General Information; Service Rules - Polaris GENERAL 2016 Service Manual

GENERAL INFORMATION

GENERAL INFORMATION

SERVICE RULES

In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual
and familiarize themselves with the procedures before beginning. Notice, Cautions and Warnings have been included
for clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are
necessary to perform some procedures in this manual safely and correctly.
Use only genuine Polaris service parts, including fasteners that require replacement if removed. Do NOT substitute
fasteners or hardware.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause
damage to precision parts. Clean the vehicle before beginning service. Clean all parts before installing.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If
it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine
damage or in the case of steering, driveline, and chassis components, can result in loss of control during operation of
the vehicle, which may result in severe personal injury or death.
If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand
tighten. Following the method and sequence indicated, tighten evenly to the specified torque value. When removing
nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn before removing them to
prevent distortion of that component.
Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating
surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances.
Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore,
they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand
or compress them beyond what is required for installation.
Polaris lubricants and greases have been specially formulated to provide maximum performance and protection when
applied properly. In some applications, warranty coverage may be void if improper lubricants are used.
Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating
grease loses lubricity and may contain abrasive foreign matter. 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.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
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