Polaris General 2020 Service Manual
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Polaris General 2020 Service Manual

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Table of Contents

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2020-2021 GENERAL / GENERAL XP
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed August 2020 (PN 9850067 R01)
© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Do you have a question about the General 2020 and is the answer not in the manual?

Questions and answers

Ron Rader
March 4, 2025

What is the procedure to restore a 2020, General 1000, after being in flood water for 24 houts

0
DJ
April 10, 2025

2018 Polaris 500 ranger side by side. Was replacing battery and the positive and negative touch causing a fuse to blow. Replaced fuse and check all other fuses all good. Hooked cables up to battery but now have no power to dash or ignition to turn it over .Ignition was changed 2 months ago .Tested a 30 amp fuse on the firewall was ok. Checked for any corroded connections ,nothing . Anyone have any ideal and anything i can also check? Thanks

0
1 comments:
Mr. Anderson
April 10, 2025

A 2018 Polaris Ranger 500 could have no power to the dash or ignition after replacing the battery and fuses due to bad or failed wiring connections and grounds. According to the manual, 80% of electrical issues are caused by poor connections or ground faults. It's important to verify all wires and wiring connections using a known good volt/ohmmeter before suspecting a component failure. Also, check that the battery cables are properly connected and secure, especially the ground connection to the chassis.

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Summary of Contents for Polaris General 2020

  • Page 1 Publication Printed August 2020 (PN 9850067 R01) © Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation 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.
  • Page 3 Initial Release FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
  • Page 5 2020-2021 GENERAL / GENERAL XP Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING SYSTEM CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION CHAPTER 8 :...

  • Page 7: Table Of Contents

    ........... . .1.55 POLARIS MOBILE DIGITAL WRENCH® (PMDW) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual ©...
  • Page 8 ................1.89 TESTING VOLTAGE DROP 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 9: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J = 2018; K= 2019; L=2020 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 10: Vehicle And Engine Serial Number Location

    The engine serial number can be found on a decal applied to the front of the engine crankcase (A) or stamped into the crankcase on the PTO side of the engine (B). Refer to Figure 1-2. Domestic VIN location International VIN location 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 11: Reference Information

    Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Polaris hardware from an authorized Polaris dealer. Working with batteries can be hazardous. Review all battery warnings and cautions.

  • Page 12: Publication Part Numbers

    9939895 NOTICE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 13: Replacement Keys

    (i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.) SERIES# PART NUMBER 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 14: Special Tools Website

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/...

  • Page 15: Special Tools Index

    (Use With Engine) Bore Stand) 2.375” Bore PU-50562 PU-50625 Stand) PW-47054 Engine Stand Clutch Center Valve Spring (2” Bore) Distance Tool Compressor PU-50624 PU-50658-A Adapter PV-43513-A 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 16 Replacement Roll Pin Axle Boot Clamp CV Boot Clamp Tool Kit Tool Removal Tool Tool Pliers 2871226 PA-47336 2872608 PU-48951 8700226 Universal Clutch Compressor PU-50518 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.10 © Copyright Polaris Inc.
  • Page 17 CHAPTER 9 — BRAKE SYSTEM Mityvac® Wireless Vehicle Digital Wrench® Digital Wrench® Pressure Test Vehicle SmartLink Link (WVL) Tool Interface Cable Module PU-51435 2870975 PU-47469 PU-47468 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.11 © Copyright Polaris Inc.
  • Page 18 Light Harness Sensor Probe Digital 2871745 Harness Multimeter 2460761 PF-51237 Battery Timing Light Connector Test Conductance 2870630 Analyzer (MDX- PV-43526 610P) PU-50296 Relay Bypass PU-49466 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.12 © Copyright Polaris Inc.

  • Page 19: Vehicle Specifications (Model Year 2021)

    GENERAL SPORT G21GAE99A4 GENERAL PREMIUM G21GAP99AM / G21GAP99BM G21GAD99AC / G21GAD99AW / G21GAD99BC / G21GAD99BW / GENERAL DELUXE G21GAJ99AC / G21GAJ99AW / G21GAJ99BC / G21GAJ99BW 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.13 © Copyright Polaris Inc.
  • Page 20 Maximum Weight Capacity (Payload) (Includes riders, cargo and accessories) (Includes riders, cargo and accessories) Hitch Towing Capacity 2000 lb (907 kg) Hitch Tongue Capacity 150 lb (68 kg) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.14 © Copyright Polaris Inc.
  • Page 21 Engine Hot Light Instrument Cluster Indicator Wet Sump Lubrication Oil Requirements PS-4 5W-50 Full Synthetic Oil Capacity 2.5 Qt (2.4 L) Coolant Capacity 5.02 qt (4.75 L) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.15 © Copyright Polaris Inc.
  • Page 22 Front Drive Ratio 3.182:1 Demand Drive Fluid Front Gearcase Lubricant Requirement 8.5 oz (250 mL) AGL Gearcase Lubricant Transmission Lubricant Requirement 44 oz (1300 mL) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.16 © Copyright Polaris Inc.
  • Page 23 ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 0-1800 Meters 35-76 58-135 7044506 (0-6000 Feet) (1327101) (7044263) 1800-3700 Meters 35-67 58-135 7044506 (6000-12000 Feet) (1323686) (7044263) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.17 © Copyright Polaris Inc.

  • Page 24: Model Specifications - 4 Seat

    G21G4D99AW / G21G4J99AW / GENERAL 4 DELUXE G21G4D99BW / G21G4J99BW G21GMD99AJ / G21GMJ99AJ / GENERAL XP 4 DELUXE G21GMD99AZ / G21GMJ99AZ GENERAL XP 4 STEALTH G21GMH99AL PURSUIT 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.18 © Copyright Polaris Inc.
  • Page 25 Engine Hot Light Instrument Cluster Indicator Wet Sump Lubrication Oil Requirements PS-4 5W-50 Full Synthetic Oil Capacity 2.5 Qt (2.4 L) Coolant Capacity 5.81 qt (5.5 L) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.19 © Copyright Polaris Inc.
  • Page 26 Front Drive Ratio 3.182:1 Demand Drive Fluid Front Gearcase Lubricant Requirement 8.5 oz (250 mL) AGL Gearcase Lubricant Transmission Lubricant Requirement 44 oz (1300 mL) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.20 © Copyright Polaris Inc.
  • Page 27 ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING 0-1800 Meters 35-69 58-135 7044506 (0-6000 Feet) (1323684) (7044263) 1800-3700 Meters 35-67 58-135 7044506 (6000-12000 Feet) (1323686) (7044263) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.21 © Copyright Polaris Inc.

  • Page 28: Model Specifications - Intl

    .006 ± .001 in (0.15 ± 0.025 mm) Valve Clearance (Exh) .010 ± .001 in (0.25 ± 0.025 mm) Engine Hot Light Instrument Cluster Indicator 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.22 © Copyright Polaris Inc.
  • Page 29 Wet Sump Lubrication Oil Requirements PS-4 5W-50 Full Synthetic Oil Capacity 2.5 Qt (2.4 L) Coolant Capacity 5.02 qt (4.75 L) 5.81 qt (5.5 L) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.23 © Copyright Polaris Inc.
  • Page 30 Front Drive Ratio 3.182:1 Demand Drive Fluid Front Gearcase Lubricant Requirement 8.5 oz (250 mL) AGL Gearcase Lubricant Transmission Lubricant Requirement 44 oz (1300 mL) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.24 © Copyright Polaris Inc.
  • Page 31 DRIVEN SPRING 0-1800 Meters 35-67 Black / White Lettering 7044505 (0-6000 Feet) (1323686) (7044465) 1800-3700 Meters 35-61 Black / White Lettering 7044505 (6000-12000 Feet) (1323687) (7044465) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.25 © Copyright Polaris Inc.

  • Page 32: Misc Specifications And Charts

    49 lb-in (5.5 Nm) Step 3: Tighten Clamp add’n 90° Engine Mount Fasteners 40 lb-ft (54 Nm) 89 in-lbs (10 N·m) Coolant Bleed Screw (Front) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.26 © Copyright Polaris Inc.
  • Page 33 PART DESCRIPTION SPECIFICATION APS Mounting Fasteners 8 lb-ft (11 Nm) Drive Clutch Spider 290 ft-lbs (393 N·m) Assembly CPS Retaining Bolt 9 lb-ft (12 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.27 © Copyright Polaris Inc.
  • Page 34 9 ft-lbs (12 Nm) Park Plate Fastener Fastener Rear Mount Bracket 20 ft-lbs (27 Nm) 30 lb-ft (41 Nm) + 90° Tie Rod End Nut Fastener 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.28 © Copyright Polaris Inc.
  • Page 35 40 lb-ft (54 Nm) Fasteners Rear Stabilizer Bar Mount 44 lb-ft (60 Nm) Front Stabilizer Bar Mount Fasteners 20 ft-lbs (27 Nm) Fasteners General XP 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.29 © Copyright Polaris Inc.
  • Page 36 Caliper Bleeder Screw 4 lb-ft (5.4 Nm) Mount Fasteners 3.5 ft-lbs (5 Nm) GENERAL / GENERAL Front Caliper Mounting 30 lb-ft (41 Nm) XP Only Bolts 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.30 © Copyright Polaris Inc.
  • Page 37 Top Frame Fastener 42 in-lbs (5 Nm) 22 ft-lbs (30 Nm) Fasteners (T-40) M8 x 1.25 x 55 Rear Door Hinge Other 17 lb-ft (23 Nm) Fasteners 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.31 © Copyright Polaris Inc.
  • Page 38 Front Speaker Cover 7 in-lbs (.75 Nm) Fasteners Front Speaker Housing 30 in-lbs (4 Nm) Mounting Fasteners 24 in-lbs (3 Nm) Pulse Bar Cable Nuts 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.32 © Copyright Polaris Inc.

  • Page 39: Conversion Table

    π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.33 © Copyright Polaris Inc.

  • Page 40: Sae Tap / Drill Sizes

    2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.34 © Copyright Polaris Inc.

  • Page 41: Decimal Equivalents

    17/32 0.5313″ 0.5469″ 14 mm = 0.5512″ 35/64 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 0.5938″ 19/32 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.35 © Copyright Polaris Inc.

  • Page 42: General Diagnostics

    Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.36 © Copyright Polaris Inc.

  • Page 43: Guided Symptom References

    Refer to the Symptom Checklist for various conditions. – If the concern has been verified and all of the information has already been collected, please start an Ask Polaris case at this time. If this information has not yet been gathered, gather this information first.

  • Page 44: Engine And Drivability Diagnostic Procedures

    Functional with MIL ON) page 1.80 • Connect to Digital Wrench®. Check codes and continue with Digital Wrench® Guided diagnosis. • If no codes are present, proceed to step 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.38 © Copyright Polaris Inc.
  • Page 45 • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.41 for more information. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.39 © Copyright Polaris Inc.
  • Page 46 These concerns may also be caused by a mechanical failure. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.40...

  • Page 47: Engine Cranks But Does Not Start

    10. Listen for unusual noises while cranking. • If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.41 © Copyright Polaris Inc.
  • Page 48 – Bent valve or stuck valve – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.42 © Copyright Polaris Inc.

  • Page 49: No Crank No Start Or Slow Crank

    (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake Switch operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.43 © Copyright Polaris Inc.

  • Page 50: Over Heating

    • Check level and correct as necessary. Check maintenance history to determine if oil need to be changed. 7. Check Cooling Fan operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.44 © Copyright Polaris Inc.

  • Page 51: Warning Lights

    Guided Diagnostic for further diagnosis. 5. BRAKE WARNING • Detects brake system failure. • Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.45 © Copyright Polaris Inc.

  • Page 52: Engine Troubleshooting

    • Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.46 © Copyright Polaris Inc.
  • Page 53 • Low fuel pressure electrical concern / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.47 © Copyright Polaris Inc.

  • Page 54: Cooling Troubleshooting

    • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.48 © Copyright Polaris Inc.

  • Page 55: Digital Wrench® Software Overview

    GENERAL INFORMATION DIGITAL WRENCH DIGITAL WRENCH® SOFTWARE OVERVIEW The Polaris Digital Wrench® software allows a technician to perform the following tasks: • Analyze real-time engine data • Create customer service account records • Generate / upload service reports • Perform guided diagnostic procedures •...

  • Page 56: Digital Wrench® Software Installation And Updates

    To check if a Digital Wrench® software update is following: available, do the following: 1. Open a web browser and log on to your Polaris dealer 1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com).

  • Page 57: Digital Wrench® Communication Errors

    DIGITAL WRENCH® COMMUNICATION ERRORS If you experience problems connecting to a vehicle, or any other Digital Wrench® software-related problem, visit the Digital Wrench® home page (www.polaris.diagsys. com) and locate the following information under Knowledge Base: • Errors and Troubleshooting • Frequently Asked Questions (FAQs) •...

  • Page 58: Digital Wrench® Serial Number Location

    2. On the Digital Wrench® main screen, select the ‘Configure the Diagnostic System Software’ menu icon. 3. Locate the serial number on the right side of the System Configuration screen. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.52 © Copyright Polaris Inc.

  • Page 59: Digital Wrench® Feature Map

    Perform specialized testing Access the Digital Wrench® and adjustment functions System Help. service reports. Print the current screen as a Open the ASSERT ASK formatted printout. form. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.53 © Copyright Polaris Inc.
  • Page 60 GENERAL INFORMATION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.54 © Copyright Polaris Inc.

  • Page 61: Engine Controller Reprogramming (Reflash)

    – Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®. progress. 10. Open a web browser and log on to your Polaris dealer • Understand the Process website (www.polarisdealers.com). Review the Digital Wrench® System Help before you 11.
  • Page 62 GENERAL INFORMATION You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download. MINIMUM SPECIFICATIONS FOR ANDROID DEVICES • Minimum operating system: Android 3.1 “Honeycomb”...

  • Page 63: Diagnostic Trouble Codes Overview

    0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present). 5. Press MODE to exit to the settings menu. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.57 © Copyright Polaris Inc.
  • Page 64 Voltage Above Normal, Or Shorted To High Source P0108 Manifold Absolute Pressure Sensor Voltage Too Low P0107 Mechanical System Not Responding Or Out Of Adjustment P1106 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.58 © Copyright Polaris Inc.
  • Page 65 P1568 Data Valid But Above Normal Operating Range - Moderately Severe P1571 Level Data Valid But Below Normal Operating Range - Moderately Severe P1573 Level 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.59 © Copyright Polaris Inc.
  • Page 66 Mechanical System Not Responding Or Out Of Adjustment P0016 Camshaft Position Sensor Abnormal Frequency Or Pulse Width Or Period P0340 Voltage Above Normal, Or Shorted To High Source P1739 Tachometer Driver Circuit 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.60 © Copyright Polaris Inc.
  • Page 67 Wheel Speed Sensor (Rear or Voltage Above Normal, Or Shorted To High Source C113D Rear Left) Voltage Below Normal, Or Shorted To Low Source C123D 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.61 © Copyright Polaris Inc.
  • Page 68 1485 Current Below Normal Or Open Circuit P0685 Voltage Above Normal P0694 1557 Fan Driver 2 Voltage Below Normal, Or Shorted To Low Source P0693 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.62 © Copyright Polaris Inc.
  • Page 69 P17AE ECU Output Supply Voltage 3 3599 Voltage Above Normal, Or Shorted To High Source P17AA Voltage Below Normal, Or Shorted To Low Source P17AB 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.63 © Copyright Polaris Inc.
  • Page 70 Data Valid But Below Normal Operating Range - Least Severe Level P0174 Data Erratic, Intermittent Or Incorrect P1684 520206 Reverse Alarm Voltage Above Normal, Or Shorted To High Source P1682 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.64 © Copyright Polaris Inc.
  • Page 71 Current Below Normal Or Open Circuit C1029 ABS Solenoid (Front Right Out) 520257 Condition Exists C1329 Voltage Above Normal, Or Shorted To High Source C1020 520260 ABS Motor 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.65 © Copyright Polaris Inc.
  • Page 72 520287 Condition Exists P1542 ECU Monitoring of Injection Cut Off 520288 (Level 1) Condition Exists P1543 ECU Monitoring of Injection Cut Off 520289 (Level 2) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.66 © Copyright Polaris Inc.
  • Page 73 Drive Mode Select Switch Voltage Below Normal, Or Shorted To Low Source P153B Voltage Above Normal, Or Shorted To High Source P251C Operator Presence Switch 524070 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.67 © Copyright Polaris Inc.
  • Page 74 EPS Fault Lamp Driver Circuit 524085 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.68 © Copyright Polaris Inc.

  • Page 75: Cylinder Misfire Detection

    Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.69 © Copyright Polaris Inc.

  • Page 76: Fluid Leaks

    • If a fluid is contaminated with metal or debris, suspect that there is a mechanical failure causing the fluid contamination. Refer to the Service Manual information related to the system in question. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.70 © Copyright Polaris Inc.

  • Page 77: Fuel System Troubleshooting

    • Intake air leak (throttle shaft, intake ducts, air box cover) • Spark plug erosion / fouling • Faulty oxygen sensor • Engine runs hot • Surging • High / Erratic idle 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.71 © Copyright Polaris Inc.
  • Page 78 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.72 © Copyright Polaris Inc.

  • Page 79: Pvt System Troubleshooting

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.73 © Copyright Polaris Inc.
  • Page 80 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.74 © Copyright Polaris Inc.

  • Page 81: Pvt System Overheating / Diagnosis

    PVT system. than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel Poor engine performance.

  • Page 82: Hard Shifting

    • If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.76 © Copyright Polaris Inc.

  • Page 83: All Wheel Drive (Awd) Concerns

    Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.77 © Copyright Polaris Inc.

  • Page 84: Brake Noise Troubleshooting

    • Brake Disc damaged VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING) • Alignment issues • Worn Suspension components 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.78 © Copyright Polaris Inc.

  • Page 85: Caliper Overheats (Brakes Drag)

    • Failed brake hose / line • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder • Faulty distribution block (INTL models only ) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.79 © Copyright Polaris Inc.

  • Page 86: Eps Troubleshooting (Power Steering Non-Functional With Mil

    Check wiring from Connector to Ignition Switch 12 VDC on Pin 3 of the 8 pin EPS Connector? Circuit ↓ Begin Digital Wrench EPS Troubleshooting Procedure 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.80 © Copyright Polaris Inc.

  • Page 87: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    Instrument during MIL lamp Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.81 © Copyright Polaris Inc.

  • Page 88: Eps Troubleshooting (Using Digital Wrench®)

    If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.82 © Copyright Polaris Inc.

  • Page 89: Shock Analysis

    (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.83 © Copyright Polaris Inc.

  • Page 90: Electrical Service Notes

    • All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.87 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) DYNAMIC TESTING for electrical testing.

  • Page 91: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate Back probing is typically not advisable on sealed adapters is required. Most terminals used on Polaris connectors, as it can easily cause damage to the wire, machines can be tested using terminal test kit PV–...

  • Page 92: Testing Continuity / Resistance

    9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.87 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.86 © Copyright Polaris Inc.

  • Page 93: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.87 © Copyright Polaris Inc.

  • Page 94: Testing For Intermittent Conditions

    Failure to do so can lead to serious injury and/or damage to the machine. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.88 © Copyright Polaris Inc.

  • Page 95: Current Draw - Key Off

    IMPORTANT Charging system damage will occur if incompatible components are installed. Always reference the Polaris TESTING VOLTAGE DROP Electronic Parts Catalog for the proper part numbers. NOTICE If you disconnect the connector at the load, and...
  • Page 96 GENERAL INFORMATION For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 1.90 © Copyright Polaris Inc.
  • Page 97 FINAL DRIVE MAINTENANCE ............... . .2.41 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 98 ............... . .2.58 THROTTLE PEDAL INSPECTION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 99: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as TOOL DESCRIPTION PART NUMBER necessary. When inspection reveals the need for PU-50105 replacement parts, use genuine Polaris parts available Oil Filter Wrench from your Polaris dealer. 2877408 Shock Spanner Wrench Inspection, adjustment and lubrication of important...

  • Page 100: Service Specifications - Maintenance

    Spring Adjustment - GENERAL Rear: 0.300 in (0.118 cm) XP 4 0.040 (1 mm) Brake Pad Thickness 0.170 (4.32 mm) Brake Disc Thickness Spark Plug Type NGK MR7F 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 101 Transmission Fluid AGL Gearcase Lubricant Brake Fluid DOT 4 Grease Fittings Premium All-Season Grease U-Joint Lubricant Premium U-Joint Lubricant 87 Octane (minimum) 9.5 Gal (36 L) Fuel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 102: Periodic Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for • Drive vehicle slowly at first while varying the throttle replacement parts, use genuine Pure Polaris parts position. Do not operate at sustained idle. available from your Polaris dealer.

  • Page 103: Pre-Ride Inspection

    Auxiliary Brake (if equipped) Inspect / adjust as needed Inspect / clean often PVT Outlet Duct Screen Spark Arrester Inspect / clean after operating in mud and water 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 104: Maintenance Interval Chart

    500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over. 25 HOUR / 250 MILES (400 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE...
  • Page 105 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Cooling System Inspect coolant strength seasonally; pressure test system yearly Inspect;...
  • Page 106 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Steering Lubricate Lubricate and inspect bushings Front / Rear Stabilizer Bars Inspect for free movement;...
  • Page 107 MAINTENANCE 150 HOUR / 1500 MILES (2400 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM...
  • Page 108 MAINTENANCE 200 HOUR / 2000 MILES (3200 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM...
  • Page 109 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Ratcheting Cam Chain Tensioner Check; replace as needed...
  • Page 110 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Inspect; adjust; replace as needed Drive Belt Cooling System Inspect coolant strength seasonally;...
  • Page 111 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Lubricate all fittings, pivots, cables, etc. General Lubrication...
  • Page 112 MAINTENANCE 350 HOUR / 3,500 MILES (5,600 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM...
  • Page 113 MAINTENANCE 400 HOUR / 4000 MILES (6400 KM) SERVICE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM...
  • Page 114 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Ratcheting Cam Chain Tensioner Check; replace as needed...
  • Page 115 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Inspect; adjust; replace as needed Drive Belt Cooling System Inspect coolant strength seasonally;...
  • Page 116 MAINTENANCE XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE. D - HAVE AN AUTHORIZED POLARIS DEALER PERFORM THESE SERVICES. E - EMISSION CONTROL SYSTEM SERVICE. CODE ITEM ACTION Shift Linkage Inspect, lubricate, adjust Steering Lubricate...

  • Page 117: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant bottle * More often under severe use, such as operation in water or under severe loads. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.21 © Copyright Polaris Inc.
  • Page 118 ITEM LUBE REC. METHOD FREQUENCY* Maintain fluid level between Check level during pre-ride inspection; Polaris DOT 4 Brake “MAX and “MIN” lines on the Brake Fluid change fluid every two years Fluid master cylinder reservoir Add lubricant until it is visible at...

  • Page 119: Grease Lubrication Points

    Propshaft Yokes Premium U-Joint Lubricant fittings submerging the vehicle Propshaft Yokes Grease middle and rear Premium U-Joint Lubricant (GENERAL 4) fittings 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.23 © Copyright Polaris Inc.

  • Page 120: Maintenance Lubricants

    50/50 EL Anti-Free (Gal) (4 count) 2880513 50/50 EL Anti-Free (55 Gal Drum) 2880512 NOTICE Each item can be purchased separately at your local Polaris dealer. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.24 © Copyright Polaris Inc.

  • Page 121: General Vehicle Inspection And Maintenance

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.25 © Copyright Polaris Inc.

  • Page 122: Heat Shield Inspection

    Chassis Heat Shield Box Heat Shield Headpipe Heat Shield Silencer Outer Heat Shield, Elbow Midpipe Heat Shield Silencer Heat Shield, Main 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.26 © Copyright Polaris Inc.

  • Page 123: Engine Maintenance

    Lower the cargo box and secure in position. dipstick tube to keep the depth of the dipstick consistent. 5. Remove the dipstick and check the oil level. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.27 © Copyright Polaris Inc.

  • Page 124: Engine Oil And Filter Change

    Component Installation” page procedure. 16. Dispose of used oil and filter properly. 6. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.28 © Copyright Polaris Inc.

  • Page 125: Engine Crankcase Breather Hose Inspection

    Cylinder Leakage Service Limit: 20% If leakage exceeds service limit, inspect the engine for the cause 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.29 © Copyright Polaris Inc.
  • Page 126 The engine will misfire if the spark plug wires are installed incorrectly. The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.30 © Copyright Polaris Inc.

  • Page 127: Cam Chain Tensioner Inspection

    4. Push on the tensioner lock and manually move the plunger in and out. It should move freely. If it does not move freely, replace the tensioner assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.31 © Copyright Polaris Inc.

  • Page 128: Cooling System Maintenance

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Antifreeze is premixed and ready to use. Do not dilute with water. With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle.
  • Page 129 3. Check tightness and condition of all hose spring clamps. Replace if necessary. Recovery Bottle Engine Hoses Radiator Hoses To Thermostat Housing To Water Pump To Radiator 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.33 © Copyright Polaris Inc.

  • Page 130: Coolant Drain / Fill

    MAX level. Refer to “Cooling System Bleeding” page 3.91 procedure. Recommended Coolant: 50 / 50 Extended Life Antifreeze 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.34 © Copyright Polaris Inc.

  • Page 131: Fuel System And Air Intake Maintenance

    Neither filter is serviceable individually. Must replace the fuel pump as an assembly. Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.35 © Copyright Polaris Inc.

  • Page 132: Fuel Tank Vent Line

    3. Be sure the vent line is routed properly and secured with appropriate retention components. NOTICE Ensure vent line is not kinked or pinched. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.36 © Copyright Polaris Inc.

  • Page 133: Air Filter Service

    5. Place the air filter into the air box and reinstall the air box cover. NOTICE Be sure the lower tabs on the air box cover are properly engaged into the airbox. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.37 © Copyright Polaris Inc.

  • Page 134: Pvt System Maintenance

    If the vehicle has ingested a large amount of water into the PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.38 © Copyright Polaris Inc.

  • Page 135: Transmission And Front Gearcase Maintenance

    Transmission Fill / Drain Plug Torque: Transmission Fill / Drain Plug Torque: 14 lb-ft (19 Nm) 14 lb-ft (19 Nm) 8. Check for leaks. Dispose of used lubricant properly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.39 © Copyright Polaris Inc.

  • Page 136: Front Gearcase Lubrication

    TORQUE 10 lb-ft (14 Nm) Front Gearcase Fill / Drain Plug Torque: 10 lb-ft (14 Nm) 8. Check for leaks. Dispose of used fluid properly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.40 © Copyright Polaris Inc.

  • Page 137: Final Drive Maintenance

    5. Remove the wheel nuts and remove the wheel. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.41 © Copyright Polaris Inc.

  • Page 138: Tire Inspection

    Worn tires can cause an accident. Always replace tires when the usable tread depth has worn out. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.42 © Copyright Polaris Inc.

  • Page 139: Steering Maintenance

    • Steering Gearbox WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.43...

  • Page 140: Tie Rod End / Wheel Hub Inspection

    (loose hub/axle center line. wheel nuts or loose front hub nut). Refer to Final Drive chapter for service procedures. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.44 © Copyright Polaris Inc.

  • Page 141: Wheel Toe Adjustment

    To adjust toe alignment: 1. Hold tie rod end to keep it from rotating. 2. Loosen jam nuts at both end of the tie rod. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.45 © Copyright Polaris Inc.

  • Page 142: Suspension Maintenance - General / General 4

    SPRING ADJUSTMENT - FACTORY SETTING FRONT REAR 6.625 in (16.828 cm) 1.625 in (4.128 cm) NOTICE Models with base suspension use softest setting for factory setting. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.46 © Copyright Polaris Inc.

  • Page 143: Shock Compression Adjustment

    The SETTING DAMPING increased suspension height will negatively impact vehicle stability when operating without a load. Softest Position 1 Factory Position 2 Firmest Position 3 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.47 © Copyright Polaris Inc.
  • Page 144 Always return the spring adjuster to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.48 © Copyright Polaris Inc.

  • Page 145: Spring Adjustment - General Xp 4

    Always return the spring adjuster to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.49 © Copyright Polaris Inc.

  • Page 146: Shock Compression Adjustment

    8 clicks from full hard Rear Shock 8 clicks from full hard GENERAL XP 4 Front Shock 8 clicks from full hard Rear Shock 11 clicks from full hard 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.50 © Copyright Polaris Inc.

  • Page 147: Brake System Maintenance

    MEASUREMENT Brake Disc Thickness Service Limit 0.170 (4.32 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.51 © Copyright Polaris Inc.
  • Page 148 5. Place the vehicle in neutral on a flat level surface. 6. Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.52 © Copyright Polaris Inc.
  • Page 149 10. If additional adjustment is needed, the cable can be adjust on the parking brake handle side jam nut 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.53 © Copyright Polaris Inc.

  • Page 150: Electrical Maintenance

    10-30% of full potential. Charge battery according to “Battery Charging Procedure” page . Do not use the vehicle’s stator/alternator to charge a new battery. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.54 © Copyright Polaris Inc.

  • Page 151: Battery Installation

    4. Remove the battery hold-down bracket . Lift the battery out of the vehicle. 5. Verify that cables are properly routed and reinstall the driver’s seat. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.55 © Copyright Polaris Inc.

  • Page 152: Battery Installation (Intl)

    2. Inspect the chassis ground terminals. Be sure the grounds are clean and tight. 5. Verify that cables are properly routed and reinstall the driver’s seat. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.56 © Copyright Polaris Inc.

  • Page 153: Spark Plug Service

    Ensure wires are pushed down all the way so they engage onto the spark plugs. 13. Lower the cargo box and secure in position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.57 © Copyright Polaris Inc.

  • Page 154: Throttle Pedal Inspection

    The throttle pedal should move freely and always return back to its idle position when released. Check throttle pedal periodically. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 2.58 © Copyright Polaris Inc.
  • Page 155 ............3.88 COOLING SYSTEM PRESSURE CAP TEST 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 156 ................3.92 WATER PUMP INSTALLATION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 157: General Information - Engine

    Water Pump Mechanical Seal • Cylinder PU-50564 Installer • Oil Pump / Oil Pump Sprocket or Chain Bosch Automotive Service Solutions: 1-800-345-2233 • Piston / Rings or http://polaris.service-solutions.com/ 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 158: Engine Cylinder Leakdown Test

    A 5 to 10 percent variance between cylinders Use caution when removing the spark plug as the would likely be considered normal. engine will be hot. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 159 This indicates that the Bubbles seen / heard in the cooling system cooling system is pressurizing, suspect a cylinder head or head gasket issue 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 160: Oil Pressure Test

    NOTICE Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.

  • Page 161: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 162: Engine Break-In Period

    5. Perform regular checks on fluid levels, controls and all important bolt torques. 6. Change oil and oil filter after 25 hour break-in period. 7. Pull only light loads. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 163: Engine Service Specifications

    Valve Seat - Contacting Width - Exhaust .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 164 Ambient Temp Range: -35° F to 100° F PS-4 10W-40 Extreme Duty Full Synthetic Ambient Temp Range: 0° F to 120° F Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature) 10 PSI (69 kPa) @ 1200 RPM 40 PSI (276 kPa) @ 7000 RPM *Additional oil may be required after complete engine disassembly.

  • Page 165: Engine Service

    IMPORTANT PU-52493 does NOT work with 2017 and older models. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.11 © Copyright Polaris Inc.
  • Page 166 4. Refer to PVT Inner Cover Assembly page the flat side of the seal facing out as shown. 5. Test drive the vehicle and recheck for leaks before putting back into service. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.12 © Copyright Polaris Inc.

  • Page 167: Engine Removal

    14. Disconnect fuel lines and remove throttle body and air inlet assembly. Refer to “Fuel Line Replacement” page procedure. Make note of line routing for installation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.13 © Copyright Polaris Inc.
  • Page 168 Remove exhaust head pipe towards the front of the vehicle. Discard exhaust gaskets NOTICE It is not necessary to remove the bolts that retain the bracket to the transmission. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.14 © Copyright Polaris Inc.
  • Page 169 • Sleeve adapter for a 2″ bore engine stand: (PU-50625) • Sleeve adapter for a 2.375″ bore engine stand: (PW-47054) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.15 © Copyright Polaris Inc.

  • Page 170: Engine Installation

    6. Align transmission joint mounting holes with the transmission front mounting holes. TORQUE Starter Motor Bolts: 7 lb-ft (10 Nm) Trans Joint Bracket Bolts: 44 lb-ft (60 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.16 © Copyright Polaris Inc.
  • Page 171 Hand tighten the bolts so they remain loose at this time. NOTICE DO NOT torque fasteners at this time. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.17 © Copyright Polaris Inc.
  • Page 172 / coolant. 15. Remove the lifting straps and overhead or portable engine hoist. 16. Install the two coolant hoses onto the engine. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.18 © Copyright Polaris Inc.
  • Page 173 35. Start engine and check for any oil or coolant leaks. 36. Check the engine oil level. 37. Refer customer to “Engine Break-In Period” page 3.8 upon returning vehicle to customer. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.19 © Copyright Polaris Inc.

  • Page 174: Engine Disassembly / Inspection - Top End

    3. Remove the two bolts retaining the fixed cam chain and the slots on the end of the camshafts should guide and remove the assembly from the engine. line up. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.20 © Copyright Polaris Inc.

  • Page 175: Camshaft Sprocket Inspection

    NOTICE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.21 © Copyright Polaris Inc.
  • Page 176 1.5142 - 1.5181" (38.46 - 38.56 mm) Service Limit: 1.5122" (38.41 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.22 © Copyright Polaris Inc.
  • Page 177 .0000 - .0026" (0.001 - 0.067 mm) without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal Service Limit: page 3.40. .0039" (0.1 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.23 © Copyright Polaris Inc.
  • Page 178 1. Remove the valve tappet from the cylinder head. Note the tappet size engraved on the underside of the bucket. MEASUREMENT Cylinder Head Warp Limit: .0039″ (0.1 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.24 © Copyright Polaris Inc.
  • Page 179 8. Clean the combustion chamber and head gasket surface. 9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.25 © Copyright Polaris Inc.
  • Page 180 .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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.26 © Copyright Polaris Inc.
  • Page 181 1. Install pilot into valve guide. 2. Apply cutting oil to valve seat and cutter. 3. Place 46° cutter on the pilot and make a light cut. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.27 © Copyright Polaris Inc.
  • Page 182 6. Insert valve into guide and tap valve lightly into place a few times. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.28 © Copyright Polaris Inc.
  • Page 183 12. Thoroughly clean cylinder head and valves. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.29 © Copyright Polaris Inc.

  • Page 184: Engine Disassembly / Inspection - Bottom End

    3. Inspect the condition of the stator windings output wires . If replacement is required, refer to the Electrical chapter. 4. Inspect the ball bearing that supports the starter motor shaft. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.30 © Copyright Polaris Inc.
  • Page 185 Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.31 © Copyright Polaris Inc.
  • Page 186 Grasp clutch gear and rotate clockwise. It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.32 © Copyright Polaris Inc.
  • Page 187 The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 5. Rotate engine to access the crankcase sump cover. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.33 © Copyright Polaris Inc.
  • Page 188 11. Lift the oil pump drive chain and remove the oil pump. 8. Remove and clean oil pump pick-up 9. Remove the three bolts that retain the oil pump to the crankcase. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.34 © Copyright Polaris Inc.
  • Page 189 13. Rotate the engine so the cylinder is facing up. 14. Remove the eleven M6 and two M8 upper crankcase bolts. 15. Rotate the engine so the cylinder is facing down. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.35 © Copyright Polaris Inc.
  • Page 190 1.4939 - 1.4946" (37.946 - 37.962 mm) from the crankcase. Service Limit: 1.4921" (37.900 mm) 4. Inspect the balance shaft gear teeth for damage. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.36 © Copyright Polaris Inc.
  • Page 191 Less than .001″ (0.025 mm) 10. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.37 © Copyright Polaris Inc.
  • Page 192 If worn past the service limit, replace the crankshaft assembly. CRANKSHAFT BEARING JOURNAL DIAMETERS 1.6140 - 1.6143" Main (40.996 - 41.004 Standard Bearing 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.38 © Copyright Polaris Inc.
  • Page 193 .002″ (0.05 mm) Inspect cylinder for wear, scratches, or damage. NOTICE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.39 © Copyright Polaris Inc.
  • Page 194 4. Carefully lift the cylinder and pistons from the upper crankcase. Cylinder Out of Round: .001″ (0.025 mm) MEASUREMENT Standard Bore Size: 3.6614 ± .0003" (93 mm ± 0.008 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.40 © Copyright Polaris Inc.
  • Page 195 (12:00 position) or bottom (6:00 position). MEASUREMENT Piston Pin Bore I.D.: .7877 - .7881" (20.009 - 20.018 mm) Service Limit: .7893" (20.05 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.41 © Copyright Polaris Inc.
  • Page 196 • By hand: Placing both thumbs on the ring ends, spread the ring open and push up on opposite side. Do not scratch ring lands. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.42 © Copyright Polaris Inc.

  • Page 197: Piston-To-Cylinder Clearance

    Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.43 © Copyright Polaris Inc.
  • Page 198 (and matching rod cap) for damage, galling of surface or pitting. 8. Refer to the number stamped onto the exhaust side of the connecting rod. This number represents the bore diameter. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.44 © Copyright Polaris Inc.
  • Page 199 10. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided in the Connecting Rod Bearing Selection page 3.47 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.45 © Copyright Polaris Inc.

  • Page 200: Engine Assembly - Bottom End

    Letters (six letters) *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.46 © Copyright Polaris Inc.

  • Page 201: Connecting Rod Bearing Selection

    Green BEARING SELECTION CHART — MAIN BEARINGS Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.47 © Copyright Polaris Inc.
  • Page 202 PTO side of piston (see illustration below). NOTICE Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.48 © Copyright Polaris Inc.
  • Page 203 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.49 © Copyright Polaris Inc.
  • Page 204 (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.50 © Copyright Polaris Inc.
  • Page 205 9. Verify piston orientation (arrow pointing toward exhaust) one last time prior to installation. NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.51 © Copyright Polaris Inc.

  • Page 206: Crankshaft Main Bearing Selection

    Press bearing insert firmly into place. is rotated. Repeat for the other connecting rod. 5. Install oil drain diverter into the upper crankcase. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.52 © Copyright Polaris Inc.
  • Page 207 ENGINE / COOLING SYSTEM 6. Apply Polaris PS-4 engine oil to each rod bearing 11. Clean bolt hole threads in connecting rod to remove journal and main bearing journal of crankshaft. all oil. 12. Install matching rod cap on connecting rod with 3 digit serial number stampings aligned &...
  • Page 208 5. Refer to Engine Oil Flow Chart page 3.7 at the beginning of this chapter and trace the oil paths through the crankcase and cylinder. 3. Apply Polaris PS-4 engine oil to both balance shaft 6. Flush all oil passages with solvent and then warm journals soapy water.
  • Page 209 8. Inspect crankcase mating surfaces to be sure they are joined properly. Investigate the cause of any gaps. 3. Apply Polaris PS-4 engine oil to the new bearings installed in the lower crankcase half. 9. Install the eight M10 , two M8 and one M6 lower crankcase bolts.
  • Page 210 11. Rotate the engine so the cylinder is facing up. and two M8 upper 12. Install the eleven M6 crankcase bolts. Tighten all bolts lightly by hand. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.56 © Copyright Polaris Inc.
  • Page 211 NOTICE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.57 © Copyright Polaris Inc.
  • Page 212 6. After assembly, be sure the starter gear rotates in the 27. Proceed to Flywheel Installation page 3.59 and then clockwise direction only. Cylinder Head Installation page 3.61. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.58 © Copyright Polaris Inc.
  • Page 213 9 ft-lbs (12 N·m) before starting engine. NOTICE Loctite cures with time, the longer the unit is let stand before engine starting the better the joint will be. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.59 © Copyright Polaris Inc.

  • Page 214: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.60 © Copyright Polaris Inc.
  • Page 215 5. Carefully set the cylinder head in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder head bolts evenly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.61 © Copyright Polaris Inc.
  • Page 216 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head.
  • Page 217 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.63 © Copyright Polaris Inc.
  • Page 218 18. Install the front camshaft carrier and two outer retaining bolts. 19. Install the fixed cam chain guide and two retaining bolts. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.64 © Copyright Polaris Inc.
  • Page 219 Camshaft Carrier Bolts: • Install the two mounting bolts. Torque fasteners to 7 ft-lbs (10 N·m) specification. 21. Apply Polaris PS-4 engine oil to the cam chain TORQUE tensioner bore prior to assembly. Use a new Tensioner Mounting Bolts: tensioner sealing washer 7 ft-lb (10 Nm) 22.

  • Page 220: Camshaft Timing - Quick Reference

    DO NOT use the “V” mark located on the flywheel opposite of the “I” mark. Only the “I” mark should be used as a TDC reference 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.66 © Copyright Polaris Inc.
  • Page 221 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes should face out as shown.
  • Page 222 15. Repeat steps 10-14 until all necessary valves have been adjusted. 16. Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification. TORQUE Camshaft Carrier Bolts: 7 ft-lbs (10 N·m) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.68 © Copyright Polaris Inc.

  • Page 223: Valve Lash - Tappet Selection

    5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be rounded to 460 since there is a 460 tappet). AVAILABLE TAPPETS 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.69 © Copyright Polaris Inc.
  • Page 224 T40 driver. 6. Torque valve cover bolts to specification. TORQUE Spark Plugs: 9 ft-lbs (12 N·m) Valve Cover Bolts: 7 ft-lbs (10 N·m) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.70 © Copyright Polaris Inc.

  • Page 225: Intake Service

    Air Box Fastener U-Nut 3.5 lb-ft (4.7 Nm) Intake Duct Hose Air Box Asm. Gear Clamp T-bolt Hose Clamp 24 lb-in (3 Nm) 49 lb-in (5.5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.71 © Copyright Polaris Inc.

  • Page 226: Intake Assembly View - General 4 / General

    3.5 lb-ft (4.7 Nm) Intake Duct Hose U-Nut Gear Clamp Air Box Asm. 24 lb-in (3 Nm) T-bolt Hose Clamp Rear Floor Intake Duct 49 lb-in (5.5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.72 © Copyright Polaris Inc.

  • Page 227: Intake Removal

    (2) holding the floor intake duct to the vehicle and remove from floor intake duct. 9. Remove the hood from the vehicle. Refer to “Hood Removal” page 11.51 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.73 © Copyright Polaris Inc.

  • Page 228: Intake Installation

    24 lb-in (3 Nm) Intake Duct Clamps: 24 lb-in (3 Nm) 3. Install the hood onto the vehicle. Refer to “Hood Installation” page 11.76 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.74 © Copyright Polaris Inc.
  • Page 229 Install the clamp holding the engine intake hose to the ETC. Torque to specification. TORQUE Engine Intake Hose Clamp: 49 lb-in (5.5 Nm) 10. Lower the cargo box and secure in position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.75 © Copyright Polaris Inc.

  • Page 230: Exhaust Service

    Outer Silencer Shield Exhaust Stud Isolator Mount 21 lb-ft (28 Nm) Spark Arrestor Fastener Exhaust Spring 8 ft-lbs (11 Nm) Spark Arrestor Double Spherical Gasket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.76 © Copyright Polaris Inc.

  • Page 231: Exhaust Removal

    5. Remove the spring holding the silencer to the vehicle. TORQUE Exhaust Headpipe to Silencer Fasteners: 21 lb-ft (28 Nm) 6. Remove the exhaust assembly out the RH side of the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.77 © Copyright Polaris Inc.
  • Page 232 ENGINE / COOLING SYSTEM 5. Install the spring holding the silencer to the vehicle. 6. Lower the cargo box and secure in position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.78 © Copyright Polaris Inc.

  • Page 233: Cooling System Service

    Radiator Oil Cooler Outlet Hose Engine Hoses Pressure Cap Bypass Hose Lower Radiator Hose Upper Radiator Hose Water Pump Outlet Hose Fan Assembly Recovery Bottle 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.79 © Copyright Polaris Inc.

  • Page 234: Coolant Hose Routing / Retention - 2 Seat

    COOLANT HOSE ROUTING / RETENTION - 2 SEAT HOT SIDE Coolant hose is secured in location as shown. Coolant hose is secured in four locations as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.80 © Copyright Polaris Inc.
  • Page 235 ENGINE / COOLING SYSTEM Coolant hose is secured in location as shown. COLD SIDE Coolant hose is secured in location as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.81 © Copyright Polaris Inc.
  • Page 236 ENGINE / COOLING SYSTEM Coolant hose is secured in four locations as shown. Coolant hose is secured in location as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.82 © Copyright Polaris Inc.

  • Page 237: Coolant Hose Routing / Retention - 4 Seat

    COOLANT HOSE ROUTING / RETENTION - 4 SEAT HOT SIDE Coolant hose is secured in location as shown. Coolant hose is secured in six locations as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.83 © Copyright Polaris Inc.
  • Page 238 ENGINE / COOLING SYSTEM Coolant hose is secured in location as shown. COLD SIDE Coolant hose is secured in location as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.84 © Copyright Polaris Inc.
  • Page 239 ENGINE / COOLING SYSTEM Coolant hose is secured in six locations as shown. Coolant hose is secured in location as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.85 © Copyright Polaris Inc.

  • Page 240: Coolant Overflow Line Routing / Retention

    COOLANT OVERFLOW LINE ROUTING / RETENTION TOP VIEW Coolant overflow line is secured in two locations as shown. BOTTOM VIEW Coolant overflow line is secured in six locations as shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.86 © Copyright Polaris Inc.

  • Page 241: Cooling System Specifications

    COOLANT TEMP °F (°C) CONDITION reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is Thermostat Open 180° F (82° C) recommended for use in all cooling systems and comes 194°...

  • Page 242: Cooling System Pressure Cap Test

    3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification. TORQUE Coolant Hose Mounting Bracket Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.88 © Copyright Polaris Inc.

  • Page 243: Radiator Replacement

    Allow the engine to cool before servicing. Lower Radiator Hose Fan Motor Assembly 4. Disconnect cooling fan electrical connector. Recovery Bottle Radiator 5. Remove the upper radiator hose from the radiator. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.89 © Copyright Polaris Inc.

  • Page 244: Thermostat Replacement

    7. Using an 8 mm swivel socket and long extension, remove the front bolt retaining the thermostat 11. Be sure to properly fill and bleed cooling system as cover. outlined in this chapter. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.90 © Copyright Polaris Inc.

  • Page 245: Cooling System Bleeding

    MAX line. 10. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

  • Page 246: Water Pump Installation

    14. Plug the water pump drive access hole in the engine block with a clean shop towel. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.92 © Copyright Polaris Inc.
  • Page 247 16. Install the hood, engine service panel and seats. NOTICE Install different bolt lengths as shown. TORQUE Water Pump Mounting Bolts: 7 lb-ft (10 Nm) (Apply Loctite® 204™ to bolt threads) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.93 © Copyright Polaris Inc.
  • Page 248 5. Remove impeller from water pump shaft. 6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.94 © Copyright Polaris Inc.
  • Page 249 7 lb-ft (10 Nm) (Apply Loctite® 204™ to bolt threads) 18. Clean cover and housing gasket surfaces 19. Install a new water pump cover gasket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.95 © Copyright Polaris Inc.
  • Page 250 ENGINE / COOLING SYSTEM WATER PUMP ASSEMBLY VIEW Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 3.96 © Copyright Polaris Inc.
  • Page 251 ................4.14 SPARK PLUG SERVICE 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 252: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU requirements for the immediate operating conditions. from another Polaris of the same model may be used The ECU then sends output signals to set injector without system or engine component damage.
  • Page 253 NOTICE Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Screws: 24 lb-in (2.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 254: Adjustable Speed Limiting Device (Asld) - Abs Models

    The setting can be adjusted at any time by the rider in the options menu on the instrument cluster. Refer to the owners manual to access the ALSD. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 255: Crankshaft Position Sensor (Cps)

    ECU (see wiring diagram). • Check the sensor mounting, air gap, flywheel encoder ring for damage or runout, and flywheel key. Inspect CPS and flywheel encoder ring for damage. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 256: Cps Replacement

    6. Torque CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 lb-ft (12 Nm) 7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 257: Electronic Throttle Control (Etc)

    ETC housing performed. If a problem is encountered, and you to intake plenum. determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization. Use Digital Wrench® to perform all troubleshooting of this component.

  • Page 258: Etc Learn Procedure

    6. Reverse these steps for installation. Torque the ETC housing retaining bolts and intake boot clamp to specification. TORQUE ETC Housing Retaining Bolts: 5 lb-ft (7 Nm) Intake Boot Clamp: 49 lb-in (5.5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 259: Accelerator Position Sensor (Aps)

    APS Mounting Fasteners: 8 lb-ft (11 Nm) The APS is calibrated to the throttle pedal. If the APS is faulty, the throttle pedal assembly must be replaced. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 260: Heated Oxygen Sensor (O2)

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 4.10 © Copyright Polaris Inc.

  • Page 261: Temp / Manifold Absolute Pressure Sensor (T-Map)

    Digital Wrench®. If the sensor is faulty, it must be replaced. NOTICE This sensor should only be tested using Digital Wrench® Diagnostic Software (dealer only). 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 4.11 © Copyright Polaris Inc.

  • Page 262: Engine Coolant Temperature (Ect) Sensor

    29.9 kΩ ± 6% ECT Resistance (248 °F / 120 °C) 1.22 kΩ ± 2% 3. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 4.12...

  • Page 263: Ignition System Service

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Retaining Bolt: 8 lb-ft (11 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 4.13 © Copyright Polaris Inc.

  • Page 264: Spark Plug Service

    Ensure wires are pushed down all the way so they engage onto the spark plugs. 13. Lower the cargo box and secure in position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 4.14 © Copyright Polaris Inc.
  • Page 265 ............... .5.33 FUEL PUMP REPLACEMENT 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 266: General Information - Fuel System

    • For the purpose of troubleshooting difficult running * Never drain the fuel system when the engine is hot. issues, a known-good ECU from another POLARIS of Severe burns may result. the same model and year may be used without * Do not overfill the tank.

  • Page 267: Special Tools - Fuel System

    58 ± 2 psi (400 ± 14 kPa) Fuel Sender Resistance - 450 ± 5 Ω Empty Fuel Sender Resistance - 100 ± 3 Ω Full Fuel Injector Resistance 11.4 - 12.6 Ω 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 268: Assembly Views - Fuel System

    70 lb-ft (95 Nm) Fuel Pump Assembly Fuel Feed Line Fuel Fill Neck and Fuel Cap Routing Clip, Hinged Vent Termination Fitting Vent Rollover Valve Routing Clip 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 269: Evap Fuel System Assembly View

    Purge Valve to Throttle Body Line Vent Rollover Valve 72 in-lbs (8 Nm) Carbon Canister to Purge Valve Hinged Routing Clip Panduit Strap Line Fuel Vent Line Carbon Canister Vent Line 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 270: Fuel Pump Assembly View

    FUEL SYSTEM FUEL PUMP ASSEMBLY VIEW Fuel Pump Fuel Level Sensor Fuel Pressure Regulator Float Arm Assembly Wire Harness Connector Pickup Filter 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 271: Evap System

    Fuel Cap: On EVAP equipped vehicles, the fuel cap will have a ratcheting style fuel cap with a tether. It is important to note that Polaris does not use an enhanced EVAP control system. This means the system does not detect a gross leak, or restrictions in the EVAP system such as a missing or loose fuel cap.

  • Page 272: Evap Conditions And Symptoms

    Excessive carbon monoxide emissions may be caused by any of the following: • Rich air/fuel mixture • Dirty air filter • Leaking fuel injectors • Fuel pressure too high/bad regulator 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 273: Carbon Canister Filter Replacement

    72 in-lbs (8 Nm) council. Reference page 11.63 8. Reinstall seats. See page 11.76. 7. Reinstall rear lower close off panel and center council. Reference page 11.63 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 274: Purge Valve Replacement

    7. Installation is performed by reversing the removal procedure. 8. Reinstall rear lower close off panel and center council. Reference page 11.63 9. Reinstall seats. See page 11.76. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.10 © Copyright Polaris Inc.

  • Page 275: Fuel Lines

    FUEL SYSTEM FUEL LINES FUEL LINE ROUTING FUEL FEED LINE ROUTING Fuel Pump Assembly Harness Clip, Interlock Routing Clip Fuel Rail 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.11 © Copyright Polaris Inc.
  • Page 276 FUEL SYSTEM FUEL VENT LINE ROUTING Fuel Vent Routing Clip, Hinged Routing Clip Vent Line Termination Fitting Harness Clip, Interlock 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.12 © Copyright Polaris Inc.

  • Page 277: Fuel Line Routing - General 4

    FUEL SYSTEM FUEL LINE ROUTING - GENERAL 4 FUEL FEED LINE ROUTING Routing Clip Harness Clip Fuel Rail Fitting 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.13 © Copyright Polaris Inc.
  • Page 278 FUEL SYSTEM FUEL VENT LINE ROUTING Routing Clip Harness Clip Routing Clip, Hinged Vent Termination Fitting 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.14 © Copyright Polaris Inc.

  • Page 279: Fuel Line Routing (Evap Models)

    FUEL SYSTEM FUEL LINE ROUTING (EVAP MODELS) FUEL FEED LINE ROUTING Fuel Pump Assembly Panduit Strap Routing Clip, Hinged Fuel Rail 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.15 © Copyright Polaris Inc.
  • Page 280 FUEL SYSTEM PURGE LINE ROUTING 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.16 © Copyright Polaris Inc.
  • Page 281 FUEL SYSTEM Fuel Vent Purge Valve Routing Clip, Hinged Panduit Strap Carbon Canister Throttle Body Panduit Strap 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.17 © Copyright Polaris Inc.
  • Page 282 Fuel Vent Canister Filter Routing Clip, Hinged Panduit Strap Carbon Canister Routing Clip, Hinged Carbon Canister to Canister Filter 5/16” Hose Vent Line Termination Fitting 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.18 © Copyright Polaris Inc.

  • Page 283: Fuel Line Routing - General 4 (Evap Models)

    FUEL SYSTEM FUEL LINE ROUTING - GENERAL 4 (EVAP MODELS) FUEL FEED LINE ROUTING Fuel Pump Assembly Panduit Strap Routing Clip, Hinged Fuel Rail 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.19 © Copyright Polaris Inc.
  • Page 284 FUEL SYSTEM PURGE LINE ROUTING 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.20 © Copyright Polaris Inc.
  • Page 285 FUEL SYSTEM Fuel Vent Purge Valve Routing Clip, Hinged Panduit Strap Carbon Canister Throttle Body Panduit Strap 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.21 © Copyright Polaris Inc.
  • Page 286 Fuel Vent Canister Filter Routing Clip, Hinged Panduit Strap Carbon Canister Routing Clip, Hinged Carbon Canister to Canister Filter 5/16” Hose Vent Line Termination Fitting 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.22 © Copyright Polaris Inc.

  • Page 287: Fuel Line Quick Connect Removal

    Do not over-pry or excessively bend the retaining tabs. This can damage the retaining clip, and require replacement of the fuel line assembly. 5. Push retaining clip upward into the open position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.23 © Copyright Polaris Inc.

  • Page 288: Fuel Line Replacement

    6. Place the fuel line back over the fitting and slide the green connector locking mechanism back into place. Verify the connector tabs snap back into place. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.24 © Copyright Polaris Inc.

  • Page 289: Vent Line Termination Fitting

    If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.25 © Copyright Polaris Inc.

  • Page 290: Fuel Injector

    Position Sensor (PPS) to allow for sequential fuel injection. IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.26 © Copyright Polaris Inc.

  • Page 291: Fuel Injector Test

    Line Quick Connect Removal page 5.23 procedure. 7. Disconnect the fuel injector harness leads. 8. Remove the two fuel rail fasteners that mount the fuel rail to the intake plenum. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.27 © Copyright Polaris Inc.

  • Page 292: Fuel Injector Troubleshooting

    18. Reconnect the negative battery cable and reinstall the driver’s seat. 19. Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.28 © Copyright Polaris Inc.

  • Page 293: Fuel Tank Service

    Refer to “Interior Body Component Removal” page 11.56 procedure. 8. Remove the fasteners holding the seat base assembly to the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.29 © Copyright Polaris Inc.

  • Page 294: Fuel Tank Installation

    3.5 lb-ft (5 Nm) 7. Reconnect the fuel line and fuel pump electrical harness. Verify connections are secure. NOTICE If equipped, re-install the rubber fuel pump cover. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.30 © Copyright Polaris Inc.

  • Page 295: Fuel Pump Service

    • Bent float rod 6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel pump assembly. Refer to Fuel Pump Replacement procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.31 © Copyright Polaris Inc.

  • Page 296: Fuel Pump Test

    Turn on the key switch and listen for the pump to activate. NOTICE If the pump starts, repeat steps 3, 4 and 5 to verify correct pressure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.32 © Copyright Polaris Inc.

  • Page 297: Fuel Pump Replacement

    4. Ensure that static has been discharged by touching a ground source such as the engine or frame. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.33 © Copyright Polaris Inc.
  • Page 298 16. Gently push down on fuel pump flange ensuring flange is centered. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.34 © Copyright Polaris Inc.
  • Page 299 “Fuel Line Replacement” page 5.24 procedure. NOTICE Be sure to engage the retainers on each fuel line until each snaps into place. Pull on fuel lines lightly to confirm connection. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.35 © Copyright Polaris Inc.
  • Page 300 FUEL SYSTEM NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 5.36 © Copyright Polaris Inc.
  • Page 301 .............6.29 DRIVEN CLUTCH SLIDER INSPECTION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 302: General Information - Pvt System

    Bosch Automotive Service Solutions: 1-800-345-2233 clutch control engagement (initial vehicle movement), or http://polaris.service-solutions.com/ clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions SPECIAL SUPPLIES PART and the vehicle’s intended usage.

  • Page 303: Service Specifications - Pvt System

    Button to Tower (0.000-0.304 mm) Clearance Drive Clutch 1.3725-1.3712 in 1.3704 in Shaft Diameter (34.8615-34.8488 (34.8088 mm) Vespel® Thrust 0.030 in (0.76 0.025 in (0.64 Washer Thickness 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 304: Pvt System Overview

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 305: Assembly Views - Pvt System

    35 in-lbs (8 Nm) Band Clamp Intake Hose 24 in-lbs (8 Nm) Hose Clamp Intake Duct Hose 35 in-lbs (8 Nm) Inner Clutch Cover Fasteners 10 lb-ft (14 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 306: Pvt Covers / Duct Assembly View - General 4

    Intake Hose 24 in-lbs (8 Nm) Hose Clamp Intake Duct Hose 35 in-lbs (8 Nm) Inner Clutch Cover Fasteners Intake Duct Hose 10 lb-ft (14 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 307: Inner Clutch Cover Assembly View

    Air Inlet/Outlet Clutch Duct Fasteners Inner Cover Seal 6 lb-in (0.7 Nm) Clutch Cover Shield Air Outlet Clutch Duct Clutch Cover Shield Fasteners 75 lb-in (8 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 308: Pvt System Service

    Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 13. Remove the seven bolts that retain inner clutch cover to engine and transmission. Remove inner clutch cover. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 309: Pvt Assembly

    12. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 13. Install the drive clutch onto the engine. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 310 4.5 lb-ft (6 Nm) 18. Install inlet and outlet ducts and tighten hose clamps. 19. Install the left rear wheel. Refer to “Wheel Installation” page procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.10 © Copyright Polaris Inc.

  • Page 311: Drive Belt Service

    1.73 chart at the end of this chapter for possible causes. 3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.11 © Copyright Polaris Inc.

  • Page 312: Drive Belt Installation

    5-7 times to properly seat the belt in the driven clutch. 5. Install the outer clutch cover and eight screws. Torque screws to specification. TORQUE Outer Clutch Cover Screws: 4.5 lb-ft (6 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.12 © Copyright Polaris Inc.

  • Page 313: Drive Clutch Service

    Weight, Shift 9 ft-lbs (12 N·m) Nut, Flex Lock Washer 20 in-lbs (2 N·m) Screw Button, Clutch 96 lb-ft (130 Nm) Washer, Clutch Spider Roller 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.13 © Copyright Polaris Inc.
  • Page 314 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 pattern and remove cover plate. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.14 © Copyright Polaris Inc.
  • Page 315 Check to see that spring coils are parallel to one another using a straight-edge. Distortion of the spring indicates stress fatigue, requiring replacement. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.15 © Copyright Polaris Inc.
  • Page 316 A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Drive Clutch Roller Pin and Button Service”. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.16 © Copyright Polaris Inc.
  • Page 317 Rollers, pins, thrust washers and buttons are not using Clutch Spider Removal / Installation Tool serviceable at the time of this publication. Spider Removal / Installation Tool: 2870341-A 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.17 © Copyright Polaris Inc.
  • Page 318 2. Remove the moveable clutch sheave. 3. Lift bearing and thrust washers off the shaft. Replace as an assembly if worn, damaged, or if operational problems were noted prior disassembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.18 © Copyright Polaris Inc.

  • Page 319: Moveable Sheave Bushing Inspection

    5020629 Bushing Removal /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.19 © Copyright Polaris Inc.
  • Page 320 Moveable Sheave - Bushing Installation 3. Remove nut from puller rod and set aside. 12. Place main adapter on puller. 4. Install puller adapter from kit PN 2871226. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.20 © Copyright Polaris Inc.
  • Page 321 29. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 30. Apply Loctite® 648 evenly to bushing bore in the cover. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.21 © Copyright Polaris Inc.
  • Page 322 Loctite® 7088™ Primer in 90° apart to the threads of the spider jamb nut. Install spider jam nut onto stationary shaft threads. Moveable Sheave Spider 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.22 © Copyright Polaris Inc.
  • Page 323 10. Install the limiter spacer and the clutch spring IMPORTANT DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.23 © Copyright Polaris Inc.

  • Page 324: Driven Clutch Service

    Spring Shoulder Sleeve Bearing Spider Spring Pin Roller Slider Washer E-clip Slider Pin Stationary Sheave Helix (Cam) Helix Screws Moveable Sheave 48 in-lb (5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.24 © Copyright Polaris Inc.

  • Page 325: Driven Clutch Alignment Procedure

    5. Reinstall the driven clutch and drive belt. 6. Test the vehicle to ensure proper operation. Universal Clutch Compressor: PU-50518-A 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.25 © Copyright Polaris Inc.
  • Page 326 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTICE Spring is compression only and has no torsional wind. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.26 © Copyright Polaris Inc.

  • Page 327: Driven Clutch Assembly

    12. Inspect the sheaves for excessive wear or damage. 3. Install the spring pins to retain the slider pins. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.27 © Copyright Polaris Inc.
  • Page 328 10. Install the drive clutch on the vehicle. See PVT 6. Align the X’s on the spider and moveable sheave. Assembly page 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.28 © Copyright Polaris Inc.

  • Page 329: Driven Clutch Slider Inspection

    . Replace the sliders if they are smaller than the service limit. MEASUREMENT Slider to Sheave Clearance Service Limit: 0.175″ (4.5 mm) Slider Width Service Limit: 0.975″ (24.8 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.29 © Copyright Polaris Inc.
  • Page 330 PVT SYSTEM NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 6.30 © Copyright Polaris Inc.
  • Page 331 ..............7.38 TRANSMISSION INSTALLATION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 332: General Information - Transmission

    PA-50231 2871698 Rear Output Seal Driver (Part of 2871702 Kit) 2871699 Rear Driveshaft Seal (Part of 2871702 Kit) Guide Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 333: Shift Cable Service

    13 lb-ft (18 Nm) Rear Shifter Cable Jam Nut Shifter Boot 13 lb-ft (18 Nm) Front Shifter Cable Jam Nut Bushing 18 lb-ft (24 Nm) Retaining Clip Shift Cable 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 334: Shift Cable Routing - General

    TRANSMISSION SHIFT CABLE ROUTING - GENERAL 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 335 Secure the jam nut in the shift cable mount bracket. 4. Finish routing by securing the shift cable end to the transmission bellcrank. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 336: Shift Lever / Cable Assembly View - General 4

    13 lb-ft (18 Nm) Hose Clamp Shifter Boot Front Shifter Cable Jam Nut Bushing 18 lb-ft (24 Nm) Retaining Clip Shift Cable Shift Cable Nut 13 lb-ft (18 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 337: Shift Cable Routing - General 4

    TRANSMISSION SHIFT CABLE ROUTING - GENERAL 4 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 338 3. Route the shift cable rearward and secure in the notch of the airbox intake duct 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 339: Shift Lever Replacement

    4. Remove the clip holding the shift lever to the mounting bracket pivot. 5. Remove shift boot and then pull shift lever down through opening in center console. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 340 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.10 © Copyright Polaris Inc.

  • Page 341: Assembly Views - Transmission

    Speed Sensor Fastener Park Plate Fastener (QTY 3) 10 ft-lbs (14 Nm) 9 ft-lbs (12 Nm) Rear Mount Bracket Fastener (QTY 2) 20 ft-lbs (27 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.11 © Copyright Polaris Inc.

  • Page 342: Transmission Mounting Torque Values

    TRANSMISSION TRANSMISSION MOUNTING TORQUE VALUES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.12 © Copyright Polaris Inc.

  • Page 343: Transmission Vent Line

    The transmission vent line runs up towards the passenger frame rail and through an open section of the frame to a vent line termination fitting. Hose Clamp Vent Line Termination Fitting Vent Line 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.13 © Copyright Polaris Inc.

  • Page 344: Vent Line Termination Fitting

    If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.14 © Copyright Polaris Inc.

  • Page 345: Transmission Service

    Swing shock outward. NOTICE Image for reference only. 10. Allow the suspension to droop and maneuver the drive shafts out of the transmission. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.15 © Copyright Polaris Inc.
  • Page 346 ETC, and rear differential intake duct to the ETC and remove duct from ETC. solenoid. T-Map Sensor Fuel Injectors Rear Differential Solenoid Oxygen Sensor 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.16 © Copyright Polaris Inc.
  • Page 347 Crankshaft Position Sensor Sensor Gear Position Switch 21. Place a spacer or support between the vehicle frame and engine to hold the engine up in position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.17 © Copyright Polaris Inc.
  • Page 348 With the help of an assistant, remove transmission from the left rear wheel well area. 24. Remove the rear transmission isolator fastener. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.18 © Copyright Polaris Inc.

  • Page 349: Differential Operation

    The rear drive shafts are now dependent on the differential allowing for tighter turns. IMPORTANT TURF mode is only available in drive gears and when the parking brake is released (INTL models). 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.19 © Copyright Polaris Inc.
  • Page 350 9 ft-lbs (12 Nm) Torsion Spring Differential Pin Pinion Gear Retainer Output Gear Shift Fork Solenoid Spring Thrust Washer Solenoid Dowel Pin 25 ft-lbs (34 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.20 © Copyright Polaris Inc.

  • Page 351: Transmission Disassembly

    6. Remove the compression spring 7. Remove the detent star . Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.21 © Copyright Polaris Inc.
  • Page 352 11. If equipped with parking brake disc (INTL models only), remove the parking brake disc fastener, washer, and disc from the transmission. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.22 © Copyright Polaris Inc.
  • Page 353 If use of a pry bar is necessary, take 19. Slide engagement dog off of shift fork guides. care not to pry on sealing surfaces of case. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.23 © Copyright Polaris Inc.
  • Page 354 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.24 © Copyright Polaris Inc.

  • Page 355: Gear Cluster Disassembly

    , and sprocket from the reverse shaft. 4. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.25 © Copyright Polaris Inc.
  • Page 356 4. Remove the snap ring and shim from the snorkel shaft. 5. Use an arbor press to remove the snorkel tube from the snorkel shaft. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.26 © Copyright Polaris Inc.

  • Page 357: Bevel Differential Disassembly

    2. Remove eight fasteners retaining the ring gear. 6. Remove output gear and Thrust washer 3. Remove ring gear , thrust washer , and output gear 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.27 © Copyright Polaris Inc.

  • Page 358: Bevel Differential Assembly

    When installing the ring gear, align with the mark made of the carrier during disassembly. NOTICE Align the hole of the differential pin with the dowel pin hole in the carrier. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.28 © Copyright Polaris Inc.
  • Page 359 TRANSMISSION 6. Install eight fasteners securing ring gear. TORQUE Ring Gear Fasteners: 28 ft-lbs (38 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.29 © Copyright Polaris Inc.

  • Page 360: 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 corresponding gear and/or gear shaft. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.30 © Copyright Polaris Inc.
  • Page 361 Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.31 © Copyright Polaris Inc.
  • Page 362 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.32 © Copyright Polaris Inc.

  • Page 363: Transmission Assembly

    Snorkel Locking Screw: 9 ft-lbs (12 Nm) TORQUE Shift Fork Screws: 9 ft-lbs (12 Nm) 4. Slide engagement dog onto retaining pins of shift fork. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.33 © Copyright Polaris Inc.
  • Page 364 Both shift forks need to be orientated the same way, so transmission housing, all at the same time. that the shift fork pins are both offset to the same side of the rail. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.34 © Copyright Polaris Inc.
  • Page 365 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.35 © Copyright Polaris Inc.
  • Page 366 13. Apply a continuous bead of Loctite® 680 Sealant to the left hand transmission mating surface. Loctite® 680 Sealant PN: 3233901 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.36 © Copyright Polaris Inc.
  • Page 367 Be sure to install the detent star with the raised edge Loctite® 680 Sealant facing outward and skip-tooth aligned. PN: 3233901 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.37 © Copyright Polaris Inc.

  • Page 368: Transmission Installation

    TORQUE Bellcrank Nut: 14 ft-lbs (19 Nm) 27. Refer to Transmission Installation page complete the repair. TORQUE Rear Transmission Isolator Fastener: 40 lb-ft (54 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.38 © Copyright Polaris Inc.
  • Page 369 2015-19 RANGER 570 Full-Size DO NOT torque fasteners at this time. 2014-19 RANGER 900/1000 2015-19 RZR 900 2016-19 RZR 1000 2016–19 ACE 900 2016–19 GENERAL 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.39 © Copyright Polaris Inc.
  • Page 370 DO NOT torque fasteners at this time. 8. Torque left side mounting bolts to specification using the numbered sequence shown. TORQUE Shift Cable Jam Nut: 13 lb-ft (18 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.40 © Copyright Polaris Inc.
  • Page 371 TORQUE Vehicle Speed Crankshaft Position Intake Duct Clamps: Sensor Sensor 24 lb-in (3 Nm) Gear Position Switch Engine Intake Hose Clamp: 49 lb-in (5.5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.41 © Copyright Polaris Inc.
  • Page 372 22. Install new spring ring on rear drive shafts. Apply an anti-seize compound to the splines. Install rear drive shafts into transmission. T-Map Sensor Fuel Injectors Rear Differential Solenoid Oxygen Sensor 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.42 © Copyright Polaris Inc.
  • Page 373 81 lb-ft (110 Nm) 27. Lubricate the transmission splines and mid propshaft 24. Install NEW stabilizer mounting fasteners and torque joint splines with Polaris All Purpose Grease. Install nut to specification. the propshaft onto the transmission output shaft. Refer to the applicable procedure.
  • Page 374 TRANSMISSION NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 7.44 © Copyright Polaris Inc.
  • Page 375 ............8.48 REAR BEARING CARRIER INSTALLATION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 376 ................8.69 REAR HUB ASSEMBLY VIEW 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 377: General Information - Final Drive

    TOOL DESCRIPTION PART NUMBER Roll Pin Removal Tool 2872608 Axle Boot Clamp Tool PU-48951 CV Boot Clamp Pliers 8700226 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 378: Assembly Views - Final Drive

    ASSEMBLY VIEWS - FINAL DRIVE PROPSHAFT ASSEMBLY VIEW - 2 SEAT Fastener Grease Fitting 33 lb-ft (45 Nm) Asm, Prop Shaft, Rear Asm, Prop Shaft, Front Asm, Bearing Pin-Spring 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 379: Propshaft Assembly View - 4 Seat

    PROPSHAFT ASSEMBLY VIEW - 4 SEAT Grease Fitting U-Joint Asm, Propshaft Rear Asm, Propshaft Center Asm, Bearing Flex Asm, Propshaft Front Fastener Pin, Spring 33 lb-ft (45 Nm) Yoke, Slip 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 380: Drive Shaft Assembly View

    Kit, Boot Plunging Joint Circlip Clamp, Large Circlip REAR DRIVE SHAFT Asm, Rear Drive Shaft Boot Circlip Clamp, Small Kit, Boot Joint, Plunging Clamp, Large Circlip Grease 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 381: Drive Shaft Assembly View (Intl Abs Models)

    DRIVE SHAFT ASSEMBLY VIEW (INTL ABS MODELS) FRONT DRIVE SHAFT (INTL ABS Models) Outer Race Cage Clamp, Large Ball Kit, Boot ABS Ring Clamp, Small Circlip Shaft 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 382 FINAL DRIVE REAR DRIVE SHAFT (INTL ABS Models) Outer Race Cage Clamp, Large Ball Kit, Boot ABS Ring Clamp, Small Circlip Shaft 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 383: Front Gearcase Assembly View

    Armature Plate 10 ft-lbs (14 N·m) Fill / Check Plug Roller Cage 10 ft-lbs (14 N·m) Roller Pinion Gear Spring Retainer Snap Ring O-ring Cover Plate Screws 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 384: Gearcase Vent Line

    GEARCASE VENT LINE The front gearcase vent line routs vertically and into an open section of the frame. Description Hose Clamp Vent Hose Retention Point 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.10 © Copyright Polaris Inc.

  • Page 385: Propshaft Service

    8. With the propshafts removed from the vehicle, inspect the shaft for cracks, damage from debris, and straightness. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.11 © Copyright Polaris Inc.

  • Page 386: Propshaft Removal - 4 Seat

    Use care not to damage brake lines when removing support bearing to the frame. propshafts. NOTICE Note the orientation of the coolant line clip for installation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.12 © Copyright Polaris Inc.
  • Page 387 NOTICE The rear of the propshaft must be angled and guided backwards to aid in clearing the mount. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.13 © Copyright Polaris Inc.

  • Page 388: U-Joint Disassembly

    6. Discard and replace all U-joint parts that were removed from the yoke. 3. Place a remover adapter on other end of U-joint with a smaller OD than the U-joint cap. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.14 © Copyright Polaris Inc.

  • Page 389: U-Joint Assembly

    8. Tighten clamp until both caps are flush with yoke and one cap is past retaining ring groove 4. Place caps into yoke bores and align with U-joint ends by hand. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.15 © Copyright Polaris Inc.

  • Page 390: Propshaft Installation - 2 Seat

    U-joint into exposed groove. 1. Lubricate front gearcase shaft splines with Anti-Seize. 2. Lubricate the transmission output shaft splines with Polaris All Purpose Grease. 3. Lubricate the front and rear prop shaft mid joint with Polaris All Purpose Grease.
  • Page 391 Reference these marks during installation if still visible. 7. Ensure proper orientation of the support bearing assembly. The shallow ridge of the bearing should be facing upwards. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.17 © Copyright Polaris Inc.

  • Page 392: Propshaft Installation - 4 Seat

    Polaris All Purpose Grease. 3. Lubricate the front, center and rear propshaft mid joint with Polaris All Purpose Grease. 4. Slide the rear propshaft forward from the left rear of the machine just below the PVT cover. Install the rear prop shaft on the transmission output shaft.
  • Page 393 TORQUE Support Bearing Fasteners: 33 lb-ft (45 Nm) 11. Install the skid plates on the vehicle. Refer to “Skid Plate Replacement” page 11.90 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.19 © Copyright Polaris Inc.

  • Page 394: Front Drive Shaft Removal

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.20 © Copyright Polaris Inc.

  • Page 395: Front Drive Shaft Installation

    3. Install drive shaft into the front bearing carrier. NOTICE Some models may feature two cone washers. 4. Install the upper and lower ball joint ends into the front bearing carrier. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.21 © Copyright Polaris Inc.

  • Page 396: Rear Drive Shaft Removal

    5. Remove the rear hub assembly from the bearing 120 lb-ft (163 Nm) carrier. NOTICE Do not lubricate the stud or the lug nut. 11. Rotate wheel and check for smooth operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.22 © Copyright Polaris Inc.

  • Page 397: Rear Drive Shaft Installation

    7. With a short, sharp jerk, remove drive shaft from the IMPORTANT transmission splines. Some models have an O-ring on the drive shaft. If applicable, ensure the O-ring is present and not damaged before installation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.23 © Copyright Polaris Inc.
  • Page 398 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.24 © Copyright Polaris Inc.

  • Page 399: Drive Shaft / Cv Joint Handling Tips

    Wheel Nuts (Alum): boots. 120 lb-ft (163 Nm) NOTICE Do not lubricate the stud or the lug nut. 9. Rotate wheel and check for smooth operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.25 © Copyright Polaris Inc.

  • Page 400: Outer Cv Joint / Boot Replacement

    IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.26 © Copyright Polaris Inc.
  • Page 401 CV Boot Clamp Pliers: 8700226 IMPORTANT The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.27 © Copyright Polaris Inc.

  • Page 402: Inner Plunging Joint / Boot Replacement

    Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 3. Clean the grease from the face of the joint and place the drive shaft in a soft-jawed vise. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.28 © Copyright Polaris Inc.
  • Page 403 NOTICE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.29 © Copyright Polaris Inc.
  • Page 404 19. Install and tighten the small clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.30 © Copyright Polaris Inc.

  • Page 405: Front Drive Shaft Removal

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.31 © Copyright Polaris Inc.

  • Page 406: Front Drive Shaft Installation

    Use a rubber mallet to tap on Ball Joint Pinch Bolts: the outboard end of the drive shaft if necessary 51 lb-ft (70 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.32 © Copyright Polaris Inc.
  • Page 407 30 lb-ft (41 Nm) IMPORTANT New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.33 © Copyright Polaris Inc.

  • Page 408: Rear Drive Shaft Removal

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the rear hub assembly from the bearing carrier. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.34 © Copyright Polaris Inc.

  • Page 409: Rear Drive Shaft Installation

    4. Install rear bearing carrier onto control arms and mounting fasteners. Torque fasteners to specification. TORQUE Rear Bearing Carrier Mounting Fasteners: 81 lb-ft (110 Nm) 5. Apply anti-seize to drive shaft splines. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.35 © Copyright Polaris Inc.

  • Page 410: Drive Shaft / Cv Joint Handling Tips

    CV joints and CV joint around end of spindle in different directions. boots. TORQUE Wheel Hub Castle Nut: 180 lb-ft (244 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.36 © Copyright Polaris Inc.

  • Page 411: Outer Cv Joint / Boot Replacement

    IMPORTANT If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.37 © Copyright Polaris Inc.
  • Page 412 CV Boot Clamp Pliers: 8700226 IMPORTANT The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.38 © Copyright Polaris Inc.

  • Page 413: Inner Plunging Joint / Boot Replacement

    Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 3. Clean the grease from the face of the joint and place the drive shaft in a soft-jawed vise. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.39 © Copyright Polaris Inc.
  • Page 414 NOTICE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.40 © Copyright Polaris Inc.
  • Page 415 19. Install and tighten the small clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.41 © Copyright Polaris Inc.

  • Page 416: Front Bearing Carrier Removal / Inspection

    10. Remove the bearing carrier from the front drive shaft. NOTICE Some models may feature two cone washers. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.42 © Copyright Polaris Inc.

  • Page 417: Front Bearing Replacement

    Use care to not allow any of the Loctite ® compound to shown. get in the bearing. 3. Wipe the housing clean of any excess compound and install the snap ring 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.43 © Copyright Polaris Inc.

  • Page 418: Front Bearing Carrier Installation

    Always use new brake caliper mounting bolts upon assembly. TORQUE Tie Rod End Fastener: 30 lb-ft (41 Nm) + 90° 5. Apply Anti-Seize to drive shaft axle splines. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.44 © Copyright Polaris Inc.
  • Page 419 Wheel Hub Castle Nut: 180 lb-ft (244 Nm) 9. Install wheel and wheel nuts. Refer to “Wheel Installation” page procedure. 10. Rotate wheel and check for smooth operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.45 © Copyright Polaris Inc.

  • Page 420: Rear Bearing Carrier Removal / Inspection

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 6. Remove the rear hub assembly from the bearing carrier. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.46 © Copyright Polaris Inc.

  • Page 421: Rear Bearing Replacement

    4. Inspect the bearing carrier housing for scratches, wear or damage. Replace rear bearing carrier if damaged. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.47 © Copyright Polaris Inc.

  • Page 422: Rear Bearing Carrier Installation

    7. Install wheel and wheel nuts. Refer to “Wheel Installation” page procedure. 8. Rotate wheel and check for smooth operation. NOTICE Some models may feature two cone washers. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.48 © Copyright Polaris Inc.

  • Page 423: Front Bearing Carrier Removal / Inspection

    12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.49 © Copyright Polaris Inc.

  • Page 424: Front Bearing Replacement

    IMPORTANT Use an arbor and press only on the outer race, otherwise bearing damage may occur. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.50 © Copyright Polaris Inc.

  • Page 425: Front Bearing Carrier Installation

    Tie Rod End Fastener: 30 lb-ft (41 Nm) + 90° TORQUE Wheel Hub Castle Nut: 5. Apply Anti-Seize to drive shaft axle splines. 180 lb-ft (244 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.51 © Copyright Polaris Inc.

  • Page 426: Rear Bearing Carrier Removal / Inspection

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 6. Remove the rear hub assembly from the bearing carrier. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.52 © Copyright Polaris Inc.

  • Page 427: Rear Bearing Replacement

    4. Inspect the bearing carrier housing for scratches, wear or damage. Replace rear bearing carrier if damaged. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.53 © Copyright Polaris Inc.

  • Page 428: Rear Bearing Carrier Installation

    Wheel Hub Castle Nut: 180 lb-ft (244 Nm) 7. Install wheel and wheel nuts. Refer to “Wheel Installation” page procedure. 8. Rotate wheel and check for smooth operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.54 © Copyright Polaris Inc.

  • Page 429: Front Gearcase Service

    “over- running” condition for the rollers upon disengagement. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.55 © Copyright Polaris Inc.

  • Page 430: Front Gearcase Removal

    12. Remove two 15mm fasteners securing support bearing. 5. Disconnect electrical wires from bus bar. 6. Disconnect contactor connector. 7. Remove the lower fastener on the passenger front shock. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.56 © Copyright Polaris Inc.
  • Page 431 15. Remove the vent line from the front gearcase and plug vent line fitting. 16. Remove the four fasteners securing the front gearcase to the frame. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.57 © Copyright Polaris Inc.

  • Page 432: Front Gearcase Disassembly / Inspection

    Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate . Refer to “Final Drive Troubleshooting” page for detailed inspection process. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.58 © Copyright Polaris Inc.
  • Page 433 9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.59 © Copyright Polaris Inc.
  • Page 434 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.60 © Copyright Polaris Inc.

  • Page 435: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.61 © Copyright Polaris Inc.
  • Page 436 11. Install a new O-ring on the cover plate assembly. IMPORTANT Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.62 © Copyright Polaris Inc.

  • Page 437: Front Gearcase Installation

    TORQUE Front Gearcase Mounting Bolts: 33 lb-ft (45 Nm) 4. Install the vent line. TORQUE Cover Plate Screws: 9 ft-lbs (12 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.63 © Copyright Polaris Inc.
  • Page 438 TORQUE Winch Mounting Plate: 30 lb-ft (41 Nm) 12. Install winch from passenger side. TORQUE Propshaft Support Bearing: 33 lb-ft (45 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.64 © Copyright Polaris Inc.
  • Page 439 GENERAL XP / GENERAL XP 4 Shock Mount Fasteners: 51 lb-ft (70 Nm) 15. Reconnect contactor connector. 16. Reconnect electrical wires from bus bar. 17. Reconnect battery. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.65 © Copyright Polaris Inc.

  • Page 440: Front Hub Assembly View

    18 lb-ft (24 Nm) Bearing Carrier Cotter Pin Hub Castle Nut Wheel Bearing 180 lb-ft (244 Nm) Washer Snap Ring Install washer with domed side out 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.66 © Copyright Polaris Inc.

  • Page 441: Rear Hub Assembly View

    18 lb-ft (24 Nm) Snap Ring Cotter Pin Hub Castle Nut Wheel Bearing 180 lb-ft (244 Nm) Washer Bearing Carrier Install washer with domed side out 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.67 © Copyright Polaris Inc.

  • Page 442: Front Hub Assembly View

    Valve Stem Wheel Studs Bearing Carrier Cotter Pin Hub Castle Nut Wheel Bearing 180 lb-ft (244 Nm) Washer Snap Ring Install washer with domed side out 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.68 © Copyright Polaris Inc.

  • Page 443: Rear Hub Assembly View

    Valve Stem Wheel Studs Snap Ring Cotter Pin Hub Castle Nut Wheel Bearing 180 lb-ft (244 Nm) Washer Bearing Carrier Install washer with domed side out 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.69 © Copyright Polaris Inc.
  • Page 444 FINAL DRIVE NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 8.70 © Copyright Polaris Inc.
  • Page 445 .............9.38 REAR STABILIZER BAR INSTALLATION 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 446 ............. .9.88 SHOCK ASSEMBLY (WALKER EVANS) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 447: General Information - Steering / Suspension

    Seal Protector Sleeve PU-50939 Shock Rod Holding Tool PU-51024 Gas Shock Fill Tool PU-51039 Shock Bearing Cap Removal Commercially Tool Available Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.

  • Page 448: Steering Assembly View

    42 lb-in (5 Nm) 40 lb-ft (54 Nm) Tilt Steering Asm. 30 lb-ft (41 Nm) Power Steering Unit Fasteners 30 lb-ft (41 Nm) 7 lb-ft (10 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 449 LH Front Knuckle Asm. Front CV Shield Front CV Shield Fasteners 42 lb-ft (57 Nm) 35 lb-in (4 Nm) Pivot Cap Asm. RH Front Knuckle Asm. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 450 Front Lower Control Arm Fastener RH Front Upper Control Arm LH Front Lower Control Arm RH Front Lower Control Arm 42 lb-ft (57 Nm) Pivot Shaft Short 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 451 Stabilizer Bar Mounting Bracket Stabilizer Bar Link Stabilizer Bar Mount Fastener 40 lb-ft (54 Nm) 20 ft-lbs (27 Nm) Stabilizer Bar Bushing 20 ft-lbs (27 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 452 Rear Upper Bearing Carrier Mounting Fastener Rear Inner Control Arm Fastener Pivot Shaft Long Washer Pivot Cap Asm. 40 lb-ft (54 Nm) + 90° Bushing Rear CV Shield 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 453 RH Rear Upper Control Arm 40 lb-ft (54 Nm) + 180° RH Rear Lower Control Arm Washer Rear Lower Bearing Carrier Mounting Fastener Pivot Shaft Short Bushing 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual © Copyright Polaris Inc.
  • Page 454 Zerk Fitting Stabilizer Bar Link Fasteners Stabilizer Bar Bushing Stabilizer Bar Link Stabilizer Bar Mounting Bracket Washer 42 lb-ft (57 Nm) 42 lb-ft (57 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.10 © Copyright Polaris Inc.
  • Page 455 42 lb-in (5 Nm) 40 lb-ft (54 Nm) Tilt Steering Asm. 30 lb-ft (41 Nm) Power Steering Unit Fasteners 30 lb-ft (41 Nm) 7 lb-ft (10 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.11 © Copyright Polaris Inc.

  • Page 456: Front Suspension Assembly View

    Front CV Shield Fasteners 81 lb-ft (110 Nm) 35 lb-in (4 Nm) Pivot Cap Asm. Front CV Shield Spiral Ring RH Front Knuckle Asm. Bushing 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.12 © Copyright Polaris Inc.
  • Page 457 Front Lower Inner Control Arm Fastener RH Front Upper Control Arm LH Front Lower Control Arm RH Front Lower Control Arm 51 lb-ft (70 Nm) Pivot Shaft Short 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.13 © Copyright Polaris Inc.

  • Page 458: Front Stabilizer Bar Assembly View

    Stabilizer Bar Mount Fasteners Stabilizer Bar Mounting Bracket Stabilizer Bar Link 22 lb-ft (30 Nm) Stabilizer Bar Link Fasteners Stabilizer Bar Bushing 81 lb-ft (110 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.14 © Copyright Polaris Inc.
  • Page 459 Pivot Shaft Long Rear Inner Control Arm Fastener Pivot Cap Asm. Washer Bushing 81 lb-ft (110 Nm) Shock Rod Shield 81 lb-ft (110 Nm) Washer Rivet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.15 © Copyright Polaris Inc.
  • Page 460 RH Rear Upper Control Arm LH Rear Lower Control Arm RH Rear Lower Control Arm 81 lb-ft (110 Nm) Pivot Shaft Short Washer Bushing Rear Bearing Carrier Fastener 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.16 © Copyright Polaris Inc.

  • Page 461: Rear Stabilizer Bar Assembly View

    Zerk Fitting Stabilizer Bar Link Fasteners Stabilizer Bar Bushing Stabilizer Bar Link Stabilizer Bar Mounting Bracket Washer 51 lb-ft (70 Nm) 44 lb-ft (60 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.17 © Copyright Polaris Inc.

  • Page 462: Steering Assembly Service

    4. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. 2. Remove and discard the pinch bolt retaining the upper steering shaft to the power steering unit. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.18 © Copyright Polaris Inc.

  • Page 463: Steering Wheel Removal

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.19 © Copyright Polaris Inc.

  • Page 464: Steering Shaft Removal - Lower

    5. Lift up on the shaft and remove it through the floor panel. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.20 © Copyright Polaris Inc.

  • Page 465: Steering Shaft Bearing Replacement

    Lower Steering Shaft Pinch Bolt: 48 lb-ft (65 Nm) 3. Install the power steering unit and reassemble the vehicle. Refer to “Power Steering Unit Installation” page 9.22 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.21 © Copyright Polaris Inc.

  • Page 466: Power Steering Unit Installation

    Lower Steering Shaft to Power Steering Pinch Bolt: 30 lb-ft (41 Nm) 5. Torque mount bracket fasteners to specification. TORQUE Power Steering Unit Mount Fasteners: 18 lb-ft (24 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.22 © Copyright Polaris Inc.

  • Page 467: Steering Shaft Installation - Upper

    1. Install the upper steering shaft and align the skip- tooth spline on the power steering stub shaft with the opening in the upper steering shaft. TORQUE Steering Wheel Nut: 65 lb-ft (88 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.23 © Copyright Polaris Inc.
  • Page 468 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.24 © Copyright Polaris Inc.

  • Page 469: Tie Rod End / Wheel Hub Inspection

    4. If abnormal movement 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.25 © Copyright Polaris Inc.

  • Page 470: Steering Rack Installation

    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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.26 © Copyright Polaris Inc.

  • Page 471: Wheel Toe Alignment Inspection

    Call this measurement “2”. 4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.27 © Copyright Polaris Inc.

  • Page 472: Wheel Toe Adjustment

    Damage may not be immediately apparent if done incorrectly. 4. After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.28 © Copyright Polaris Inc.

  • Page 473: Front Control Arm Removal

    10. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.29 © Copyright Polaris Inc.

  • Page 474: Front Control Arm Installation

    5. Examine control arm bushings and pivot tube. Replace if worn. Discard hardware. 6. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.30 © Copyright Polaris Inc.
  • Page 475 TORQUE Stabilizer Bar Link Fastener: 42 lb-ft (57 Nm) 8. Install NEW ball joint into control arm. Refer to “Ball Joint Installation” page 9.52 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.31 © Copyright Polaris Inc.
  • Page 476 2016–2018 models have M10 hardware. WARNING Upon control arm installation, test vehicle at low speeds before putting into service. TORQUE Front Control Arm Fasteners: 42 lb-ft (57 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.32 © Copyright Polaris Inc.

  • Page 477: Front Stabilizer Bar Removal

    7. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. TORQUE Front Stabilizer Bar Link Fasteners: 40 lb-ft (54 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.33 © Copyright Polaris Inc.

  • Page 478: Rear Control Arm Removal

    The locking agent 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.34 © Copyright Polaris Inc.

  • Page 479: Rear Control Arm Installation

    7. If not replacing the control arm, thoroughly clean the control arm and pivot tube. TORQUE Rear Inner Control Arm Fasteners: 40 lb-ft (54 Nm) + 90° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.35 © Copyright Polaris Inc.
  • Page 480 3. Install brake line mounting bracket. 1. Insert NEW pivot caps , control arm bushings and pivot tube into new control arm. A light press force may be needed. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.36 © Copyright Polaris Inc.
  • Page 481 Upon control arm installation, test vehicle at low speeds before putting into service. TORQUE Rear Outer Lower Control Arm Fasteners: 40 lb-ft (54 Nm) + 180° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.37 © Copyright Polaris Inc.

  • Page 482: Rear Stabilizer Bar Removal

    7. Carefully remove the stabilizer bar from the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. TORQUE Stabilizer Bar Link Fasteners: 42 lb-ft (57 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.38 © Copyright Polaris Inc.
  • Page 483 STEERING / SUSPENSION 5. Install wheels and torque lugs to specification. TORQUE Wheel Nuts: 120 lb-ft (163 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.39 © Copyright Polaris Inc.
  • Page 484 7. Loosen and remove the upper control arm through- bolt fasteners . Remove the upper control arm from the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.40 © Copyright Polaris Inc.
  • Page 485 Completely remove the ball joint end from the bearing carrier. 3. Loosen and remove the lower control arm through- bolt fasteners 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.41 © Copyright Polaris Inc.

  • Page 486: Front Control Arm Installation

    5. Install brake line mounting brackets and routing frame. Torque NEW fasteners to specification. clamp onto the control arm. TORQUE Front Inner Control Arm Fasteners: 81 lb-ft (110 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.42 © Copyright Polaris Inc.
  • Page 487 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.43 © Copyright Polaris Inc.

  • Page 488: Front Stabilizer Bar Removal

    6. Carefully remove the stabilizer bar. 7. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.44 © Copyright Polaris Inc.

  • Page 489: Front Stabilizer Bar Installation

    Torque fasteners to specification. TORQUE Front Stabilizer Bar Link Fasteners: 81 lb-ft (110 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.45 © Copyright Polaris Inc.
  • Page 490 6. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 3. Remove the fastener connecting the lower control arm to the bearing carrier. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.46 © Copyright Polaris Inc.

  • Page 491: Rear Control Arm Installation

    Install NEW fastener holding control arm to vehicle. Torque fasteners to specification. TORQUE Rear Inner Control Arm Fastener: 81 lb-ft (110 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.47 © Copyright Polaris Inc.
  • Page 492 Torque fasteners to specification. TORQUE Rear Bearing Carrier Fastener: 81 lb-ft (110 Nm) TORQUE Rear Inner Control Arm Fasteners: 81 lb-ft (110 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.48 © Copyright Polaris Inc.
  • Page 493 WARNING Upon control arm installation, test vehicle at low speeds before putting into service. TORQUE Rear Bearing Carrier Fastener: 81 lb-ft (110 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.49 © Copyright Polaris Inc.

  • Page 494: Rear Stabilizer Bar Removal

    7. Carefully remove the stabilizer bar from the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. TORQUE Stabilizer Bar Link Fasteners: 51 lb-ft (70 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.50 © Copyright Polaris Inc.
  • Page 495 STEERING / SUSPENSION 5. Install wheels and torque lugs to specification. TORQUE Wheel Nuts: 120 lb-ft (163 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.51 © Copyright Polaris Inc.

  • Page 496: Ball Joint Service

    2. Place a proper sized driver on the ball joint and place the A-arm in a press. 3. Carefully press the ball joint out of the A-arm and discard the ball joint. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.52 © Copyright Polaris Inc.
  • Page 497 3.00 3.20 IFP Depth Bottom of reservoir to bottom of Bottom of reservoir to bottom of (inches) floating piston floating piston Oil Volume Full Full 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.53 © Copyright Polaris Inc.
  • Page 498 1.425 x .012 1.425 x .015 1.350 x .012 1.350 x .015 1.570 x .128 Top Out 1.250 x .015 1.570 x .128 Top Out 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.54 © Copyright Polaris Inc.

  • Page 499: Shock Specifications - General 4

    3.00 3.20 IFP Depth Bottom of reservoir to bottom of Bottom of reservoir to bottom of (inches) floating piston floating piston Oil Volume Full Full 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.55 © Copyright Polaris Inc.
  • Page 500 1.250 x .012 1.600 x .012 1.250 x .012 1.250 x .006 1.100 x .012 1.570 x .128 Top Out 1.570 x .128 Top Out 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.56 © Copyright Polaris Inc.

  • Page 501: Shock Removal

    5. Tighten the spring adjustment ring to set the preload distance noted in Step 1. 6. Reinstall the shock onto the vehicle. Refer to “Shock Installation” page 9.60 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.57 © Copyright Polaris Inc.

  • Page 502: Spring Adjustment

    SPRING ADJUSTMENT - FACTORY SETTING FRONT REAR 6.625 in (16.828 cm) 1.625 in (4.128 cm) NOTICE Models with base suspension use softest setting for factory setting. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.58 © Copyright Polaris Inc.

  • Page 503: Spring Adjustment - General 4

    Always return the spring adjuster to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.59 © Copyright Polaris Inc.

  • Page 504: Shock Compression Adjustment

    20 lb-ft (27 Nm) + 90° 3. Remove the control arm support and lower the vehicle. COMPRESSION SETTING DAMPING Softest Position 1 Factory Position 2 Firmest Position 3 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.60 © Copyright Polaris Inc.

  • Page 505: Shock Disassembly (Fox)

    2. Discharge nitrogen pressure from reservoir chamber. 5. Place a commercially available bearing cap removal tool around the shock body and install supplied retaining ring. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.61 © Copyright Polaris Inc.
  • Page 506 At the same time push the IFP tool upwards with your thumbs. 12. Dump out used oil. 13. Using a 9/16-inch open end wrench and a 1/8-inch Hex Tee handle wrench, remove the bleed screw. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.62 © Copyright Polaris Inc.
  • Page 507 16. Remove the DSC using a DSC removal socket. 19. To assist in breaking the bond with the Loctite® adhesive, apply heat to the body cap. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.63 © Copyright Polaris Inc.
  • Page 508 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.64 © Copyright Polaris Inc.
  • Page 509 32. Remove the piston. Note the orientation of the piston as it comes off the shock shaft - compression side down. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.65 © Copyright Polaris Inc.
  • Page 510 34. Remove the piston bearing if it shows any signs of damage or wear. 38. Place shock shaft in clamp blocks. 35. Remove piston O-ring. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.66 © Copyright Polaris Inc.
  • Page 511 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.67 © Copyright Polaris Inc.
  • Page 512 DX BUSHING AND SEAL STYLE EYELET On some models the seal may be in the bearing assembly. NOTICE DX Bushing style eyelets have larger bore diameters than conventional eyelets. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.68 © Copyright Polaris Inc.

  • Page 513: Shock Assembly (Fox)

    3. Install second retaining ring. 6. Remove external O-ring from bearing assembly. NOTICE If internal bearing is damaged, replace with complete bearing assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.69 © Copyright Polaris Inc.
  • Page 514 Adjust rebound knob to allow metering rod to obtain maximum travel in eyelet. 7. Install a NEW O-ring on needle and apply thin layer of Slick Honey. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.70 © Copyright Polaris Inc.
  • Page 515 Slick Honey to metering rod. Eyelet: 30 lb-ft (41 Nm) 3. Reverse shock shaft in clamp blocks and install air side shaft spacers (if equipped) and jounce bumper. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.71 © Copyright Polaris Inc.
  • Page 516 There are two different sides on the U-Cup seal. When seal is installed, energizing side should be facing internal bearing. 9. Install bearing assembly using the appropriate bullet tool. 6. Install U-Cup seal. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.72 © Copyright Polaris Inc.
  • Page 517 NOTICE 15. Install rebound valve stack with required top out Bearing will be fully seated around piston when done correctly. washer. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.73 © Copyright Polaris Inc.
  • Page 518 20. Install appropriate O-ring and apply a thin layer of shock oil to the O-ring ONLY. NOTICE Ensure retaining ring is fully installed and secure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.74 © Copyright Polaris Inc.
  • Page 519 23. Place body in clamp blocks and install body cap. Torque body cap to specification using body cap socket. TORQUE LSC Knob: 14 lb-in (1.6 Nm) TORQUE Body Cap: 100 lb-ft (136 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.75 © Copyright Polaris Inc.
  • Page 520 34. Fill shock body with oil about 0.750″ from top, or about 1.250″ from top on cup shocks. 35. Quickly pass a propane torch over oil to eliminate any micro air bubbles. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.76 © Copyright Polaris Inc.
  • Page 521 Shock Charge Pressure: 39. Use IFP tool to push down on IFP and fully extend the 100 PSI (690 kPa) shock shaft assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.77 © Copyright Polaris Inc.
  • Page 522 NOTICE Check for any leaks or faults in the shock absorber’s functionality. 45. Tap body cap into position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.78 © Copyright Polaris Inc.
  • Page 523 2.875 3.75 IFP Depth Bottom of reservoir to bottom of Bottom of reservoir to bottom of (inches) floating piston floating piston Oil Volume Full Full 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.79 © Copyright Polaris Inc.
  • Page 524 Adjuster 1.10 x .025 1.00 x .015 .700 x .006 .900 X .015 1.00 x .025 .600 X .015 .625 x .065 .600 X .015 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.80 © Copyright Polaris Inc.

  • Page 525: Shock Specifications - General Xp 4

    2.875 3.75 IFP Depth Bottom of reservoir to bottom of Bottom of reservoir to bottom of (inches) floating piston floating piston Oil Volume Full Full 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.81 © Copyright Polaris Inc.
  • Page 526 Adjuster 1.10 x .025 1.00 x .015 .700 x .006 .900 X .015 1.00 x .025 .600 X .015 .625 x .065 .600 X .015 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.82 © Copyright Polaris Inc.

  • Page 527: Shock Removal

    5. Tighten the spring adjustment ring to set the preload distance noted in Step 1. 6. Reinstall the shock onto the vehicle. Refer to “Shock Installation” page 9.86 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.83 © Copyright Polaris Inc.

  • Page 528: Spring Adjustment - General Xp

    Always return the spring adjuster to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.84 © Copyright Polaris Inc.
  • Page 529 Always return the spring adjuster to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.85 © Copyright Polaris Inc.

  • Page 530: Shock Compression Adjustment

    Rear Shock 8 clicks from full hard vehicle. GENERAL XP 4 Front Shock 8 clicks from full hard Rear Shock 11 clicks from full hard 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.86 © Copyright Polaris Inc.

  • Page 531: Shock Disassembly (Walker Evans)

    Torque nut to specification. 4. Remove needle from charge port. 5. Remove the wire ring. TORQUE Piston Lock Nut: 36 lb-ft (49 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.87 © Copyright Polaris Inc.

  • Page 532: Shock Assembly (Walker Evans)

    15. Remove the IFP from reservoir eyelet cap. 3. Install the base valve into the can. Then, install the 16. Replace all o-rings. second o-ring into the coupler. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.88 © Copyright Polaris Inc.
  • Page 533 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 case is still 1.500” from the top of the main body. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.89 © Copyright Polaris Inc.
  • Page 534 STEERING / SUSPENSION NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 9.90 © Copyright Polaris Inc.
  • Page 535 ..............10.54 FRONT CALIPER ASSEMBLY 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.1 © Copyright Polaris Inc.
  • Page 536 ..............10.90 PARKING BRAKE ASSEMBLY VIEW 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.2 © Copyright Polaris Inc.

  • Page 537: General Information - Brake System

    • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.3 © Copyright Polaris Inc.

  • Page 538: Service Specifications - Brake System (General / General 4)

    Brake Fluid Type Polaris DOT 4 Brake Fluid PN 2872189 Up to MAX line inside reservoir Brake Fluid Capacity Brake Pedal Free-Play 0.090 in (2.28 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.4 © Copyright Polaris Inc.
  • Page 539 Brake Fluid Type Polaris DOT 4 Brake Fluid PN 2872189 Brake Fluid Capacity Up to MAX line inside reservoir Brake Pedal Free-Play 0.090 in (2.28 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.5 © Copyright Polaris Inc.

  • Page 540: Service Specifications - Brake System (Intl)

    Brake Fluid Type Polaris DOT 4 Brake Fluid PN 2872189 Up to MAX line inside reservoir Brake Fluid Capacity Brake Pedal Free-play 0.090 in (2.28 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.6 © Copyright Polaris Inc.

  • Page 541: Brake System Service

    BRAKE SYSTEM OPERATION BRAKE BLEEDING / FLUID CHANGE OVERVIEW The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.

  • Page 542: Brake Burnishing Procedure

    3. Add brake fluid to the indicated MAX level of 10. Add brake fluid to MAX level inside reservoir. reservoir. Master Cylinder Fluid Level Polaris DOT 4 Brake Fluid Up to MAX line inside reservoir (PN 2872189) 11. Install master cylinder reservoir cover.

  • Page 543: Assembly Views - Brake System (General / General 4)

    LH Rear Brake Caliper RH Front Brake Caliper Junction Block Brake Switch Master Cylinder Brake Line 15 lb-ft (20 Nm) Banjo Bolt 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.9 © Copyright Polaris Inc.
  • Page 544 Junction Block Fasteners 7 lb-ft (9 Nm) 35 in-lbs (4 Nm) Front Caliper Fasteners Clip 30 lb-ft (41 Nm) Inner Brake Line Clip Plastic Dart Clip Rivet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.10 © Copyright Polaris Inc.
  • Page 545 BRAKE SYSTEM BRAKE LINE ROUTING - GENERAL FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.11 © Copyright Polaris Inc.
  • Page 546 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Junction Block 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.12 © Copyright Polaris Inc.
  • Page 547 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Brake Line Retention Points Rear Brake Calipers 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.13 © Copyright Polaris Inc.

  • Page 548: Brake System Assembly View - General 4

    LH Rear Brake Caliper RH Front Brake Caliper Junction Block Brake Switch Master Cylinder Brake Line 15 lb-ft (20 Nm) Banjo Bolt 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.14 © Copyright Polaris Inc.
  • Page 549 Junction Block Fasteners 7 lb-ft (9 Nm) 35 in-lbs (4 Nm) Front Caliper Fasteners Panduit Strap 30 lb-ft (41 Nm) Inner Brake Line Clip Routing Clip Rivet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.15 © Copyright Polaris Inc.

  • Page 550: Brake Line Routing - General 4

    BRAKE SYSTEM BRAKE LINE ROUTING - GENERAL 4 FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.16 © Copyright Polaris Inc.
  • Page 551 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Junction Block 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.17 © Copyright Polaris Inc.
  • Page 552 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Brake Line Retention Points Rear Brake Calipers 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.18 © Copyright Polaris Inc.

  • Page 553: Brake Caliper Assembly View - General / General 4

    Caliper, Brake Cap, Plug Boot, Pin Seal Bleeder Screw Boot, Pin Bushing 4 lb-ft (5.4 Nm) Piston, Brake Bolt Lubricate with DOT 4 Brake Fluid 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.19 © Copyright Polaris Inc.
  • Page 554 Caliper, Brake Cap, Plug Boot, Pin Seal Bleeder Screw Boot, Pin Bushing 4 lb-ft (5.4 Nm) Piston, Brake Bolt Lubricate with DOT 4 Brake Fluid 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.20 © Copyright Polaris Inc.

  • Page 555: Brake Line Fitting Orientation - General / General 4

    Cylinder. The right front brake line is positioned on outside and the left front brake line is positioned on the inside. The rear brake line is attached to the rear port of the Master Cylinder. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.21 © Copyright Polaris Inc.
  • Page 556 BRAKE SYSTEM FRONT BRAKE CALIPER Front Brake Line Fitting 10.0° ± 2.5° REAR BRAKE CALIPER Rear Brake Line Fitting 60.0° - 65.0° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.22 © Copyright Polaris Inc.

  • Page 557: Assembly Views - Brake System (General Xp / General Xp 4)

    LH Rear Brake Caliper RH Front Brake Caliper Junction Block Brake Switch Master Cylinder Brake Line 15 lb-ft (20 Nm) Banjo Bolt 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.23 © Copyright Polaris Inc.
  • Page 558 46 lb-ft (62 Nm) Front Caliper Fasteners Junction Block Fasteners 30 lb-ft (41 Nm) 35 in-lbs (4 Nm) Inner Brake Line Clip Routing Clip Rivet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.24 © Copyright Polaris Inc.
  • Page 559 BRAKE LINE ROUTING - GENERAL XP FRONT BRAKE LINES FROM MASTER CYL- INDER TO CALIPERS ROUTING Master Cylinder LH Front Brake Caliper Brake Line Retention Points RH Front Brake Caliper 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.25 © Copyright Polaris Inc.
  • Page 560 15 lb-ft (20 Nm) 3. Continue routing the brake line down the upper control arm and secure with the routing clamp two brake line retainers 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.26 © Copyright Polaris Inc.
  • Page 561 BRAKE SYSTEM REAR BRAKE LINE FROM MASTER CYLIN- DER TO JUNCTION BLOCK ROUTING Master Cylinder Junction Block Brake Line Retention Points 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.27 © Copyright Polaris Inc.
  • Page 562 4. Install brake line onto the junction block. TORQUE Brake Line to Junction Block: 13 lb-ft (18 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.28 © Copyright Polaris Inc.
  • Page 563 BRAKE SYSTEM REAR BRAKE LINE FROM JUNCTION BLOCK TO CALIPERS ROUTING RH Rear Brake Caliper LH Rear Brake Caliper Brake Line Retention Points Junction Block 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.29 © Copyright Polaris Inc.
  • Page 564 TORQUE Brake Line Retention Fastener: NOTICE 8 lb-ft (11 Nm) The routing clip secures both the right and left rear break lines together. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.30 © Copyright Polaris Inc.
  • Page 565 6. Route the brake line down the rear upper control arm and secure with the routing clamps and wire/tube clamp 7. Install brake line onto rear caliper. TORQUE Rear Caliper Fasteners: 46 lb-ft (62 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.31 © Copyright Polaris Inc.
  • Page 566 Caliper, Brake Cap, Plug Boot, Pin Seal Bleeder Screw Boot, Pin Bushing 4 lb-ft (5.4 Nm) Piston, Brake Bolt Lubricate with DOT 4 Brake Fluid 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.32 © Copyright Polaris Inc.
  • Page 567 Boot, Pin Bushing 4 lb-ft (5.4 Nm) Piston, Brake Bolt Lubricate with DOT 4 Brake Fluid Seal - Caliper Outer Lubricate with DOT 4 Brake Fluid 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.33 © Copyright Polaris Inc.

  • Page 568: Brake System Assembly View - General Xp 4

    LH Rear Brake Caliper RH Front Brake Caliper Junction Block Brake Switch Master Cylinder Brake Line 15 lb-ft (20 Nm) Banjo Bolt 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.34 © Copyright Polaris Inc.
  • Page 569 7 lb-ft (9 Nm) 35 in-lbs (4 Nm) Front Caliper Fasteners Routing Clip 30 lb-ft (41 Nm) Inner Brake Line Clip Edge Clip Rivet RH Front Scraper 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.35 © Copyright Polaris Inc.

  • Page 570: Brake Line Routing - General Xp 4

    BRAKE LINE ROUTING - GENERAL XP 4 FRONT BRAKE LINES FROM MASTER CYL- INDER TO CALIPERS ROUTING Master Cylinder LH Front Brake Caliper Brake Line Retention Points RH Front Brake Caliper 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.36 © Copyright Polaris Inc.
  • Page 571 15 lb-ft (20 Nm) 3. Continue routing the brake line down the upper control arm and secure with the routing clamp two brake line retainers 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.37 © Copyright Polaris Inc.
  • Page 572 BRAKE SYSTEM REAR BRAKE LINE FROM MASTER CYLIN- DER TO JUNCTION BLOCK ROUTING Master Cylinder Junction Block Brake Line Retention Points 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.38 © Copyright Polaris Inc.
  • Page 573 TORQUE Brake Line to Junction Block: 13 lb-ft (18 Nm) 3. Route the brake line rearward along the chassis and secure with the routing clips 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.39 © Copyright Polaris Inc.
  • Page 574 BRAKE SYSTEM REAR BRAKE LINE FROM JUNCTION BLOCK TO CALIPERS ROUTING RH Rear Brake Caliper LH Rear Brake Caliper Brake Line Retention Points Junction Block 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.40 © Copyright Polaris Inc.
  • Page 575 TORQUE Brake Line Retention Fastener: NOTICE 8 lb-ft (11 Nm) The routing clip secures both the right and left rear break lines together. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.41 © Copyright Polaris Inc.
  • Page 576 6. Route the brake line down the rear upper control arm and secure with the routing clamps and wire/tube clamp 7. Install brake line onto rear caliper. TORQUE Rear Caliper Fasteners: 46 lb-ft (62 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.42 © Copyright Polaris Inc.

  • Page 577: Brake Caliper Assembly View - General Xp 4

    Caliper, Brake Cap, Plug Boot, Pin Seal Bleeder Screw Boot, Pin Bushing 4 lb-ft (5.4 Nm) Piston, Brake Bolt Lubricate with DOT 4 Brake Fluid 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.43 © Copyright Polaris Inc.
  • Page 578 Caliper, Brake Cap, Plug Boot, Pin Seal Bleeder Screw Boot, Pin Bushing 4 lb-ft (5.4 Nm) Piston, Brake Bolt Lubricate with DOT 4 Brake Fluid 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.44 © Copyright Polaris Inc.

  • Page 579: Brake Line Fitting Orientation - General Xp / General Xp 4

    Cylinder. The right front brake line is positioned on outside and the left front brake line is positioned on the inside. The rear brake line is attached to the rear port of the Master Cylinder. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.45 © Copyright Polaris Inc.
  • Page 580 BRAKE SYSTEM FRONT BRAKE CALIPER Front Brake Line Fitting 15.0° ± 2.5° REAR BRAKE CALIPER Rear Brake Line Fitting 15.0° ± 2.5° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.46 © Copyright Polaris Inc.

  • Page 581: Master Cylinder Service

    Brake Pedal Free-play: 0.090 in (2.28 mm) 5. Bleed the brake system. Refer to “Brake Bleeding / Fluid Change” page 10.7 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.47 © Copyright Polaris Inc.

  • Page 582: Brake Pedal Service

    4. Ensure brake pedal freeplay is within specification. Brake Pedal Free-play: 0.090 in (2.28 mm) 2. Remove the E-clip from the pedal mount and remove the brake pedal lever from the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.48 © Copyright Polaris Inc.

  • Page 583: Front Pad Service

    WARNING When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.49 © Copyright Polaris Inc.

  • Page 584: Brake Pad Inspection

    4. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2" (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.50 © Copyright Polaris Inc.
  • Page 585 Up to MAX line inside reservoir 7. Install front wheels. Refer to “Wheel Installation” page procedure. NOTICE If new pads are installed, refer to “Brake Burnishing Procedure” page 10.8. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.51 © Copyright Polaris Inc.

  • Page 586: Front Caliper Removal

    5. Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 3. Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.52 © Copyright Polaris Inc.
  • Page 587 5. Once the pistons are removed, use a pick to carefully remove the square O-rings from the caliper. O- rings should be replaced during caliper service. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.53 © Copyright Polaris Inc.

  • Page 588: Front Caliper Inspection

    Replace if damaged or worn beyond may drag upon assembly. service limit. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install pistons with a twisting motion MEASUREMENT while pushing inward. Piston should slide in and out Front Caliper Piston Bore I.D.:...

  • Page 589: Front Caliper Installation

    If new pads are installed, refer to “Brake Burnishing 3. Torque the banjo bolt to specification. Procedure” page 10.8. TORQUE Brake Line Banjo Bolts: 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.55 © Copyright Polaris Inc.

  • Page 590: Front Caliper Removal

    5. Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 2. Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.56 © Copyright Polaris Inc.
  • Page 591 NOTICE Be sure to clean all the seal grooves in the caliper body. 6. Inspect caliper body for nicks, scratches, pitting or wear. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.57 © Copyright Polaris Inc.

  • Page 592: Front Caliper Assembly

    FRONT CALIPER ASSEMBLY 3. Torque the banjo bolt to specification. 1. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.

  • Page 593: Rear Pad Service

    7. Remove the inner brake pad. WARNING When removing caliper, be careful not to damage brake line. Support caliper to avoid kinking or bending brake line. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.59 © Copyright Polaris Inc.

  • Page 594: Brake Pad Inspection

    WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.60 © Copyright Polaris Inc.
  • Page 595 & 5. Using a hammer and a small punch, remove the piston from the caliper body . Remove the square O-rings from the caliper body 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.61 © Copyright Polaris Inc.
  • Page 596 Rear Caliper Piston Bore I.D.: Std: 1.191 in (30.251 mm) Service Limit: 1.192 in (30.277 mm) 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
  • Page 597 If the brake drags, re-check assembly and installation. NOTICE If new pads are installed, refer to “Brake Burnishing Procedure” page 10.8. TORQUE Rear Caliper Mounting Bolts: 46 lb-ft (62 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.63 © Copyright Polaris Inc.

  • Page 598: Rear Caliper Removal

    2. Push upper pad retainer pin inward and slip brake pads past the edge and remove from the caliper. 3. Remove mount bracket and dust boots 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.64 © Copyright Polaris Inc.

  • Page 599: Rear Caliper Inspection

    Rear Caliper Piston O.D.: Standard: 1.500" (38.10 mm) Service Limit: 1.498" (38.05 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.65 © Copyright Polaris Inc.

  • Page 600: Rear Caliper Assembly

    3. Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn. 4. Follow the BRAKE BLEEDING / FLUID CHANGE procedure as outlined earlier in this chapter. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.66 © Copyright Polaris Inc.
  • Page 601 If the brake drags, re-check assembly and installation. NOTICE If new brake pads are installed, brake burnishing is recommended. Refer to “Brake Burnishing Procedure” page 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.67 © Copyright Polaris Inc.

  • Page 602: Disc Service

    2. Slowly rotate the disc and read total runout on the dial indicator. 3. Replace the disc if runout exceeds specification. Brake Disc Runout: 0.010" (0.254 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.68 © Copyright Polaris Inc.
  • Page 603 7. Reinstall the applicable brake caliper. Refer to applicable caliper installation procedure. 8. Bleed brakes if needed. Follow the bleeding procedure outlined earlier in this chapter. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.69 © Copyright Polaris Inc.

  • Page 604: Brake Disc Replacement

    Torque castle nut to specification and install a new cotter pin. TORQUE Wheel Hub Castle Nut: 180 lb-ft (244 Nm) 7. Reinstall the applicable brake caliper. Refer to applicable caliper installation procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.70 © Copyright Polaris Inc.

  • Page 605: International (Intl) Brake Service

    The ABS feature can be enabled and disabled by the rider. Reference the owners manual for ABS settings. Speed Sensor Tone Ring 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.71 © Copyright Polaris Inc.

  • Page 606: Brake System Assembly View (Intl Abs)

    Junction Block Fasteners Rear Brake Caliper Fasteners46 lb-ft (62 Nm) 35 in-lbs (4 Nm) Brake Pressure Switch Junction Block Master Cylinder Fasteners 22 lb-ft (30 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.72 © Copyright Polaris Inc.

  • Page 607: Brake Line Routing And Retention (Intl Abs)

    BRAKE SYSTEM BRAKE LINE ROUTING AND RETENTION (INTL ABS) MASTER CYLINDER TO ABS MODULE Master Cylinder Routing Clips ABS Module 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.73 © Copyright Polaris Inc.
  • Page 608 BRAKE SYSTEM ABS MODULE TO FRONT BRAKE CALIPERS ABS Module Brake Clip Routing Clip Front Brake Calipers 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.74 © Copyright Polaris Inc.
  • Page 609 BRAKE SYSTEM ABS MODULE TO JUNCTION BLOCK ABS Module Routing Clip Junction Block 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.75 © Copyright Polaris Inc.
  • Page 610 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Hose Clamp Routing Clip Rear Brake Caliper Clip 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.76 © Copyright Polaris Inc.

  • Page 611: Brake Line Fitting Orientation - Abs

    BRAKE LINE FITTING ORIENTATION - ABS MASTER CYLINDER (ABS MODELS) Master Cylinder to ABS Rear Port Fitting Master Cylinder to ABS Front Fitting 80.0° ± 2.5° 30.0° ± 2.5° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.77 © Copyright Polaris Inc.
  • Page 612 Right Front Caliper Brake Line Fitting 67.5° ± 2.5° 50.0° ± 2.5° Left Rear Caliper Brake Line Fitting Left Front Caliper Brake Line Fitting 75.0° ± 2.5° 75.0° ± 2.5° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.78 © Copyright Polaris Inc.
  • Page 613 BRAKE SYSTEM ABS UNIT (CONNECTOR SIDE) Master Cylinder Front Port Fitting Master Cylinder Rear Port Fitting 45.0° ± 2.5° 55.0° ± 2.5° 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.79 © Copyright Polaris Inc.

  • Page 614: Brake Line Routing And Retention Non-Abs (Intl)

    BRAKE SYSTEM BRAKE LINE ROUTING AND RETENTION NON-ABS (INTL) FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.80 © Copyright Polaris Inc.
  • Page 615 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Master Cylinder 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.81 © Copyright Polaris Inc.
  • Page 616 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Brake Line Retention Points Rear Brake Caliper 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.82 © Copyright Polaris Inc.

  • Page 617: Brake Pedal Removal (Intl)

    TORQUE Brake Pedal Shoulder Bolt: 13 lb-ft (18 Nm) 4. Ensure brake pedal freeplay is within specification. Brake Pedal Free-play: 0.090 in (2.28 mm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.83 © Copyright Polaris Inc.

  • Page 618: Brake Pressure Switch Replacement (Intl)

    6. Release brake pedal. 7. Open the reservoir cap. 8. Pump the brake pedal several times until no air bubbles appear and the brake pedal feels firm. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.84 © Copyright Polaris Inc.

  • Page 619: Tone Ring Inspection (Intl Abs)

    3. Reinstall drive shaft onto vehicle. Take care when installing to prevent damage to tone ring. Refer to Front Drive Shaft Installation page 8.21 or Rear Drive shaft Installation page 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.85 © Copyright Polaris Inc.

  • Page 620: Wheel Speed Sensor Air Gap Adjustment (Intl Abs)

    Two sensors are located on the right and left hand side of the transmission. Two sensor are located on right and left hand side of the front gearcase. Air Gap Specification 0.8–1.0 mm 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.86 © Copyright Polaris Inc.

  • Page 621: Abs Hecu Removal (Intl Abs)

    5. Repeat the procedure on the adjacent side of the gearcase. 2. Disconnect the brake lines and allow the brake fluid to drain. NOTICE Note orientation and location of each brake line for reassembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.87 © Copyright Polaris Inc.

  • Page 622: Abs Hecu Installation (Intl Abs)

    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 all three fasteners to 4 lb-ft (5.4 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.88 © Copyright Polaris Inc.

  • Page 623: Abs Troubleshooting (Intl Abs)

    • Faulty wheel speed sensor wiring • Low brake fluid • Air in brake system TORQUE ABS HECU Flare Fittings (INTL): 15 lb-ft (20 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.89 © Copyright Polaris Inc.

  • Page 624: Parking Brake (Intl)

    37 lb-ft (50 Nm) Parking Brake Lever Fastener Parking Brake Spacer 22 lb-ft (30 Nm) 2 in (51 mm) Parking Brake Cable Parking Brake Caliper Battery Pad 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.90 © Copyright Polaris Inc.
  • Page 625 5. Place the vehicle in neutral on a flat level surface. 6. Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.91 © Copyright Polaris Inc.
  • Page 626 / shift cable bracket. 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.92 © Copyright Polaris Inc.
  • Page 627 3. Install the cable, pin and clip pin . Test the park specification. brake for proper function. TORQUE Parking Brake Disc Mounting Bolt: 26 lb-ft (35 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.93 © Copyright Polaris Inc.
  • Page 628 BRAKE SYSTEM NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 10.94 © Copyright Polaris Inc.
  • Page 629 BODY COMPONENT INSTALLATION ............. . . 11.63 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.1 © Copyright Polaris Inc.
  • Page 630 ............. 11.90 SKID PLATE REPLACEMENT - GENERAL 4 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.2 © Copyright Polaris Inc.

  • Page 631: General Information - Body / Frame

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.3 © Copyright Polaris Inc.

  • Page 632: Assembly Views - Body / Frame

    Upper Front Fascia LH Lower Front Fascia Bracket Lower Front Fascia Bracket Fasteners Bumper Screen 3.5 lb-ft (4.7 Nm) RH Lower Front Fascia Bracket Plastic Push Rivet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.4 © Copyright Polaris Inc.

  • Page 633: Hood & Front Fender Assembly View - General / General 4

    Front Hood Fasteners Plastic Push Rivet 10 in-lbs (1.1 Nm) Body Fasteners Rear Hood Fasteners 3.5 lb-ft (4.7 Nm) 22 in-lbs (2.5 Nm) RH Fender Flair 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.5 © Copyright Polaris Inc.

  • Page 634: Hood & Front Fender Assembly View - General Xp / General Xp 4

    Front Hood Fasteners Plastic Push Rivet 10 in-lbs (1.1 Nm) Body Fasteners Rear Hood Fasteners 3.5 lb-ft (4.7 Nm) 22 in-lbs (2.5 Nm) RH Fender Flair 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.6 © Copyright Polaris Inc.

  • Page 635: Dash Assembly View

    Trim Clip RH Dash Tray Upper Dash Tube Plug Plastic Push Rivet Glovebox Door Trim Clip Rubber Grommet Console Controls Panel Glovebox Seal Hole Plug 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.7 © Copyright Polaris Inc.

  • Page 636: Floor & Rocker Assembly View - General

    Body Fastener RH Floor Clip 3.5 lb-ft (4.7 Nm) Floor Drain Plug U-Nut LH Floor Clip Plastic Push Rivet LH Rocker Panel RH Rocker Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.8 © Copyright Polaris Inc.

  • Page 637: Floor & Rocker Assembly View - General Xp

    Body Fastener RH Floor Clip 3.5 lb-ft (4.7 Nm) Floor Drain Plug U-Nut LH Floor Clip Plastic Push Rivet LH Rocker Panel RH Rocker Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.9 © Copyright Polaris Inc.

  • Page 638: Center Console Assembly View - General / General Xp

    Body Fastener Inner Center Console Cover 3.5 lb-ft (4.7 Nm) RH Center Console Center Console Seal Center Console Cover Fastener U-Nut 22 in-lbs (2.5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.10 © Copyright Polaris Inc.

  • Page 639: Closeoff & Rear Fender Assembly View - General

    22 in-lbs (2.5 Nm) Body Fastener Clutch Intake Filter 3.5 lb-ft (4.7 Nm) Fuel Tank Debris Shield Rear Fender Intake Upper Rear Closeoff Panel Lower Rear Closeoff Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.11 © Copyright Polaris Inc.

  • Page 640: Closeoff & Rear Fender Assembly View - General Xp

    22 in-lbs (2.5 Nm) Body Fastener Clutch Intake Filter 3.5 lb-ft (4.7 Nm) Fuel Tank Debris Shield Rear Fender Intake Upper Rear Closeoff Panel Lower Rear Closeoff Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.12 © Copyright Polaris Inc.

  • Page 641: Front Closeoff & Floor Assembly View - General 4 / General Xp 4

    RH Upper Center Fender Floor Drain Plug Body Fastener LH Lower Center Fender 3.5 lb-ft (4.7 Nm) LH Upper Center Fender RH Lower Center Fender Underseat Storage Bin 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.13 © Copyright Polaris Inc.

  • Page 642: Center Console Assembly View - General 4 / General Xp 4

    Body Fastener Inner Center Console Cover 3.5 lb-ft (4.7 Nm) RH Center Console Center Console Seal Center Console Cover Fastener U-Nut 22 in-lbs (2.5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.14 © Copyright Polaris Inc.
  • Page 643 Plastic Push Rivet 22 in-lbs (2.5 Nm) Rear Center Console Center Console Cover Storage Bin Inner Center Console Cover Cup Holder Center Console Seal Rubber Grommet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.15 © Copyright Polaris Inc.

  • Page 644: Rear Closeoff, Fenders, & Floor Assembly View - General 4

    Lower Rear Closeoff Panel End Cap Plug RH Rear Floor Floor Drain Plug Upper Rear Closeoff Panel LH Rear Floor Fuel Tank Debris Shield LH Rocker Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.16 © Copyright Polaris Inc.

  • Page 645: Rear Closeoff, Fenders, & Floor Assembly View - General Xp 4

    Lower Rear Closeoff Panel End Cap Plug RH Rear Floor Floor Drain Plug Upper Rear Closeoff Panel LH Rear Floor Fuel Tank Debris Shield LH Rocker Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.17 © Copyright Polaris Inc.

  • Page 646: Seat Assembly View - General

    Seat Back / Bottom Mounting Fasteners Tube Spacer 6 ft-lbs (8 Nm) Seat Base Asm. Seat Frame Seat Base Mounting Fasteners 6 ft-lbs (8 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.18 © Copyright Polaris Inc.
  • Page 647 40 lb-ft (54 Nm) Seat Belt Buckle LH T-Rail Bracket Seat Belt Buckle Seat Belt Adjuster Mount Fastener RH T-Rail Bracket 3.5 ft-lbs (5 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.19 © Copyright Polaris Inc.

  • Page 648: Seat Assembly View - General 4

    Seat Back / Bottom Mounting Fasteners Sleeve 6 ft-lbs (8 Nm) Seat Slider Base Asm. Seat Base Asm. Seat Base Mounting Fasteners 6 ft-lbs (8 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.20 © Copyright Polaris Inc.
  • Page 649 Seat Belt / Buckle Fasteners Washer 40 lb-ft (54 Nm) Seat Belt Adjuster Mount Fastener Seat Belt Buckle 3.5 ft-lbs (5 Nm) Seat Belt Buckle 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.21 © Copyright Polaris Inc.

  • Page 650: Cargo Box Assembly View - General

    Cargo Box Assembly Cargo Box Body Fasteners Tailgate Support Mounting Fasteners 3.5 ft-lbs (5 Nm) 8 ft-lbs (11 Nm) Tailgate Assembly Washer Box Tiedown Bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.22 © Copyright Polaris Inc.
  • Page 651 Lower Front Fender Flair Fastener Box Latch Bushing 3.5 lb-ft (4.7 Nm) Latch Spring Box Latch Rubber Bumper Box Latch Handle Box Latch Bushing Fastener Hitch Pin 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.23 © Copyright Polaris Inc.
  • Page 652 Box Panel Fasteners 3.5 lb-ft (4.7 Nm) Bottom Fender Flair Fasteners RH Fender Flair 3.5 lb-ft (4.7 Nm) LH Tailgate Support RH Box Panel Rubber Bumper 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.24 © Copyright Polaris Inc.
  • Page 653 22 in-lbs (2.5 Nm) Outer Tailgate Panel Tailgate Pivot Bracket Outer Tailgate Pivot Bracket Fasteners Tailgate Handle Latch 3 ft-bs (4 Nm) Tailgate Trim Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.25 © Copyright Polaris Inc.

  • Page 654: Cargo Box Assembly View - General Xp

    Cargo Box Assembly Cargo Box Body Fasteners Tailgate Support Mounting Fasteners 3.5 ft-lbs (5 Nm) 8 ft-lbs (11 Nm) Tailgate Assembly Washer Box Tiedown Bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.26 © Copyright Polaris Inc.
  • Page 655 Lower Front Fender Flair Fastener Box Latch Bushing 3.5 lb-ft (4.7 Nm) Rubber Bumper Box Latch Latch Spring Box Latch Handle Box Latch Bushing Fastener Hitch Pin 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.27 © Copyright Polaris Inc.
  • Page 656 22 in-lbs (2.5 Nm) LH Box Panel 1/4 Turn Stud RH Fender Flair Bottom Fender Flair Fasteners RH Box Panel 3.5 lb-ft (4.7 Nm) LH Tailgate Support 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.28 © Copyright Polaris Inc.
  • Page 657 22 in-lbs (2.5 Nm) Outer Tailgate Panel Tailgate Pivot Bracket Outer Tailgate Pivot Bracket Fasteners Tailgate Handle Latch 3 ft-bs (4 Nm) Tailgate Trim Panel 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.29 © Copyright Polaris Inc.

  • Page 658: Door Assembly View - Front

    Door Hinge Pivot Fastener Washer Door Pivot Bushing Striker Mount Striker Mount Fasteners 8 lb-ft (11 Nm) 5 lb-ft (7 Nm) Striker Pin 25 lb-ft (34 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.30 © Copyright Polaris Inc.
  • Page 659 Door Grab Handle Fasteners 3.5 ft-lbs (4.7 Nm) Door Seal Inner Door Panel Fasteners (T-25) 22 in-lbs (2.5 Nm) Door Grab Handle Door Hinge Mount Cover Inner Door Trim 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.31 © Copyright Polaris Inc.
  • Page 660 Door Handle Bracket / Latch Mount 3.5 ft-lbs (4.7 Nm) Panduit Strap Cable Retainer Front Door Cable NOTICE LH door frame shown. RH door frame similar. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.32 © Copyright Polaris Inc.
  • Page 661 FRONT OUTER DOOR ASSEMBLY Outer Door Panel Fasteners Outer Front Door Panel 42 in-lbs (5 Nm) U-Nut NOTICE LH outer door panel shown. RH outer door panel similar. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.33 © Copyright Polaris Inc.

  • Page 662: Door Assembly View - Rear

    RH Rear Bolster 8 lb-ft (11 Nm) Striker Mount Fasteners LH Rear Bolster 5 lb-ft (7 Nm) Lower Rear Bolster Fasteners Rear Striker 5 lb-ft (7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.34 © Copyright Polaris Inc.
  • Page 663 Inner Door Panel Fasteners LH Inner Front Door Panel 22 in-lbs (2.5 Nm) Door Seal NOTICE LH inner door panel shown. RH inner door panel similar. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.35 © Copyright Polaris Inc.
  • Page 664 Adjustable Rear Door Cable 16 in-lbs (2 Nm) Door Latch Clip Cable Clip Door Latch U-Nut NOTICE LH door frame shown. RH door frame similar. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.36 © Copyright Polaris Inc.
  • Page 665 Bolster Bar Cover Outer Door Panel / Bolster Bar Cover Fasteners U-Nut 22 in-lbs (2.5 Nm) NOTICE LH outer door panel shown. RH outer door panel similar. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.37 © Copyright Polaris Inc.

  • Page 666: Rops Assembly View - General

    40 lb-ft (54 Nm) ROPS, Rear Front Support Fasteners ROPS, RH 40 lb-ft (54 Nm) Visor Panel Fasteners ROPS, Front Support 3.5 lb-ft (4.7 Nm) Panel, Visor U-Nut 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.38 © Copyright Polaris Inc.
  • Page 667 ROPS, Rear RH 40 lb-ft (54 Nm) ROPS, Front Support ROPS, Front RH Visor Panel Fasteners U-Nut 3.5 lb-ft (4.7 Nm) ROPS, Front LH Panel, Visor ROPS,Center 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.39 © Copyright Polaris Inc.

  • Page 668: Frame Assembly View - General

    Front Seat Base Frame M10 Fasteners Front Frame 30 ft-lbs (41 Nm) Top Frame Suspension Mount Bracket Suspension Mount Bracket Fasteners Main Frame 18 ft-lbs (24 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.40 © Copyright Polaris Inc.
  • Page 669 BODY / FRAME SKID PLATE Main Skid Plate Skid Plate Washer Skid Plate Fasteners Rear Skid Plate 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.41 © Copyright Polaris Inc.
  • Page 670 FRAME MOUNTING TORQUE SEQUENCE Upper Frame Fasteners Lower Frame Fasteners Step 1: 35 ft-lbs (47 Nm) Step 2: 40 ft-lbs (54 Nm) Shaded callouts indicate torque sequence. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.42 © Copyright Polaris Inc.

  • Page 671: Frame Assembly View - General 4

    Rear Seat Base Frame M10 Fasteners Front Frame 30 ft-lbs (41 Nm) Suspension Mount Bracket Rear Seat Base Frame Suspension Mount Bracket Fasteners Top Frame 18 ft-lbs (24 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.43 © Copyright Polaris Inc.
  • Page 672 Front Skid Plate Skid Plate Washer Skid Plate Fasteners Center Skid Plate 3.5 lb-ft (4.7 Nm) Skid Plate Fasteners Rear Skid Plate 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.44 © Copyright Polaris Inc.
  • Page 673 Upper Outer Frame Fasteners Lower Outer Frame Fasteners Step 1: 35 ft-lbs (47 Nm) Inner Frame Fasteners Step 2: 40 ft-lbs (54 Nm) Shaded callouts indicate torque sequence. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.45 © Copyright Polaris Inc.

  • Page 674: Frame Assembly View - General Xp

    22 ft-lbs (30 Nm) Front Seat Base Frame M8 Fasteners 10 ft-lbs (14 Nm) Front Seat Base Frame M10 Fasteners Main Frame 30 ft-lbs (41 Nm) Top Frame 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.46 © Copyright Polaris Inc.
  • Page 675 BODY / FRAME SKID PLATE Main Skid Plate Skid Plate Washer Skid Plate Fasteners Rear Skid Plate 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.47 © Copyright Polaris Inc.
  • Page 676 Rear Seat Base Frame M8 Fasteners 10 ft-lbs (14 Nm) Rear Seat Base Frame M10 Fasteners Main Frame 30 ft-lbs (41 Nm) Rear Seat Base Frame 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.48 © Copyright Polaris Inc.
  • Page 677 Front Skid Plate Skid Plate Washer Skid Plate Fasteners Center Skid Plate 3.5 lb-ft (4.7 Nm) Skid Plate Fasteners Rear Skid Plate 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.49 © Copyright Polaris Inc.

  • Page 678: Body Component Removal

    3. Remove door from vehicle. REAR DOOR REMOVAL 1. Open door to expose door hinge. 2. Remove door hinge fasteners. 3. Remove door from vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.50 © Copyright Polaris Inc.

  • Page 679: Seat Removal

    1. Remove the fasteners holding the front fender to the vehicle. Pull the front fender off the vehicle. NOTICE Remove the front grill mesh to access the fasteners on the front of the fender. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.51 © Copyright Polaris Inc.
  • Page 680 Remove the lower front fascia from the tabs holding it to the vehicle. vehicle. NOTICE Remove the clutch intake hose from the LH rear fender. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.52 © Copyright Polaris Inc.

  • Page 681: Exterior Body Component Removal - General

    2. Remove the fasteners holding the hood liner to the vehicle and remove the hood liner. NOTICE Remove the front grill mesh to access the fasteners on the front of the fender. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.53 © Copyright Polaris Inc.
  • Page 682 Pull the rear fender from the tabs holding it to the vehicle. NOTICE Remove the clutch intake hose from the LH rear fender. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.54 © Copyright Polaris Inc.
  • Page 683 Remove the lower front fascia from the vehicle. 2. To remove the hood liner, remove the fasteners and clamps securing the pulse bar mounting bracket, intake vent, and coolant expansion bottle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.55 © Copyright Polaris Inc.

  • Page 684: Interior Body Component Removal

    1. Remove the fasteners holding the upper floor panel to the main floor panels. NOTICE Remove the gauge cluster, if necessary, to aid in removal. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.56 © Copyright Polaris Inc.
  • Page 685 3. Remove the fasteners holding the RH and LH center console panels to the vehicle. NOTICE If necessary, loosen/remove the fasteners holding the door latch mounts to the vehicle to aid in panel removal. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.57 © Copyright Polaris Inc.

  • Page 686: Interior Body Component Removal - General

    2. Remove the remaining fasteners holding the RH and LH main floors to the vehicle. UPPER FLOOR PANEL REMOVAL 1. Remove the fasteners holding the upper floor panel to the main floor panels. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.58 © Copyright Polaris Inc.
  • Page 687 3. Remove the fasteners holding the RH and LH center console panels to the vehicle. NOTICE Remove the gauge cluster, if necessary, to aid in removal. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.59 © Copyright Polaris Inc.
  • Page 688 2. Remove the fasteners holding the rear center console to the vehicle. 3. Disconnect the accessory power outlet and remove the rear center console and top from the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.60 © Copyright Polaris Inc.
  • Page 689 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.61 © Copyright Polaris Inc.

  • Page 690: Cargo Box Removal

    4. Remove the fasteners holding the cargo box to the vehicle frame. With the help of an assistant, remove the cargo box from the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.62 © Copyright Polaris Inc.

  • Page 691: Body Component Installation

    Torque fasteners to specification. 4. Lower the cargo box and secure in position. TORQUE Rear Lower Close-off Panel Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.63 © Copyright Polaris Inc.
  • Page 692 1. Install the center console top into the vehicle and over the shift lever. Install the shift boot into the center console top. Connect the 12 V power receptacles to the wiring harness. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.64 © Copyright Polaris Inc.
  • Page 693 CONTROLS CONSOLE PANEL INSTALLATION 1. Install the wiring harness connectors to the controls console panel components. Install the controls console panel into the main dash tabs. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.65 © Copyright Polaris Inc.

  • Page 694: Interior Body Component Installation - General

    TORQUE Floor Fasteners: 3.5 lb-ft (4.7 Nm) 2. Install the brake pedal, accelerator pedal, and mounting bracket. Refer to “Brake Pedal Installation” page 10.48 procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.66 © Copyright Polaris Inc.
  • Page 695 2. Install the seat belt buckles and seat belt shoulder strap mounts. TORQUE Seat Belt Fasteners: 40 lb-ft (54 Nm) 3. Install the fuse box. Refer to “Fuse Box Replacement page 12.42” procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.67 © Copyright Polaris Inc.
  • Page 696 2. 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.68 © Copyright Polaris Inc.
  • Page 697 3. Install the center tunnel access cover and fasteners securing it to the RH and LH center console panels. 1. Install the fasteners holding the upper floor panel to the main floor panels. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.69 © Copyright Polaris Inc.
  • Page 698 CONTROLS CONSOLE PANEL INSTALLATION 1. Install the wiring harness connectors to the controls console panel components. Install the controls console panel into the main dash tabs. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.70 © Copyright Polaris Inc.

  • Page 699: Exterior Body Component Installation

    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) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.71 © Copyright Polaris Inc.
  • Page 700 Torque the fasteners to specification. TORQUE Front Fender Fasteners: 3.5 lb-ft (4.7 Nm) TORQUE Rear Fender Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.72 © Copyright Polaris Inc.

  • Page 701: Exterior Body Component Installation - General

    Installation” page 11.76 procedure. 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) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.73 © Copyright Polaris Inc.
  • Page 702 Install the fasteners holding the rear fender to the vehicle and rocker panel. Torque the fasteners to specification. TORQUE Rear Fender Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.74 © Copyright Polaris Inc.
  • Page 703 Torque fasteners to specification. TORQUE Front Fender Fasteners: 3.5 lb-ft (4.7 Nm) TORQUE Center Lower Fender Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.75 © Copyright Polaris Inc.

  • Page 704: Hood Installation

    2. Press down on the back of the seat to latch the seat onto the frame. Lift up on the seat to ensure it is fully installed. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.76 © Copyright Polaris Inc.

  • Page 705: Door Installation

    6. Verify the stiker is in a nominal position both vertically and laterally and adjust if needed. 3. With the help of an assistant, align the Driver door hinges with door hinge mounting brackets. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.77 © Copyright Polaris Inc.

  • Page 706: Door Installation - General 4

    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 properly open, closes, and locks. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.78 © Copyright Polaris Inc.
  • Page 707 4. With the help of an assistant, align the Driver side front door hinges with door hinge mounting brackets. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.79 © Copyright Polaris Inc.
  • Page 708 2,7, and 8. 10. Verify the door properly opens, closes, and locks. 4. Ensure the door is fully locked 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.80 © Copyright Polaris Inc.

  • Page 709: Door Cable Adjustment

    1–4. 2. Remove door hinge fastener covers 7. Verify that the door properly opens, closes, and locks. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.81 © Copyright Polaris Inc.
  • Page 710 6. Loosen the door cable lock collar and adjuster until no threads are showing. 4. Push door latch into double lock position. 7. Hold the exterior door handle in the full open position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.82 © Copyright Polaris Inc.
  • Page 711 13. When cable is adjusted properly tighten lock collar. 14. Locate interior door cable adjuster. 15. Push door latch into double lock position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.83 © Copyright Polaris Inc.
  • Page 712 4. Push door latch into double lock position. NOTICE The interior door handle should be about 3/4 of the way through its throw when it releases the latch. Adjust cable if necessary. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.84 © Copyright Polaris Inc.
  • Page 713 The door handle should be about 3/4 of the way through its throw when it releases the latch. 8. Reinstall the door panel and fasteners. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.85 © Copyright Polaris Inc.

  • Page 714: Frame Component Installation

    ROPS to the vehicle frame and rear ROPS. 3. Close the cargo box and secure in position. 4. Pull the cargo box handle and lift the cargo box out of the way. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.86 © Copyright Polaris Inc.

  • Page 715: Rops Removal - General 4

    40 lb-ft (54 Nm) Front Cross Fasteners: 40 lb-ft (54 Nm) 2. Remove the fasteners that hold the front cross to the front RH and LH ROPS. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.87 © Copyright Polaris Inc.

  • Page 716: Rops Installation - General 4

    2. Pull the cargo box handle and lift the cargo box out of the way. 3. Loosely install the fasteners that hold the rear ROPS to the vehicle frame. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.88 © Copyright Polaris Inc.
  • Page 717 7. Install the fasteners that hold the visor panel to the front cross. Torque the fasteners to specification. TORQUE Visor Panel Fasteners: 3.5 lb-ft (4.7 Nm) 8. Close the cargo box and secure in position. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.89 © Copyright Polaris Inc.

  • Page 718: Skid Plate Replacement

    TORQUE 4. Reverse removal for installation. Torque fasteners to Skid Plate Fasteners: specification. 3.5 lb-ft (4.7 Nm) TORQUE Skid Plate Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 11.90 © Copyright Polaris Inc.
  • Page 719 ..........12.37 AGM LOW MAINTENANCE BATTERY CHARGING 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.1 © Copyright Polaris Inc.
  • Page 720 ............12.68 TRANSMISSION / GEAR POSITION SWITCH 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.2 © Copyright Polaris Inc.
  • Page 721 ..................12.77 DIAGNOSTIC PLUG 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.3 © Copyright Polaris Inc.

  • Page 722: General Information - Electrical System

    Fluke™ 77 Digital Multimeter (PV-43568). This meter is used when diagnosing electrical problems. Readings obtained with other meters may differ. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.4 © Copyright Polaris Inc.

  • Page 723: Special Tools - Electrical System

    Hall Effect Sensor Probe Harness 2460761 (Max) Battery Conductance Analyzer PU-50296 (MDX-610P) Connector Test Kit PV-43526 Timing Light 2870630 Relay Bypass PU-49466 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.5 © Copyright Polaris Inc.

  • Page 724: Chassis Harness

    12V Receptacle LO (Dash) LH Headlight LED Light #1 Brake Pressure Switch Infotainment Pedal Position Sensor LED Light #3 EPS Signal Diagnostic EPS Power Pulse Bar 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.6 © Copyright Polaris Inc.
  • Page 725 12V Receptacle HI (Console) 2& Turf Relay Ground, Rear Chassis #1 Taillight Harness Ground, Rear Chassis #2 Video Rear Seatbelt Switch Reverse Beeper #2 Coil Ground Diode 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.7 © Copyright Polaris Inc.

  • Page 726: Harness Routing / Retention - 2 Seat

    The white tape on the harness signifies a zip tie retention Edge Clip point. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.8 © Copyright Polaris Inc.
  • Page 727 The white tape on the harness signifies a zip tie retention Cable Clip point. Edge Clip NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.9 © Copyright Polaris Inc.

  • Page 728: Harness Component Locations - 4 Seat

    Brake Pressure Switch LED Light #1 Pedal Position Sensor Infotainment 2& EPS Signal LED Light #3 EPS Power Diagnostic LED Light #2 Pulse Bar Headlight Switch 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.10 © Copyright Polaris Inc.
  • Page 729 12V Receptacle HI (Rear Console) 2& Turf Relay Ground, Rear Chassis #1 Taillight Harness Ground, Rear Chassis #2 Video Rear Coil Ground Diode Reverse Beeper #2 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.11 © Copyright Polaris Inc.

  • Page 730: Harness Routing / Retention - 4 Seat

    The white tape on the harness signifies a zip tie retention Edge Clip point. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.12 © Copyright Polaris Inc.
  • Page 731 The white tape on the harness signifies a zip tie retention Cable Clip point. Edge Clip NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.13 © Copyright Polaris Inc.

  • Page 732: Cargo Box Harness Component Locations

    CHASSIS / BODY ELECTRICAL CARGO BOX HARNESS COMPONENT LOCATIONS Chassis Harness RH Taillight LH Taillight 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.14 © Copyright Polaris Inc.

  • Page 733: Cargo Box Harness Routing / Retention

    The white tape on the harness signifies a zip tie retention Zip Tie Retention Locations point. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.15 © Copyright Polaris Inc.

  • Page 734: Chassis Harness (Intl)

    LED Light #3 AWD Coil Turn/Light/Horn Switch Flasher Module LH Headlight Speedometer Diagnostic LH Front Turn Signal EPS Power Pulse Bar Brake Pressure Switch EPS Signal 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.16 © Copyright Polaris Inc.
  • Page 735 Ground, Ignition Coil MAG Fuel Injector Ground, Rear Chassis #3 Coolant Temp Sensor T-Map Ground, Rear Chassis #2 Oxygen Sensor PTO Fuel Injector Ground, Rear Chassis #1 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.17 © Copyright Polaris Inc.

  • Page 736: Harness Routing / Retention - Intl (Non-Abs)

    The white tape on the harness signifies a zip tie retention Edge Clip point. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.18 © Copyright Polaris Inc.
  • Page 737 The white tape on the harness signifies a zip tie retention Cable Clip point. Edge Clip NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.19 © Copyright Polaris Inc.
  • Page 738 AWD Coil Speedometer ABS Controller 3& LH Headlight EPS Power Pulse Bar LH Front Turn Signal EPS Signal RF ABS Sensor Brake Pressure Switch Key Switch 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.20 © Copyright Polaris Inc.
  • Page 739 Ignition Coil Crank Position Sensor Ground, Rear Chassis #3 Coolant Temp Sensor MAG Fuel Injector Ground, Rear Chassis #2 Oxygen Sensor T-Map Ground, Rear Chassis #1 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.21 © Copyright Polaris Inc.

  • Page 740: Harness Routing / Retention - Intl (Abs)

    The white tape on the harness signifies a zip tie retention Edge Clip point. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.22 © Copyright Polaris Inc.
  • Page 741 The white tape on the harness signifies a zip tie retention Cable Clip point. Edge Clip NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.23 © Copyright Polaris Inc.

  • Page 742: Cargo Box Harness Component Locations - Intl

    CHASSIS / BODY ELECTRICAL CARGO BOX HARNESS COMPONENT LOCATIONS - INTL Chassis Harness License Plate Lamp Fog Light RH Taillight LH Taillight 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.24 © Copyright Polaris Inc.

  • Page 743: Cargo Box Harness Routing / Retention - Intl

    The white tape on the harness signifies a zip tie retention Zip Tie Retention Locations point. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.25 © Copyright Polaris Inc.

  • Page 744: Instrument Cluster Service

    TORQUE Instrument Cluster Mounting Bracket to Vehicle Fasteners: 3.5 lb-ft (4.7 Nm) 3. Remove the fasteners holding the instrument cluster mounting bracket to the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.26 © Copyright Polaris Inc.
  • Page 745 Accy Air Temp Input INPUT HIGH BEAM SWITCH INPUT — TRAILER TURN SIGNAL ANALOG FUEL LEVEL INPUT BLACKOUT MODE INPUT — — ACCY AIR TEMP INPUT — 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.27 © Copyright Polaris Inc.

  • Page 746: Battery Service

    CHASSIS / BODY ELECTRICAL BATTERY SERVICE BATTERY SPECIFICATIONS 4. Remove the battery hold-down bracket . Lift the battery out of the vehicle. Polaris / Johnson Controls Type Sealed - Maintenance Free Voltage 12 V Nominal Capacity 30 AH @ 10 HR Rate Nominal Open 12.8 V or more.

  • Page 747: Battery Specifications (Intl)

    (negative) cable first. When reinstalling the battery, install the black (negative) cable last. 3. Disconnect the red (positive) battery cable. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.29 © Copyright Polaris Inc.

  • Page 748: Battery Identification

    • Vent tube on side of battery (Lead Acid only) LOW MAINTENANCE BATTERY • Battery activated when packaged • Non removable cap(s) on top of battery • Distilled water or electrolyte NEVER added 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.30 © Copyright Polaris Inc.

  • Page 749: Lead Acid Conventional Battery Activation

    Battery must be fully charged before use or battery life will be significantly reduced 10-30% of the battery's full potential. To activate a Lead Acid Conventional battery, do the following: 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.31 © Copyright Polaris Inc.

  • Page 750: Lead Acid Conventional Battery Charging And Testing

    LEAD ACID CONVENTIONAL BATTERY LEAD ACID CONVENTIONAL BATTERY CHARGING AND TESTING MAINTENANCE Polaris recommends using a BatteryMINDer® 1510- 1.5 Recharge the battery to its full capacity every 30 to 60 AMP charger (or a similar charger), which can be ordered days.

  • Page 751: Dry Shipped Agm Battery Activation

    6. Press down evenly to break the foil seals and allow electrolyte to flow into the battery. NOTICE Air bubbles will begin to rise, indicating the flow of electrolytes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.33 © Copyright Polaris Inc.
  • Page 752 9. Allow battery to stand for 1-2 hours. This allows the electrolyte to permeate the plates for optimal performance. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.34 © Copyright Polaris Inc.

  • Page 753: Dry Shipped Agm Battery Charging And Testing

    To charge a Dry Shipped AGM battery, do the following: maintain the Absorbent Glass Mat (AGM) battery with the BatteryMINDer® 2012 AGM - 2 AMP charger. 1. Charge the battery for 1 hour using the Polaris recommended charger. BatteryMINDer® 2012 AGM - 2 AMP battery charger...

  • Page 754: Lead Acid Low Maintenance Battery Charging And Testing

    CHARGING AND TESTING If the battery is stored or used in a partially charged Polaris recommends using a BatteryMINDer® 1510- 1.5 condition, hard crystal sulfation will form on the plates, AMP charger (or a similar charger), which can be ordered reducing the efficiency and service life of the battery.

  • Page 755: Agm Low Maintenance Battery Charging

    The battery will self-discharge when CHARGING disconnected from a vehicle, and will discharge at a Polaris recommends using the BatteryMINDer® 2012 faster rate when connected. If the battery voltage falls AGM - 2 AMP battery charger to charge and maintain below 12.5V, it should be charged immediately using the...

  • Page 756: Agm Battery Charging - Deeply Discharged (Below 3 Volts)

    BATTERY CHARGING BATTERY CHARGING TIME CAPACITY RATE 2 amps 4011496 11 hours 18 AH 2 amps 4014770 8 hours 12 AH 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.38 © Copyright Polaris Inc.

  • Page 757: Agm Low Maintenance Battery Maintenance

    If you do not drive the vehicle for more than TWO weeks, Authorized Polaris dealers / distributors are required to maintain the Absorbent Glass Mat (AGM) battery with the use the conductance analyzer when testing 12V Polaris BatteryMINDer®...
  • Page 758 9.5 volts. If the beginning voltage is 12.6 volts or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.40 © Copyright Polaris Inc.

  • Page 759: Battery Charging Procedure

    Do not exceed 10 amps when charging the battery. NOTICE NOTICE Battery charge can be maintained by using a Polaris Charge the battery using an automatic charger that will battery tender or by charging once a month to make up not exceed 14.6 Vdc.

  • Page 760: Fuse / Relay Service

    4. Disconnect the fuse box from the main harness and remove from the vehicle. 5. To install, reverse installation procedure. Torque fuse panel fasteners to specification. TORQUE Fuse Box Fasteners: 35 lb-in (4 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.42 © Copyright Polaris Inc.

  • Page 761: Fuse / Relay Center - 2 Seat

    FUEL PUMP COIL LO EFI B+, CHASSIS RELAY SPLICE,EFI B+ 2 RD/DB RELAY/FUSE BLOCK COIL Chassis Relay CHASSIS RELAY POWER START SOLENOID B+ RELAY/FUSE BLOCK 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.43 © Copyright Polaris Inc.
  • Page 762 EPS FUSE POWER OUT SPLICE, EFI RELAY/FUSE BLOCK UNSW B+, FUSE IN UNSW 10A Fuse SPLICE,B+ UNSWITCHED UNSWITCHED FUSED B+, RD/WH RELAY/FUSE BLOCK FUSED #1 UNSW FUSE OUT 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.44 © Copyright Polaris Inc.
  • Page 763 FUNCTION COLOR FAN B+, FUSE IN RELAY/FUSE BLOCK START SOLENOID B+ Fan 25A Circuit Breaker FAN B+, FUSED RELAY IN OG/BK RELAY/FUSE BLOCK RELAY/FUSE BLOCK 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.45 © Copyright Polaris Inc.

  • Page 764: Fuse / Relay Center - 4 Seat

    FUEL PUMP COIL LO EFI B+, CHASSIS RELAY SPLICE,EFI B+ 2 RD/DB RELAY/FUSE BLOCK COIL Chassis Relay CHASSIS RELAY POWER START SOLENOID B+ RELAY/FUSE BLOCK 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.46 © Copyright Polaris Inc.
  • Page 765 EPS FUSE POWER OUT SPLICE, EFI RELAY/FUSE BLOCK UNSW B+, FUSE IN UNSW 10A Fuse SPLICE,B+ UNSWITCHED UNSWITCHED FUSED B+, RD/WH RELAY/FUSE BLOCK FUSED #1 UNSW FUSE OUT 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.47 © Copyright Polaris Inc.
  • Page 766 FUNCTION COLOR FAN B+, FUSE IN RELAY/FUSE BLOCK START SOLENOID B+ Fan 30A Circuit Breaker FAN B+, FUSED RELAY IN OG/BK RELAY/FUSE BLOCK RELAY/FUSE BLOCK 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.48 © Copyright Polaris Inc.

  • Page 767: Fuse / Relay Center - Intl (Non-Abs)

    RELAY/FUSE BLOCK CHASSIS RELAY OUT ECM,CODE 4 RELAY/FUSE BLOCK CHASSIS RELAY COIL LO Fan Relay RD/DB SPLICE,EFI B+ 2 RELAY/FUSE BLOCK EFI B+, FAN COIL HI 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.49 © Copyright Polaris Inc.
  • Page 768 ACCESSOY FUSE IN Accessory 10A Fuse SPLICE, ACCESSORY OG/WH RELAY/FUSE BLOCK ACCESSOY FUSE OUT Trailer Brake 10A TRAILER BRAKE SIGNAL SPLICE,BRAKE RELAY/FUSE BLOCK Fuse FUSE IN 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.50 © Copyright Polaris Inc.
  • Page 769 COLOR SPLICE,FAN B+ FUSIBLE FAN B+, FUSE IN RELAY/FUSE BLOCK LINK Fan 25A Circuit Breaker OG/BK RELAY/FUSE BLOCK RELAY/FUSE BLOCK FAN B+, FUSED RELAY IN 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.51 © Copyright Polaris Inc.

  • Page 770: Fuse / Relay Center - Intl (Abs)

    RELAY/FUSE BLOCK CHASSIS RELAY OUT ECM,CODE 4 RELAY/FUSE BLOCK CHASSIS RELAY COIL LO Fan Relay SPLICE,EFI B+ 2 EFI B+, FAN COIL HI RD/DB RELAY/FUSE BLOCK 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.52 © Copyright Polaris Inc.
  • Page 771 ABS Sensors 5A Fuse KEY SWITCH B+, ABS OG/WH RELAY/FUSE BLOCK ABS CONTROLLER FUSED ABS Valves 20A SPLICE, ABS RELAY/FUSE BLOCK ABS VALVES, FUSE IN Fuse 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.53 © Copyright Polaris Inc.
  • Page 772 COLOR SPLICE,FAN B+ FUSIBLE FAN B+, FUSE IN RELAY/FUSE BLOCK Fan 25A Circuit LINK Breaker FAN B+, FUSED RELAY IN OG/BK RELAY/FUSE BLOCK RELAY/FUSE BLOCK 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.54 © Copyright Polaris Inc.

  • Page 773: Charging System Service

    Y2 to Y3 0.07 - 0.13 Ω Coil 3. Shift transmission into park and start the engine. With the engine running at idle, observe meter readings. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.55 © Copyright Polaris Inc.

  • Page 774: Stator (Alternator) Replacement

    AC VOLTAGE (VAC) airflow is present. RPM READING READING 1300 21 VAC ± 25% 3000 47 VAC ± 25% 5000 79 VAC ± 25% 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.56 © Copyright Polaris Inc.

  • Page 775: Current Draw - Key Off

    Maximum of .01 DCA (10 mA) Charging system damage will occur if incompatible components are installed. Always reference the Polaris 9. If over 10 milliamps, go to the fuse block and start Electronic Parts Catalog for the proper part numbers.

  • Page 776: Charging System Testing

    If all the previous tests indicate a good condition, but the charging voltage does not rise above battery voltage at the connector or wire harness, replace the voltage regulator. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.58 © Copyright Polaris Inc.

  • Page 777: Starting System Service

    The (-) negative battery cable is mounted to the engine using the upper starter mounting bolt / stud. 6. Remove the starter from the engine. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.59 © Copyright Polaris Inc.

  • Page 778: Starter Motor Installation

    • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. NOTICE See “Starting System Breakout page ” for starter solenoid operation. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.60 © Copyright Polaris Inc.

  • Page 779: Electronic Power Steering (Eps)

    EPS system is detected, the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system. The system is Polaris Digital Wrench® compatible for simplified diagnostics and system troubleshooting through the vehicle’s diagnostic port.

  • Page 780: Lighting System Service

    5. Adjust the beam to the desired position by loosening or tightening the three adjustment screws moving the lamp to the appropriate height. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.62 © Copyright Polaris Inc.

  • Page 781: Headlight Removal

    . 6. Adjust headlight position. Refer to “Headlight Adjustment page 12.62” procedure. 3. Carefully lift and remove headlight assembly from the bumper. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.63 © Copyright Polaris Inc.

  • Page 782: Tail Light Replacement

    4. Remove the tail light from the cargo box and disconnect the wire harness. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.64 © Copyright Polaris Inc.

  • Page 783: Switch Service

    Re-test and replace switch if necessary. SWITCH POSITION CONTINUITY BETWEEN No continuity between Brake Pedal Released pins Continuity between pins Brake Pedal Pressed 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.65 © Copyright Polaris Inc.

  • Page 784: Headlight Switch

    Jumper, Headlight Switch Low Beam, Switch Out Jumper, Headlight Switch Lights, Headlight Switch High Beam, Switch Out Ground, Headlight Switch Key Switch B+, Headlight Switch Light 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.66 © Copyright Polaris Inc.

  • Page 785: Ignition / Key Switch

    Pins 1 and 2 SWITCH FUNCTION FUNCTION Turf Request Input Ground, AWD Switch AWD Request Input — — — Key Switch B+, AWD Switch Light — 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.67 © Copyright Polaris Inc.

  • Page 786: Transmission / Gear Position Switch

    Pins 7 and 2 provide power and ground to light the POSITION TERMINALS A AND B switch lamp. HIGH 620 Ω 300 Ω 160 Ω 75 Ω PARK 24 Ω 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.68 © Copyright Polaris Inc.

  • Page 787: Seat Belt Switch

    2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT ENGAGED DISENGAGED 457 kΩ 187 kΩ 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.69 © Copyright Polaris Inc.

  • Page 788: Brake Fluid Level Switch

    Enable switch fails testing, replacement of the master cylinder is required. Refer to the Brake System chapter for master — cylinder removal and installation procedures. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.70 © Copyright Polaris Inc.

  • Page 789: Hazard Switch (Int'l / Tractor)

    C and D; E and F. • Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and F. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.71 © Copyright Polaris Inc.

  • Page 790: Turn/Lights/Horn Switch (Int'l/Tractor)

    The rear turn lights are integrated into the rear taillight. If the taillights are functioning properly but there is no blinker, check the wiring connections and the flasher module. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.72 © Copyright Polaris Inc.

  • Page 791: Flasher Module

    Engine speed is limited to 1500 RPM in all gears, except neutral. If throttle is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.73 © Copyright Polaris Inc.

  • Page 792: Fog Light Switch

    • Move switch to ON. There should be continuity between switch pins 2 and 3. • Move the switch to OFF. There should be no continuity between any switch pins. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.74 © Copyright Polaris Inc.

  • Page 793: Vehicle Speed Sensor (Vss)

    ECU. The ECU then interprets this switching into the speed the output 4. Connect the harness going to the peed sensor. gear is rotating. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.75 © Copyright Polaris Inc.

  • Page 794: Misc Electrical Service

    1. To remove the 12V receptacle, disconnect the battery negative (-) cable. 2. Remove the upper dash panel. Refer to “Interior Body Component Removal page 11.56” procedure. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.76 © Copyright Polaris Inc.

  • Page 795: Pulse Bar

    6. Reinstall the new pulse bar to the pulse bar bracket and secure with fasteners. TORQUE Pulse Bar Fasteners: Torque Until Fastener Is Fully Seated 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.77 © Copyright Polaris Inc.
  • Page 796 CHASSIS / BODY ELECTRICAL NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 12.78 © Copyright Polaris Inc.
  • Page 797 ........13.37 ROCKFORD FOSGATE & RIDE COMMAND HARNESS ROUTING 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.1 © Copyright Polaris Inc.
  • Page 798 ..........13.67 VEHICLE-TO-VEHICLE (V2V) ANTENNA SERVICE (4-SEAT) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.2 © Copyright Polaris Inc.

  • Page 799: Factory-Installed Options

    Standard options found on base models (such as EPS) may be found in the other chapters in this service manual. If you cannot find a particular service topic, please reference the INDEX prior to submitting feedback to Polaris 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.3...

  • Page 800: Roof Service - General

    ROOF SERVICE - GENERAL ROOF ASSEMBLY VIEW Front Roof Fasteners Rear Roof Fasteners 3.5 lb-ft (4.7 Nm) 5 lb-ft (7 Nm) Roof Rear Roof Bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.4 © Copyright Polaris Inc.

  • Page 801: Roof Removal

    4. Install mounting bracket on the rear ROPS and align mounting points. 5. Install mounting bracket fasteners and torque to specification. TORQUE Roof Mounting Bracket Fasteners: 8 lb-ft (11 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.5 © Copyright Polaris Inc.
  • Page 802 FACTORY-INSTALLED OPTIONS 6. Install upper rear fasteners into the roof and ROPS visor. TORQUE Front Roof Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.6 © Copyright Polaris Inc.

  • Page 803: Roof Assembly View - General 4

    Rear Roof Fasteners 3.5 lb-ft (4.7 Nm) 5 lb-ft (7 Nm) Front Roof Panel Rear Roof Bracket Roof Fasteners Rear Roof Panel 20 lb-in (2.3 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.7 © Copyright Polaris Inc.

  • Page 804: Roof Removal - General 4

    3. Push up and forward on the back of the roof to remove it from the ROPS visor. TORQUE Roof Mounting Bracket Fasteners: 8 lb-ft (11 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.8 © Copyright Polaris Inc.
  • Page 805 FACTORY-INSTALLED OPTIONS 6. Install upper rear fasteners into the roof and ROPS visor. TORQUE Front Roof Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.9 © Copyright Polaris Inc.

  • Page 806: Rear View Mirror Service

    FACTORY-INSTALLED OPTIONS REAR VIEW MIRROR SERVICE REAR VIEW MIRROR ASSEMBLY VIEW Upper Mirror Arm Mirror Mirror Mounting Fasteners Lower Mirror Arm 5 lb-ft (7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.10 © Copyright Polaris Inc.

  • Page 807: Rear View Mirror Removal

    4. Adjust the rear mirror view with respect to the driver’s seat position. NOTICE Tightening or loosening the lower screw will make adjustment harder or easier depending on torque. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.11 © Copyright Polaris Inc.

  • Page 808: Side Mirror Service (Intl)

    SIDE MIRROR SERVICE (INTL) SIDE MIRROR ASSEMBLY VIEW (INTL) Mirror Set LH Mirror Bracket RH Mirror Bracket LH Mirror Bracket Cover RH Mirror Bracket Cover Plastic Push Rivet 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.12 © Copyright Polaris Inc.

  • Page 809: Side Mirror Removal (Intl)

    3. Remove the two ROPS fasteners securing the mirror bracket and ROPS to the vehicle frame. Remove the mirror bracket. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.13 © Copyright Polaris Inc.

  • Page 810: Light Bar Service

    Torque nut to specification. LIGHT BAR ASSEMBLY VIEW Nut-M8X1.25 18 lb-ft (25Nm) TORQUE Screw M8X1.25X20 8.8 Side Mirror Mounting Nut: lb-ft (Nm) Light Bar, 11-inch Wire Harness Switch 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.14 © Copyright Polaris Inc.

  • Page 811: Light Bar Removal

    5. Remove light bar from vehicle. 2. Cut cable tie securing wire lead to front bumper. 3. Remove bumper screen to gain access to the light bar electrical connector. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.15 © Copyright Polaris Inc.

  • Page 812: Light Bar Installation

    SWITCH CONTINUITY SWITCH POSITION CONTINUITY BETWEEN No continuity between pins 2 and 3 Continuity between pins 2 and 3 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.16 © Copyright Polaris Inc.
  • Page 813 Do not pull on the wiring. 2. Test between the single set of outputs (ON/OFF). If the test below fails, replace the switch assembly. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.17 © Copyright Polaris Inc.

  • Page 814: Front Bumper Service

    Front Bumper Lower Backer Plate Upper Front Bumper Fasteners Bumper Cap 30 lb-ft (41 Nm) End Cap Lower Front Bumper Fasteners 30 lb-ft (41 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.18 © Copyright Polaris Inc.

  • Page 815: Front Bumper Removal

    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 front bumper. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.19 © Copyright Polaris Inc.

  • Page 816: Front Bumper Installation

    Front Bumper Fasteners: 30 lb-ft (41 Nm) 2. Install the front bumper upper mounting fasteners and torque to specification. TORQUE Front Bumper Fasteners: 30 lb-ft (41 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.20 © Copyright Polaris Inc.

  • Page 817: Winch Service

    24 in-lbs (3 Nm) Pulse / Contactor Cable Winch Fairlead Roller Fasteners Electrical Grommet Winch Latch Hook Winch Fasteners Attachment Clip 16 lb-ft (22 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.21 © Copyright Polaris Inc.

  • Page 818: Winch Cable Routing / Retention

    2. Pass the two winch cables through the grommet in the hood liner. 3. Route the two winch cables through the intake ducts and connect the cables to the pulse bar. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.22 © Copyright Polaris Inc.

  • Page 819: Winch Replacement

    30 lb-ft (41 Nm) 6. Remove winch from passenger side. 2. Install the winch from the passenger side. NOTICE If required, remove winch mounting plate. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.23 © Copyright Polaris Inc.
  • Page 820 GENERAL XP / GENERAL XP 4 Shock Mount Fasteners: 51 lb-ft (70 Nm) 5. Reconnect contactor connector. 6. Reconnect electrical wires from bus bar. 7. Reconnect battery. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.24 © Copyright Polaris Inc.

  • Page 821: Winch Switch

    Switch Winch Switch Out — — — Ground, Winch Switch Key Switch B+, Winch Switch Light Ground, Winch Switch Key Switch B+, Winch Switch Light 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.25 © Copyright Polaris Inc.

  • Page 822: Rockford Fosgate Stage 1 (Base) Audio

    LH Speaker Asm. Washer Panduit Strap 25 in-lbs (3 Nm) Audio Display Mounting Fasteners AM/FM Antenna Ground Strap 30 in-lbs (4 Nm) RH Speaker Asm. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.26 © Copyright Polaris Inc.

  • Page 823: Audio Harness Routing

    NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.27 © Copyright Polaris Inc.

  • Page 824: Front Speaker Assembly Service

    3. Remove the speaker assembly from the vehicle. NOTICE Ensure the connector has been retained with the fir tree clip. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.28 © Copyright Polaris Inc.

  • Page 825: Front Speaker Service

    1. Remove the four fasteners securing the front speaker cover. 2. Remove the front speaker cover. 3. Remove the four fasteners securing the speaker to the speaker housing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.29 © Copyright Polaris Inc.
  • Page 826 3. Install the speaker cover and align mounting holes. INSTALLATION 1. Connect the speaker connectors and carefully install the speaker back into the speaker housing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.30 © Copyright Polaris Inc.

  • Page 827: Base Audio Display Pinout

    USB DATA - USB DATA + USB GROUND — — — — — RIGHT - FRONT RIGHT + FRONT GROUND, PMX SW B+ — — 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.31 © Copyright Polaris Inc.

  • Page 828: Ride Command With Rockford Fosgate Stage 4 Audio

    Rear Audio Harness AM/FM Antenna Ground Strap Fastener LH Speaker Asm. 14 ft-lbs (19 Nm) NOTICE 2-Seat and 4-seat rear speaker harness is identical except for length. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.32 © Copyright Polaris Inc.
  • Page 829 LH Rear Speaker Asm. Rear Audio Y Harness Outer Rear Speaker Mount Bracket Fasteners Edge Clip 30 in-lbs (4 Nm Outer Lower Speaker Mount Bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.33 © Copyright Polaris Inc.

  • Page 830: Ride Command Assembly View

    40 in-lbs (4.5 Nm) Display Mounting Bracket Front Camera Mount Edge Clip RideCommand Display Display Mounting Bracket Fasteners Edge Clip 40 in-lbs (4.5 Nm) Panduit Strap 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.34 © Copyright Polaris Inc.
  • Page 831 V2V Mount Bracket Washer V2V Mount Bracket Fastener Rear Camera Mount Fasteners 40 in-lbs (4.5 Nm) 5 ft-lbs (7 Nm) Edge Clip Edge Clip Edge Clip 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.35 © Copyright Polaris Inc.
  • Page 832 V2V Antenna 5 ft-lbs (7 Nm) V2V Mounting Fastener Edge Clip 40 in-lbs (4.5 Nm) Panduit Strap Rear Camera Edge Clip Rear Camera Mount Bracket 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.36 © Copyright Polaris Inc.

  • Page 833: Rockford Fosgate & Ride Command Harness Routing

    No corresponding routing clip is used for RH side. NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.37 © Copyright Polaris Inc.
  • Page 834 The V2V Antenna Harness Lead is routed up through the ROPS. Edge Clip Rear Audio Y Harness NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.38 © Copyright Polaris Inc.
  • Page 835 The V2V Antenna Harness Lead is routed up through the ROPS. Edge Clip Rear Audio Y Harness Panduit Strap NOTICE If harness replacement is required, note the routing of the harness for installation purposes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.39 © Copyright Polaris Inc.

  • Page 836: Ride Command Overview

    Ride Command Display Mount. 2. Remove seven push pins retaining upper dash panel. 5. Remove three fasteners securing Ride Command Display to its mount. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.40 © Copyright Polaris Inc.

  • Page 837: Ride Command Display Pinout

    GROUND, VIDEO FRONT AUDIO 1 LINE OUT R- VIDEO FRONT P GROUND, SHIELD AMP — AUDIO 1 LINE OUT L- — AUDIO 1 LINE OUT L+ 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.41 © Copyright Polaris Inc.
  • Page 838 FACTORY-INSTALLED OPTIONS FUNCTION GROUND, VIDEO REAR VIDEO REAR P — — — — — CAN HI, DISPLAY CAN LO, DISPLAY SW B+ DISPLAY UNSW B+ DISPLAY 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.42 © Copyright Polaris Inc.
  • Page 839 2. Fix any shorts in the wiring and reinstall new fuse. Go to Step 8 Go to Step 4 Did you find and repair the condition? 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.43 © Copyright Polaris Inc.
  • Page 840 7. If resistance value is out of spec, check for breaks in yellow/green CAN wiring. 8. If all values are within specification, replace GPS antenna with new unit. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.44 © Copyright Polaris Inc.

  • Page 841: Front Speaker Assembly Service

    3. Remove the speaker assembly from the vehicle. NOTICE Ensure the connector has been retained with the fir tree clip. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.45 © Copyright Polaris Inc.

  • Page 842: Front Speaker Service

    1. Remove the four fasteners securing the front speaker cover. 2. Remove the front speaker cover. 3. Remove the four fasteners securing the speaker to the speaker housing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.46 © Copyright Polaris Inc.
  • Page 843 3. Install the speaker cover and align mounting holes. INSTALLATION 1. Connect the speaker connectors and carefully install the speaker back into the speaker housing. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.47 © Copyright Polaris Inc.

  • Page 844: Subwoofer Service

    Retain rivets. TORQUE Speaker Cover Fasteners: 7 in-lbs (.75 Nm) 4. Slide panel upward and rearward, detaching eight spring clips. Set dash aside. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.48 © Copyright Polaris Inc.
  • Page 845 NOTICE Ensure the USB harness was pulled through the glove box prior to fully removing the main dash panel from the vehicle. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.49 © Copyright Polaris Inc.
  • Page 846 18. If required, remove the three fasteners securing the bracket to the subwoofer. NOTICE Note the location of the amp connector. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.50 © Copyright Polaris Inc.
  • Page 847 Ensure amp connector is on LH side as shown. TORQUE Subwoofer / Amp Bracket Fasteners: 30 in-lbs (4 Nm) TORQUE Amplifier Mounting Fasteners: 30 in-lbs (4 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.51 © Copyright Polaris Inc.

  • Page 848: Subwoofer Pinout

    3.5 lb-ft (4.7 Nm) 11. Connect main chassis harness connector to instrument cluster. 12. Install center control console. 13. Install upper dash panel. 14. Install hood. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.52 © Copyright Polaris Inc.

  • Page 849: Amplifier Service

    3. Connect the connector to the amplifier. 7. Lift the amplifier straight out of the dash. 4. Install the upper dash. 5. Install the hood. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.53 © Copyright Polaris Inc.

  • Page 850: Amplifier Pinout

    AUDIO 1 LINE OUT R + SUB LINE OUT L + SUB LINE OUT L - SUB LINE OUT R + SUB LINE OUT R - 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.54 © Copyright Polaris Inc.
  • Page 851 30 in-lbs (4 Nm 4. If required, temporarily remove speaker to tighten the two fasteners of the outer speaker bracket assembly and inner speaker bracket fastener. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.55 © Copyright Polaris Inc.

  • Page 852: Rear Speaker Service

    2. Remove the rear speaker cover. 3. Carefully pull the speaker out of the speaker housing. IMPORTANT Do not allow the speaker to hang from the harness. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.56 © Copyright Polaris Inc.
  • Page 853 1. Connect the speaker connectors and carefully 11 in-lbs (1.25 Nm) install the speaker back into the speaker housing. 2. Install the speaker cover and align mounting holes. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.57 © Copyright Polaris Inc.

  • Page 854: Front Camera Service

    2. Holding grille near vehicle, disconnect the main chassis connector from front camera connector 3. Remove the edge clip securing the harness to grille and remove grille. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.58 © Copyright Polaris Inc.
  • Page 855 • Camera mount is positioned as high as possible on grille with camera pointing DOWNWARD • Camera wiring is not pinched or kinked as it passes through grille 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.59 © Copyright Polaris Inc.

  • Page 856: Rear Camera Service

    5. If required, remove the rear camera from the rear camera bracket. 2. Remove the edge clip securing the camera harness / connector. 3. Disconnect main chassis connector from rear camera connector 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.60 © Copyright Polaris Inc.
  • Page 857 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. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.61 © Copyright Polaris Inc.

  • Page 858: Ambient Air Temperature Sensor Service

    Front fascia hidden for clarity. Front fascia hidden for clarity. Chassis structure may vary slightly from that shown. Chassis structure may vary slightly from that shown. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.62 © Copyright Polaris Inc.

  • Page 859: Gps Antenna Service

    3. Holding grille near vehicle, connect the main harness connector to front camera connector. 4. Install the front grille. 7. Carefully pull the harness forward through firewall grommet. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.63 © Copyright Polaris Inc.
  • Page 860 If installing the existing GPS antenna, use a piece of commercially available double sided tape and press firmly in place. 5. Install the upper dash panel. 6. Install the hood. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.64 © Copyright Polaris Inc.

  • Page 861: Vehicle-To-Vehicle (V2V) Antenna Service (2-Seat)

    3. Remove roof bracket and V2V antenna by removing two roof bracket fasteners. Clamshell Cover Slotted Nut 5. If required, remove the fastener securing the antenna bracket to the roof bracket. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.65 © Copyright Polaris Inc.
  • Page 862 3. Reinstall roof bracket and V2V antenna to roof using two roof bracket fasteners. Torque to specification. TORQUE Roof Mounting Bracket Fasteners: 3.5 lb-ft (4.7 Nm) 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.66 © Copyright Polaris Inc.

  • Page 863: Vehicle-To-Vehicle (V2V) Antenna Service (4-Seat)

    V2V antenna to ROPS B-pillar bracket. 4. Carefully remove the V2V antenna by removing the antenna cable through hole in ROPS B-pillar bracket. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.67 © Copyright Polaris Inc.
  • Page 864 NOTICE Bracket Antenna cable not shown for clarity. Rubber Washer TORQUE Antenna Slotted Nut: 60 in-lbs (7 Nm) NOTICE Antenna cable not shown for clarity. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.68 © Copyright Polaris Inc.
  • Page 865 40 in-lbs (4.5 Nm) 3. Join connector from antenna to connector on RIDE COMMAND harness. Ensure harness is routed and secured to ROPS using two panduit straps. 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.69 © Copyright Polaris Inc.
  • Page 866 FACTORY-INSTALLED OPTIONS NOTES 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual 13.70 © Copyright Polaris Inc.
  • Page 867 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams To view a wiring diagram, click on the desired model / schematic. 2- Seat Models • GENERAL / GENERAL XP 1000 (2414814) • GENERAL 1000 INTL Non-ABS (2415088) • GENERAL 1000 INTL ABS (2415089) Headlight Jumper (For Models Equipped With Halogen Headlights) •...
  • Page 869 Routing - General XP ..........10.25 Charging ............12.32 Routing - General XP 4.......... 10.36 Inspection............12.31 Brake Line Routing And Retention Testing ............12.32 ABS (INTL) ............10.73 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.1 © Copyright Polaris Inc.
  • Page 870 Removal...............3.23 Center Console Warp ..............3.24 Assembly View - GENERAL / GENERAL XP ....11.10 Assembly View - GENERAL 4 / GENERAL XP 4 ..11.14 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.2 © Copyright Polaris Inc.
  • Page 871 Current Draw - Key Off ........1.89, 12.57 Feature Map............1.53 Digital Multi-Meter (DMM) ........1.84 Guided Diagnostics ..........1.49 Engine / Chassis Electrical Ground ......2.56 Polaris Mobile Digital Wrench® (PMDW) .....1.55 Service Notes ............1.84 Serial Number Location ...........1.52 Static and Dynamic Testing ........1.84 Software Installation and Updates ......1.50 Testing Current Flow (Amperage) ......1.88...
  • Page 872 General / General 4 ..........8.20 Assembly View - GENERAL ........11.8 General XP / General XP 4 ........8.31 Assembly View - GENERAL XP......... 11.9 Front Facia 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.4 © Copyright Polaris Inc.
  • Page 873 Service Specifications ..........5.3 Instrument Cluster Overview ............12.26 Special Tools ............5.3 Pinouts .............. 12.27 Troubleshooting .............1.71 Replacement............12.26 Fuel Tank Intake Installation ............5.30 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.5 © Copyright Polaris Inc.
  • Page 874 Assembly View ............ 10.90 General XP / General XP 4 ........8.54 Caliper Removal (INT’L) ........10.92 Removal / Inspection Disc Inspection/Replacement........10.93 General / General 4 ..........8.46 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.6 © Copyright Polaris Inc.
  • Page 875 General / General 4 ..........9.8 Inspection.............. 7.9 Inspection / Adjustment ..........7.9 General XP / General XP 4 ........9.15 Rear View Mirror Shift Cable Inspection / Adjustment .......2.25 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.7 © Copyright Polaris Inc.
  • Page 876 Bevel Differential Assembly ........7.28 Bevel Differential Disassembly ........7.27 Cover Installation ...........3.59 Stator Cover.............3.30 Disassembly ............7.21 Steering Gear / Shaft / Bearing Inspection .......7.30 Assembly View Gear Cluster Disassembly........7.25 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.8 © Copyright Polaris Inc.
  • Page 877 Valve Cover Installation ..........3.70 Valve Spring Removal...............3.24 Vehicle Information VIN Number ............1.3 Vehicle Speed Sensor (VSS) Operation Overview ..........12.75 Replacement............12.75 Test ..............12.75 9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual IX.9 © Copyright Polaris Inc.

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