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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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Chapters
Table of Contents
Troubleshooting
Related Manuals for Polaris General 2021
Summarization of Contents
General Information
Vehicle Identification
Details on how vehicle identification numbers and model designations are structured.
Reference Information
Information regarding service rules, publication part numbers, and replacement keys.
Vehicle Specifications (Model Year 2021)
Specifications for 2-seat, 4-seat, and International models.
Misc Specifications and Charts
Includes torque tables and conversion charts for various measurements.
General Diagnostics
Information and procedures for diagnosing common vehicle issues and warning lights.
Maintenance
General Information - Maintenance
General notes and special tools for maintenance procedures.
Periodic Maintenance
Overview of inspection, lubrication, adjustment, and replacement of components based on intervals.
General Vehicle Inspection and Maintenance
Daily pre-ride inspection checklist and maintenance for various vehicle parts.
Engine Maintenance
Procedures for checking engine oil level, changing oil and filter, and inspecting breather hoses.
Cooling System Maintenance
Procedures for checking coolant level, strength, and hoses, as well as radiator and fan inspection.
Fuel System and Air Intake Maintenance
Maintenance for fuel lines, fuel pump, filters, and air intake systems.
PVT System Maintenance
Procedures for PVT system maintenance, including drying and inspection.
Transmission and Front Gearcase Maintenance
Maintenance procedures for the transmission and front gearcase lubrication.
Final Drive Maintenance
Maintenance for drive shaft boots and wheel removal/installation.
Engine / Cooling System
General Information - Engine
General information, service notes, special tools, and specifications for the engine and cooling system.
Engine Service
Procedures for engine service, including top end and bottom end work, removal, and installation.
Intake Service
Procedures for removing and installing intake assemblies for different models.
Exhaust Service
Procedures for removing and installing the exhaust system.
Cooling System Service
Procedures for servicing the cooling system, including hose routing, specifications, and pressure testing.
Engine Electrical
Electronic Control Unit (ECU)
Overview of ECU operation, service, and replacement procedures.
Adjustable Speed Limiting Device (ASLD) - ABS Models
Overview of ASLD function and its operation on ABS models.
Crankshaft Position Sensor (CPS)
Overview of CPS operation and testing procedures.
Electronic Throttle Control (ETC)
Overview, testing, and replacement procedures for the ETC.
Accelerator Position Sensor (APS)
Overview of APS operation, testing, and replacement.
Heated Oxygen Sensor (O2)
Overview of O2 sensor operation, testing, and replacement.
Temp / Manifold Absolute Pressure Sensor (T-MAP)
Overview of T-MAP sensor operation, testing, and replacement.
Engine Coolant Temperature (ECT) Sensor
Overview of ECT sensor operation, testing, and replacement.
Ignition System Service
Overview of ignition system operation, coil/HT lead replacement, and coil tests.
Spark Plug Service
Procedures for inspecting and replacing spark plugs.
Fuel System
General Information - Fuel System
General information, service notes, special tools, and specifications for the fuel system.
Assembly Views - Fuel System
Views of the fuel system and EVAP fuel system components.
EVAP System
Overview of the evaporative emission control system and its components.
Fuel Lines
Procedures for fuel line routing, removal, and replacement.
Vent Line Termination Fitting
Inspection and testing of the vent line termination fitting.
Fuel Injector
Operation overview, O-rings, testing, replacement, and troubleshooting for fuel injectors.
Fuel Tank Service
Procedures for fuel tank removal and installation.
Fuel Pump Service
Operation overview, testing, and replacement procedures for the fuel pump.
PVT System
General Information - PVT System
General information, service notes, special tools, and specifications for the PVT system.
PVT System Overview
Overview of drive clutch and driven clutch operation, and PVT system break-in.
PVT System Maintenance / Inspection
Periodic inspection and maintenance requirements for PVT system components.
Assembly Views - PVT System
Assembly views of PVT covers, ductwork, and inner clutch cover.
PVT System Service
Procedures for PVT system disassembly and assembly.
Drive Belt Service
Procedures for drive belt removal, inspection, and installation.
Drive Clutch Service
Drive clutch assembly view and service procedures.
Driven Clutch Service
Driven clutch assembly view, alignment procedure, disassembly, assembly, and slider inspection.
Transmission
General Information - Transmission
General information, service notes, special tools, and specifications for the transmission.
Shift Cable Service
Procedures for shift lever/cable assembly views, routing, replacement, inspection, and adjustment.
Assembly Views - Transmission
Assembly views of the transmission and its mounting torque values.
Transmission Vent Line
Transmission vent line routing and termination fitting information.
Transmission Service
Procedures for transmission removal, differential operation, disassembly, and assembly.
Transmission Installation
Procedures for installing the transmission assembly into the vehicle frame.
Final Drive
General Information - Final Drive
General information, service notes, special tools, and specifications for the final drive system.
Assembly Views - Final Drive
Assembly views of propshafts and drive shafts.
Propshaft Service
Procedures for propshaft removal and installation for 2-seat and 4-seat models.
Drive Shaft Service - General / General 4
Procedures for front and rear drive shaft removal and installation.
Drive Shaft / CV Joint Handling Tips
Important tips for handling drive shafts and CV joints during service.
Bearing Carrier Service - General / General 4
Procedures for front and rear bearing carrier removal, inspection, replacement, and installation.
Front Gearcase Service
Overview of AWD operation and procedures for front gearcase removal, disassembly, inspection, and assembly.
Steering / Suspension
General Information - Steering / Suspension
General information, service notes, special tools, and specifications for steering and suspension systems.
Assembly Views - Steering / Suspension General / General 4
Assembly views of the steering system for General and General 4 models.
Assembly Views - Steering / Suspension General XP / General XP 4
Assembly views of the steering system for General XP and General XP 4 models.
Steering Assembly Service
Procedures for steering shaft removal, steering wheel removal, power steering unit removal, and bearing replacement.
Tie Rod End / Wheel Hub Inspection
Inspection procedures for tie rod ends and wheel hubs.
Steering Rack Removal
Procedures for removing the steering rack assembly.
Wheel Toe Alignment Inspection
Procedures for inspecting and adjusting wheel toe alignment.
Wheel Toe Adjustment
Procedures for adjusting wheel toe alignment.
Steering Wheel Free-Play
Inspection of steering wheel free-play and related components.
Suspension Service - General / General 4
Procedures for front and rear control arm, stabilizer bar, and ball joint service.
Shock Service - General / General 4
Shock specifications and procedures for shock removal, spring replacement, and compression adjustment.
Suspension Service - General XP / General XP 4
Procedures for front and rear control arm and stabilizer bar service for General XP models.
Shock Service - General XP / General XP 4
Shock specifications and procedures for shock removal, spring replacement, and compression adjustment.
Brake System
General Information - Brake System
General information, service notes, special tools, and specifications for the brake system.
Brake System Service
Overview of brake system operation, bleeding, fluid change, and burnishing procedures.
Assembly Views - Brake System (General / General 4)
Assembly views and component identification for the brake system.
Assembly Views - Brake System (General XP / General XP 4)
Assembly views and component identification for the brake system.
Master Cylinder Service
Procedures for master cylinder removal, installation, and related services.
Brake Pedal Service
Procedures for brake pedal removal and installation.
Front Pad Service
Procedures for front brake pad removal, inspection, and installation.
Rear Pad Service
Procedures for rear brake pad removal, inspection, and installation.
Disc Service
Procedures for inspecting and replacing brake discs.
International (INTL) Brake Service
Service procedures specific to international models with ABS.
Body / Frame
General Information - Body / Frame
General information, service notes, special tools, and decal replacement for body and frame.
Assembly Views - Body / Frame
Assembly views of various body components like fascia, hood, fenders, dash, consoles, and ROPS.
Body Component Removal
Procedures for removing doors, seats, hood, exterior body components, and interior body components.
Cargo Box Removal
Procedures for removing the cargo box assembly and its related components.
Body Component Installation
Procedures for installing cargo box, interior body components, main floors, and lower rear closeoff panels.
Frame Component Installation
Installation procedures for ROPS and skid plates.
Chassis / Body Electrical
General Information - Electrical System
General information, service notes, special tools, and specifications for the electrical system.
Chassis Harness
Component locations and routing/retention for chassis harnesses on different models.
Instrument Cluster Service
Overview, replacement, and pinout information for the instrument cluster.
Battery Service
Battery specifications, removal, installation, charging, testing, and maintenance procedures.
Lead Acid Conventional Battery
Procedures for activating, charging, testing, and maintaining lead-acid batteries.
Dry Shipped AGM Battery
Procedures for activating, charging, testing, and maintaining dry-shipped AGM batteries.
Fuse / Relay Service
Overview of fuse/relay operation, fuse box replacement, and detailed fuse/relay information.
Circuit Breaker Details
Details on circuit breakers used in the system.
Charging System Service
Overview of charging system operation, break-even test, and stator/regulator tests.
Starting System Service
Overview of starting system operation, voltage drop test, starter motor removal/installation, and solenoid service.
Electronic Power Steering (EPS)
Overview of EPS operation, fuse information, and troubleshooting.
Lighting System Service
Procedures for headlight adjustment, bulb replacement, and removal/installation.
Switch Service
Service procedures for brake pressure switch, headlight switch, and ignition/key switch.
Hazard Switch (INT'L / TRACTOR)
Testing procedure for the hazard switch.
Turn/Lights/Horn Switch (INT'L/TRACTOR)
Testing procedures for the turn/lights/horn switch.
Flasher Module
Location and access information for the flasher module.
Brake Alarm
Location of the brake alarm and its function.
Parking Brake Switch
Location and testing procedure for the parking brake switch.
Fog Light Switch
Testing procedure for the fog light switch.
Vehicle Speed Sensor (VSS)
Overview of VSS operation, testing, and replacement.
Misc Electrical Service
Service procedures for 12V receptacles, AWD coil, pulse bar, and chassis ground.
Diagnostic Plug
Location of the diagnostic plug for Digital Wrench connection.
Factory-Installed Options
General Information - Factory-Installed Options
General information about factory-installed options and variations.
Roof Service - General
Assembly view, removal, and installation procedures for the roof on general models.
Roof Service - General 4
Assembly view, removal, and installation procedures for the roof on General 4 models.
Rear View Mirror Service
Assembly view, removal, and installation procedures for rear view mirrors.
Side Mirror Service (INTL)
Assembly view, removal, and installation procedures for side mirrors on international models.
Light Bar Service
Assembly view, removal, and installation procedures for light bars.
Front Bumper Service
Assembly view, removal, and installation procedures for the front bumper.
Winch Service
Assembly view, cable routing, replacement, and switch procedures for the winch.
Rockford Fosgate Stage 1 (Base) Audio
Assembly view and harness routing for the base audio system.
Front Speaker Assembly Service
Procedures for front speaker assembly service, including removal and installation.
Front Speaker Service
Procedures for front speaker service, including removal and installation.
Subwoofer Service
Procedures for subwoofer removal and installation.
Amplifier Service
Procedures for amplifier service, including removal and installation.
Rear Speaker Assembly Service
Procedures for rear speaker assembly service, including removal and installation.
Ride Command Assembly View
Assembly view of the Ride Command system.
Vehicle-to-Vehicle (V2V) Antenna Service (2-Seat)
Procedures for V2V antenna service on 2-seat models.
Vehicle-to-Vehicle (V2V) Antenna Service (4-Seat)
Procedures for V2V antenna service on 4-seat models.
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