Joint / Boot Replacement
    413
  - Front Bearing Carrier Removal / Inspection
    416
  - Front Bearing Replacement
    417
  - Front Bearing Carrier Installation
    418
  - Rear Bearing Carrier Removal / Inspection
    420
  - Rear Bearing Replacement
    421
  - Rear Bearing Carrier Installation
    422
- Front Bearing Carrier Removal / Inspection
  423
- Front Bearing Replacement
  424
- Front Bearing Carrier Installation
  425
- Rear Bearing Carrier Removal / Inspection
  426
- Rear Bearing Replacement
  427
- Rear Bearing Carrier Installation
  428
- All-Wheel Drive Operation
  429
- Front Gearcase Service
  429
- Front Gearcase Removal
  430
- Front Gearcase Disassembly / Inspection
  432
- Front Gearcase Assembly
  435
- Front Gearcase Installation
  437
- Front Hub Assembly View
  440
- Rear Hub Assembly View
  441
- Front Hub Assembly View
  442
- Rear Hub Assembly View
  443
Chapter 9 Steering / Suspension

445
- General Information - Steering / Suspension
  447
- Service Notes - Steering / Suspension
  447
- Service Specifications - Steering
  447
- Special Tools - Steering / Suspension
  447
- Steering Assembly View
  448
- Front Suspension Assembly View
  456
- Front Stabilizer Bar Assembly View
  458
- Rear Stabilizer Bar Assembly View
  461
- Steering Assembly Service
  462
  - Steering Shaft Removal - Upper
    462
  - Steering Wheel Removal
    463
  - Power Steering Unit Removal
    463
  - Steering Shaft Removal - Lower
    464
  - Steering Shaft Bearing Replacement
    465
  - Steering Shaft Installation - Lower
    465
  - Power Steering Unit Installation
    466
  - Steering Shaft Installation - Upper
    467
  - Tie Rod End / Wheel Hub Inspection
    469
  - Steering Rack Removal
    469
  - Steering Rack Installation
    470
  - Wheel Toe Alignment Inspection
    471
  - Wheel Toe Adjustment
    472
  - Steering Wheel Free-Play
    472
  - Front Control Arm Removal
    473
  - Front Control Arm Installation
    474
  - Front Stabilizer Bar Removal
    477
  - Front Stabilizer Bar Installation
    477
  - Rear Control Arm Removal
    478
  - Rear Control Arm Installation
    479
  - Rear Stabilizer Bar Removal
    482
  - Rear Stabilizer Bar Installation
    482
- Front Control Arm Installation
  486
- Front Stabilizer Bar Removal
  488
- Front Stabilizer Bar Installation
  489
- Rear Control Arm Removal
  489
- Rear Control Arm Installation
  491
- Rear Stabilizer Bar Installation
  494
- Rear Stabilizer Bar Removal
  494
- Ball Joint Installation
  496
- Ball Joint Preparation
  496
- Ball Joint Service
  496
- Shock Specifications - General 4
  499
- Shock Removal
  501
- Spring Replacement
  501
- Spring Adjustment
  502
- Spring Adjustment - General 4
  503
- Shock Compression Adjustment
  504
- Shock Installation
  504
  - Shock Disassembly (Fox)
    505
  - Shock Assembly (Fox)
    513
- Shock Specifications - General Xp 4
  525
- Shock Removal
  527
- Spring Replacement
  527
- Spring Adjustment - General Xp
  528
- Shock Compression Adjustment
  530
- Shock Installation
  530
  - Shock Disassembly (Walker Evans)
    531
  - Shock Assembly (Walker Evans)
    532
Chapter 10 Brake System

535
- General Information - Brake System
  537
- Service Notes - Brake System
  537
- Special Tools - Brake System
  537
- Service Specifications - Brake System (General / General 4)
  538
- Service Specifications - Brake System (Intl)
  540
- Brake System Service
  541
  - Brake Bleeding / Fluid Change
    541
  - Brake Burnishing Procedure
    542
- Assembly Views - Brake System (General / General 4)
  543
- Assembly Views - Brake System (General Xp / General Xp 4)
  557
- Master Cylinder Service
  581
  - Master Cylinder Removal
    581
  - Master Cylinder Installation
    581
- Brake Pedal Service
  582
  - Brake Pedal Removal
    582
  - Brake Pedal Installation
    582
- Front Pad Service
  583
  - Front Brake Pad Removal
    583
  - Brake Pad Inspection
    584
  - Brake Pad Inspection (Intl)
    584
  - Front Brake Pad Installation
    584
  - Front Caliper Removal
    586
  - Front Caliper Disassembly
    586
  - Front Caliper Inspection
    588
  - Front Caliper Assembly
    588
  - Front Caliper Installation
    589
  - Front Caliper Removal
    590
  - Front Caliper Disassembly / Inspection
    590
  - Front Caliper Assembly
    592
  - Front Caliper Installation
    592
- Rear Pad Service
  593
  - Rear Brake Pad Removal
    593
  - Brake Pad Inspection
    594
  - Rear Brake Pad Installation
    594
  - Rear Caliper Removal
    598
  - Rear Caliper Disassembly
    598
- Rear Caliper Service - General Xp
  598
  - Rear Caliper Inspection
    599
  - Rear Caliper Assembly
    600
  - Rear Caliper Installation
    600
- Disc Service
  602
  - Brake Disc Runout
    602
  - Brake Disc Inspection
    602
  - Brake Disc Replacement
    604
- International (Intl) Brake Service
  605
- Parking Brake (Intl)
  624
  - Parking Brake Assembly View
    624
Chapter 11 Body / Frame

629
- Decal Replacement
  631
- General Information - Body / Frame
  631
- Service Notes - Body / Frame
  631
- Special Tools - Body / Frame
  631
- Assembly Views - Body / Frame
  632
- Body Component Removal
  678
  - Door Removal
    678
  - Door Removal - General 4
    678
  - Seat Removal
    679
  - Hood Removal
    679
  - Exterior Body Component Removal
    679
  - Exterior Body Component Removal - General
    681
  - Interior Body Component Removal
    684
  - Interior Body Component Removal - General
    686
  - Cargo Box Removal
    690
- Body / Frame
  691
- Body Component Installation
  691
- Cargo Box Installation
  691
- Interior Body Component Installation
  691
- Interior Body Component Installation - General
  694
- Exterior Body Component Installation
  699
- Exterior Body Component Installation - General
  701
- Hood Installation
  704
- Seat Installation
  704
- Door Installation
  705
- Door Installation - General 4
  706
- Door Cable Adjustment
  709
- Frame Component Installation
  714
- Rops Installation
  714
- Rops Removal
  714
- Rops Removal - General 4
  715
- Rops Installation - General 4
  716
- Skid Plate Replacement
  718
- Skid Plate Replacement - General
  718
Chapter 12 Chassis / Body Electrical

719
- General Information - Electrical System
  722
- Service Specifications - Electrical System
  723
- Special Tools - Electrical System
  723
- Chassis Harness
  724
- Chassis Harness (Intl)
  734
- Instrument Cluster Service
  744
  - Instrument Cluster Overview
    744
  - Instrument Cluster Replacement
    744
- Battery Service
  746
- Chassis / Body Electrical
  755
- Fuse / Relay Service
  760
  - Fuse / Relay Operation Overview
    760
  - Fuse Box Replacement
    760
  - Fuse / Relay Center - 2 Seat
    761
  - Fuse / Relay Center - 4 Seat
    764
  - Fuse / Relay Center - Intl (Non-Abs)
    767
  - Fuse / Relay Center - Intl (Abs)
    770
- Charging System Service
  773
  - Charging System Break Even Test
    773
  - Charging System Stator (Alternator) Tests
    773
  - Stator (Alternator) Replacement
    774
  - Regulator / Rectifier Operation
    774
  - Current Draw - Key off
    775
  - Charging System Testing
    776
- Starting System Service
  777
  - Voltage Drop Test
    777
  - Starter Motor Removal
    777
  - Starter Motor Installation
    778
  - Starter Solenoid Service
    778
  - Starting System Troubleshooting
    778
- Electronic Power Steering (Eps)
  779
  - Eps Operation
    779
- Lighting System Service
  780
  - Headlight Adjustment
    780
  - Headlight Bulb Replacement
    780
  - Headlight Removal
    781
  - Headlight Installation
    781
  - Tail Light Replacement
    782
  - Interior Led Lights
    782
- Switch Service
  783
  - Brake Pressure Switch
    783
  - Headlight Switch
    784
  - Ignition / Key Switch
    785
  - Transmission / Gear Position Switch
    786
  - Seat Belt Switch
    787
    
    Brake Fluid Level Switch
    788
    
    Ignition / Key Switch
    788
    
    Hazard Switch (Int'l / Tractor)
    789
    
    Horn
    790
    
    Turn Lights
    790
    
    Turn/Lights/Horn Switch (Int'l/Tractor)
    790
    
    Brake Alarm
    791
    
    Flasher Module
    791
    
    Parking Brake Switch
    791
    
    Fog Light Switch
    792
- Vehicle Speed Sensor (Vss)
  793
  - Vss Operation Overview
    793
  - Vss Test
    793
  - Vss Replacement
    793
- Misc Electrical Service
  794
  - 12V Receptacle
    794
  - Awd Coil
    794
  - Pulse Bar
    795
  - Chassis Ground
    795
  - Diagnostic Plug
    795
Factory-Installed Options Chapter 13 Factory-Installed Options 13

797
- Factory-Installed Options
  799
- General Information - Factory-Installed Options
  799
- Chapter 13
  800
- Roof Assembly View
  800
- Roof Service - General
  800
- Roof Installation
  801
- Roof Removal
  801
- Roof Assembly View - General 4
  803
- Roof Installation - General 4
  804
- Roof Removal - General 4
  804
- Rear View Mirror Service
  806
  - Rear View Mirror Assembly View
    806
  - Rear View Mirror Removal
    807
  - Rear View Mirror Installation
    807
- Side Mirror Service (Intl)
  808
  - Side Mirror Assembly View (Intl)
    808
  - Side Mirror Removal (Intl)
    809
  - Side Mirror Installation (Intl)
    809
- Light Bar Service
  810
  - Light Bar Assembly View
    810
  - Light Bar Removal
    811
  - Light Bar Installation
    812
  - Light Bar Switch
    812
- Front Bumper Service
  814
  - Front Bumper Assembly View
    814
  - Front Bumper Removal
    815
  - Front Bumper Installation
    816
- Winch Service
  817
  - Winch Assembly View
    817
  - Winch Cable Routing / Retention
    818
  - Winch Replacement
    819
  - Winch Switch
    821
- Rockford Fosgate Stage 1 (Base) Audio
  822
  - Base Audio Assembly View
    822
  - Audio Harness Routing
    823
  - Front Speaker Assembly Service
    824
  - Front Speaker Service
    825
  - Base Audio Display Pinout
    827
- Ride Command with Rockford Fosgate Stage 4 Audio
  828
- Front Speaker Assembly Service
  841
- Front Speaker Service
  842
- Subwoofer Service
  844
- Subwoofer Pinout
  848
- Amplifier Service
  849
- Amplifier Pinout
  850
- Rear Speaker Assembly Service
  850
- Rear Speaker Service
  852
- Front Camera Service
  854
- Rear Camera Service
  856
- Ambient Air Temperature Sensor Service
  858
- Gps Antenna Service
  859
- Vehicle-To-Vehicle (V2V) Antenna Service (2-Seat)
  861
- Vehicle-To-Vehicle (V2V) Antenna Service (4-Seat)
  863

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