Polaris General & General 4 (2016-2017) - Repair, Service Manual and Electrical Wiring Diagrams

CLICK HERE FOR SAMPLE MANUAL

POLARIS GENERAL & GENERAL 4 (2016-2017) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for UTV Polaris General / General 4 (2016-2017).

CONTENTS:

CHAPTER 1: GENERAL INFORMATION
- GENERAL INFORMATION
- Service Rules
- Publication Part Numbers
- Replacement Keys
- Special Tools Website
- Special Tools Index
- Master Torque List
- VEHICLE IDENTIFICATION
- Model Number Designation
- Vehicle Identification Number (Vin) Designation
- Engine Designation Number
- Vehicle And Engine Serial Number Location
- VEHICLE SPECIFICATIONS
- 2016-2017 Polaris General Overview
- 2016-2017 Polaris General Specifications
- 2017 Polaris General 4 Overview
- 2017 Polaris General 4 Specifications
- MISC SPECIFICATIONS AND CHARTS
- Conversion Table
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- Sae Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents

CHAPTER 2: MAINTENANCE
- GENERAL INFORMATION - MAINTENANCE
- Service Notes - Maintenance
- Special Tools - Maintenance
- Torque Specifications - Maintenance
- Service Specifications - Maintenance
- PERIODIC MAINTENANCE
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride Inspection
- Periodic Maintenance Chart
- Maintenance Quick Reference
- Grease Lubrication Points
- Maintenance Lubricants
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, And Fasteners
- Shift Cable Inspection / Adjustment
- ENGINE MAINTENANCE
- Engine Oil Level
- Engine Oil And Filter Change
- Engine Crankcase Breather Hose Inspection
- Engine Cylinder Leakdown Test
- Valve Clearance Inspection
- Cam Chain Tensioner Inspection
- COOLING SYSTEM MAINTENANCE
- Cooling System Overview
- Coolant Strength
- Coolant Level Inspection
- Cooling System Hoses
- Radiator Inspection / Cleaning
- Coolant Drain / Fill
- FUEL SYSTEM AND AIR INTAKE MAINTENANCE
- Fuel Lines
- Fuel Pump / Fuel Filters
- Fuel Tank Vent Line
- Air Filter Service
- Intake Duct Drain Inspection
- PVT SYSTEM MAINTENANCE
- Pvt Drying
- TRANSMISSION AND FRONT GEARCASE MAINTENANCE
- Transmission Lubrication
- Transmission Lubricant Level Check
- Transmission Lubricant Change
- Front Gearcase Lubrication
- Front Gearcase Fluid Level Check
- Front Gearcase Fluid Change
- FINAL DRIVE MAINTENANCE
- Drive Shaft Boot Inspection
- Wheel Removal
- Wheel Installation
- Tire Inspection
- Tire Pressure Inspection
- STEERING MAINTENANCE
- Steering Inspection
- Steering Wheel Free-Play
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
- SUSPENSION MAINTENANCE
- Spring Adjustment
- Spring Adjustment - Crew
- Shock Compression Adjustment
- BRAKE SYSTEM MAINTENANCE
- Brake Hose And Fitting Inspection
- Brake Fluid Inspection
- Brake Pad / Disc Inspection
- ELECTRICAL MAINTENANCE
- Battery Maintenance
- Battery Removal
- Battery Installation
- Engine / Chassis Electrical Ground
- Spark Plug Service
- Throttle Pedal Inspection

CHAPTER 3: ENGINE / COOLING SYSTEM
- GENERAL INFORMATION - ENGINE
- Service Notes - Engine / Cooling System
- Special Tools - Engine / Cooling System
- Torque Specifications - Engine / Cooling System
- Service Specifications - Engine / Cooling System
- ASSEMBLY VIEWS - ENGINE
- Main Engine Components - Torque Specification And Sequence
- Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
- Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
- Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
- Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
- GENERAL ENGINE SERVICE
- Engine Oil Level
- Engine Oil And Filter Change
- Engine Crankcase Breather Hose Inspection
- Engine Cylinder Leakdown Test
- Valve Clearance Inspection
- Top End Service (Engine In Chassis)
- Engine Removal
- Engine Installation
- Engine Break-In Period
- Oil Pressure Test
- Engine Oil Flow Chart
- ENGINE DISASSEMBLY / INSPECTION - TOP END
- Valve Cover Removal
- Camshaft Removal
- Camshaft Sprocket Inspection
- Camshaft / Camshaft Bore Inspection (1000)
- Cylinder Head Removal
- Cylinder Head Warp Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber Cleaning
- Valve Sealing Test
- Valve Seat Reconditioning (1000)
- ENGINE DISASSEMBLY / INSPECTION - BOTTOM END
- Stator Cover Removal / Inspection
- Water Pump Housing Removal
- Flywheel Removal
- Starter One-Way Clutch Disassembly
- Crankcase Disassembly / Inspection
- Balance Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Inspection
- Cylinder Inspection
- Cylinder / Piston Removal
- Piston Disassembly / Inspection (1000)
- Piston Ring Removal
- Piston Ring To Groove Clearance Inspection
- Piston Ring Installed Gap (1000)
- Piston-To-Cylinder Clearance
- Connecting Rod Inspection
- ENGINE ASSEMBLY - BOTTOM END
- Bearing Selection Identification Letters And Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- Upper Crankcase Preparation
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Cylinder / Piston Installation
- Crankshaft Installation
- Balance Shaft Installation
- Lower Crankcase Preparation
- Crankcase Assembly
- Starter One-Way Clutch Assembly
- Flywheel Installation
- Stator Cover Installation
- ENGINE ASSEMBLY - TOP END
- Cylinder Head Assembly
- Cylinder Head Installation
- Camshaft Installation / Timing
- Camshaft Timing - Quick Reference
- Valve Clearance Adjustment
- Valve Cover Installation
- Intake Valve Lash - Tappet Selection Matrix
- Exhaust Valve Lash - Tappet Selection Matrix
- INTAKE / EXHAUST SERVICE
- Intake Removal
- Intake Installation
- Exhaust Removal
- Exhaust Installation
- COOLING SYSTEM SERVICE
- Cooling System Assembly View
- Engine Cooling System Specifications
- Cooling System Pressure Test
- Cooling System Pressure Cap Test
- Cooling System Hose Replacement
- Radiator Replacement
- Thermostat Replacement
- Cooling System Bleeding
- Water Pump Removal
- Water Pump Installation
- Water Pump Service
- TROUBLESHOOTING - ENGINE / COOLING SYSTEM
- Engine
- Cooling System

CHAPTER 4: FUEL SYSTEM
- GENERAL INFORMATION - FUEL SYSTEM
- Service Notes - Fuel System
- Special Tools - Fuel System
- Torque Specifications - Fuel System
- Service Specifications - Fuel System
- ASSEMBLY VIEWS - FUEL SYSTEM
- Fuel System Assembly View
- Fuel Pump Assembly View
- FUEL TANK SERVICE
- Fuel Line Replacement
- Fuel Tank Removal
- Fuel Tank Installation
- FUEL PUMP SERVICE
- Fuel Pump Operation Overview
- Fuel Sender Test
- Fuel Pump Test
- Fuel Pump Replacement
- FUEL INJECTOR SERVICE
- Fuel Injector Operation Overview
- Fuel Injector Troubleshooting
- Fuel Injector Test
- Fuel Injector Replacement
- TROUBLESHOOTING - FUEL SYSTEM
- Fuel System Troubleshooting

CHAPTER 5: PVT SYSTEM
- GENERAL INFORMATION - PVT SYSTEM
- Service Notes - Pvt System
- Special Tools - Pvt System
- Torque Specifications - Pvt System
- Service Specifications - Pvt System
- ASSEMBLY VIEWS - PVT SYSTEM
- Pvt Covers And Duct Components
- Drive Clutch Assembly View
- Driven Clutch Assembly View
- PVT SYSTEM OVERVIEW
- Pvt System Operation Overview
- Drive Clutch Operation
- Driven Clutch Operation
- Pvt Break-In
- Pvt System Maintenance / Inspection
- Pvt System Overheating / Diagnosis
- PVT SYSTEM SERVICE
- Pvt Disassembly
- Pvt Assembly
- DRIVE BELT SERVICE
- Drive Belt Removal
- Drive Belt Inspection
- Drive Belt Installation
- DRIVE CLUTCH SERVICE
- Drive Clutch Disassembly / Inspection
- Needle Bearing Inspection
- Shift Weight Inspection
- Button To Tower Clearance Inspection
- Spider Removal
- Roller, Pin, And Thrust Washer Inspection
- Clutch Inspection
- Moveable Sheave Bushing Inspection
- Bushing Service
- Drive Clutch Assembly
- DRIVEN CLUTCH SERVICE
- Driven Clutch Disassembly
- Driven Clutch Assembly
- TROUBLESHOOTING - PVT SYSTEM
- Pvt System Troubleshooting

CHAPTER 6: TRANSMISSION
- GENERAL INFORMATION - TRANSMISSION
- Service Notes - Transmission
- Special Tools - Transmission
- Torque Specifications - Transmission
- Service Specifications - Transmission
- ASSEMBLY VIEWS - TRANSMISSION
- Transmission Assembly View
- SHIFT CABLE SERVICE
- Shift Lever Replacement
- Shift Cable Inspection / Adjustment
- TRANSMISSION SERVICE
- Transmission Removal
- Transmission Disassembly
- Gear / Shaft / Bearing Inspection
- Transmission Assembly / Snorkel Gear Backlash Procedure
- Transmission Installation
- TROUBLESHOOTING - TRANSMISSION
- Transmission Troubleshooting

CHAPTER 7: FINAL DRIVE
- GENERAL INFORMATION - FINAL DRIVE
- Service Notes - Final Drive
- Special Tools - Final Drive
- Torque Specifications - Final Drive
- Service Specifications - Final Drive
- ASSEMBLY VIEWS - FINAL DRIVE
- Propshaft Assembly View
- Propshaft Assembly View - General 4
- Drive Shaft Assembly View
- Front Gearcase Assembly View
- PROPSHAFT SERVICE
- Propshaft Removal
- Propshaft Removal - General 4
- U-Joint Disassembly
- U-Joint Assembly
- Propshaft Installation
- Propshaft Installation - General 4
- DRIVE SHAFT SERVICE
- Front Drive Shaft Removal
- Front Drive Shaft Installation
- Rear Drive Shaft Removal
- Rear Drive Shaft Installation
- Drive Shaft / Cv Joint Handling Tips
- Outer Cv Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- BEARING CARRIER SERVICE
- Front Bearing Carrier Removal / Inspection
- Front Bearing Replacement
- Bearing Removal
- Bearing Installation
- Front Bearing Carrier Installation
- Rear Bearing Carrier Removal / Inspection
- Rear Bearing Replacement
- Bearing Removal
- Bearing Installation
- Rear Bearing Carrier Installation
- FRONT GEARCASE SERVICE
- All-Wheel Drive Operation
- Front Gearcase Removal
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- Front Gearcase Installation
- TROUBLESHOOTING - FINAL DRIVE
- Final Drive Troubleshooting

CHAPTER 8: STEERING / SUSPENSION
- GENERAL INFORMATION - STEERING / SUSPENSION
- Service Notes - Steering / Suspension
- Special Tools - Steering / Suspension
- Torque Specifications - Steering / Suspension
- Service Specifications - Steering / Suspensions
- ASSEMBLY VIEWS - STEERING / SUSPENSION
- Steering Assembly View
- Front Suspension Assembly View
- Rear Suspension Assembly View
- STEERING ASSEMBLY SERVICE
- Steering Shaft Removal - Upper
- Steering Wheel Removal
- Power Steering Unit Removal
- Steering Shaft Removal - Lower
- Steering Shaft Bearing Replacement
- Steering Shaft Installation - Lower
- Power Steering Unit Installation
- Steering Shaft Installation - Upper
- Tie Rod End / Wheel Hub Inspection
- Steering Rack Removal
- Steering Rack Installation
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
- Steering Wheel Free-Play
- Epas Operation Overview
- SHOCK SERVICE
- Shock Specifications (Fox)
- Shock Specifications - Crew (Walker Evans™)
- Shock Compression Adjustment
- Shock Removal
- Spring Replacement
- Spring Adjustment
- Spring Adjustment - Crew
- Shock Installation
- Shock Disassembly (Fox)
- Eyelet-Mounted Rebound Adjuster
- Dx Bushing And Seal Style Eyelet
- Shock Assembly (Fox)
- Eyelet-Mounted Rebound Adjuster
- Assembly Continued
- Shock Disassembly (Walker Evans)
- Shock Assembly (Walker Evans)
- SUSPENSION SERVICE
- Control Arm Removal - Front
- Upper Control Arm
- Lower Control Arm
- Control Arm Installation - Front
- Upper Control Arm
- Lower Control Arm
- Control Arm Removal - Rear
- Upper Control Arm
- Lower Control Arm
- Control Arm Installation - Rear
- Upper Control Arm
- Lower Control Arm
- Stabilizer Bar Removal
- Stabilizer Bar Installation
- BALL JOINT SERVICE
- Ball Joint Preparation
- Ball Joint Removal
- Ball Joint Installation
- TROUBLESHOOTING - STEERING / SERVICE
- Epas Troubleshooting
- Power Steering Non-Functional With Mil On
- Power Steering Non-Functional With Mil Off
- Epas Troubleshooting Using Digital Wrench

CHAPTER 9: BRAKE SYSTEM
- GENERAL INFORMATION - BRAKE SYSTEM
- Service Notes - Brake System
- Special Tools - Brake System
- Torque Specifications - Brake System
- Service Specifications - Brake System
- ASSEMBLY VIEWS - BRAKE SYSTEM
- Brake System Assembly View
- Brake Caliper Assembly View
- Front Caliper
- Rear Caliper
- BRAKE SYSTEM SERVICE
- Brake System Operation Overview
- Brake Bleeding / Fluid Change
- Brake Burnishing Procedure
- MASTER CYLINDER SERVICE
- Master Cylinder Removal
- Master Cylinder Installation
- BRAKE PEDAL SERVICE
- Brake Pedal Removal
- Brake Pedal Installation
- FRONT PAD SERVICE
- Brake Pad Removal - Front
- Brake Pad Inspection
- Brake Pad Installation - Front
- FRONT CALIPER SERVICE
- Brake Caliper Removal - Front
- Brake Caliper Disassembly - Front
- Brake Caliper Inspection - Front
- Brake Caliper Assembly - Front
- Brake Caliper Installation - Front
- DISC SERVICE
- Brake Disc Runout
- Brake Disc Inspection
- Brake Disc Replacement
- REAR PAD SERVICE
- Brake Pad Removal - Rear
- Brake Pad Inspection
- Brake Pad Installation - Rear
- REAR CALIPER SERVICE
- Brake Caliper Removal - Rear
- Break Caliper Disassembly - Rear
- Brake Caliper Inspection - Rear
- Brake Caliper Assembly - Rear
- Brake Caliper Installation - Rear
- TROUBLESHOOTING - BRAKE SYSTEM
- Brake System Troubleshooting
- Brakes Squeal / Poor Brake Performance
- Pedal Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock

CHAPTER 10: BODY / FRAME
- GENERAL INFORMATION - BODY / FRAME
- Service Notes - Body / Frame
- Special Tools - Body / Frame
- Torque Specifications - Body / Frame
- ASSEMBLY VIEWS - BODY / FRAME
- Exterior Body Component Assembly View
- Exterior Body Component Assembly View - General 4
- Interior Body Component Assembly View
- Interior Body Component Assembly View - General 4
- Seat Assembly View
- Cargo Box Assembly View
- Door Assembly View
- Door Assembly View - General 4
- Rops Assembly View
- Rops Assembly View - General 4
- Frame Assembly View
- Frame Assembly View - General 4
- BODY COMPONENT REMOVAL
- Roof Removal
- Audio System Removal
- Rear View Mirror Removal
- Door Removal
- Door Removal - General 4
- Seat Removal
- Hood Removal
- Front Bumper Removal
- Exterior Body Component Removal
- Exterior Body Component Removal - General 4
- Interior Body Component Removal
- Interior Body Component Removal - General 4
- Cargo Box Removal
- Decal Replacement
- BODY COMPONENT INSTALLATION
- Cargo Box Installation
- Interior Body Component Installation
- Interior Body Component Installation - General 4
- Exterior Body Component Installation
- Exterior Body Component Installation - General 4
- Front Bumper Installation
- Hood Installation
- Seat Installation
- Door Installation
- Door Installation - General 4
- Audio System Installation
- Rear View Mirror Installation
- Roof Installation
- FRAME COMPONENT INSTALLATION
- Rops Removal
- Rops Removal - General 4
- Rops Installation
- Rops Installation - General 4
- Skid Plate Replacement
- Skid Plate Replacement - General 4

CHAPTER 11: ELECTRICAL
- GENERAL INFORMATION - ELECTRICAL SYSTEM
- Service Notes - Electrical System
- Special Tools - Electrical System
- Torque Specifications - Electrical System
- Service Specifications - Electrical System
- INSTRUMENT CLUSTER SERVICE
- Instrument Cluster Overview
- Rider Information Display
- Information Display Area
- Display Area Modes
- Gauge Settings Menu
- Backlight Color
- Clock
- Display Units
- Trip Meter
- Trip Time
- Programmed Service Interval
- Instrument Cluster Pinouts
- Instrument Cluster Replacement
- ELECTRONIC CONTROL UNIT (ECU)
- Ecu Operation Overview
- Ecu Service
- Ecu Replacement
- Diagnostic Trouble Codes Overview
- Diagnostic Trouble Code List
- Cylinder Misfire Detection
- BATTERY SERVICE
- Battery Specifications
- Battery Removal
- Battery Installation
- Battery Off-Season Storage
- Battery Testing
- Open Circuit Voltage (Ocv) Test
- Load Test
- Current Draw - Key Off
- Battery Charging Procedure
- FUSE / RELAY SERVICE
- Fuse / Relay Operation Overview
- Fuse Box Replacement
- Relay Circuits
- Fuse / Circuit Breaker Circuits
- CHARGING SYSTEM SERVICE
- Charging System Operation Overview
- Charging System Break Even Test
- Charging System Stator (Alternator) Tests
- Test 1: Resistance Value Of Each Stator Leg
- Test 2: Resistance Value Of Each Stator Leg To Ground
- Test 3: Measure Ac Voltage Output Of Each Stator Leg At Charging Rpm
- Stator (Alternator) Replacement
- Regulator / Rectifier Operation
- Battery Conductance Analyzer
- Charging System Testing
- STARTING SYSTEM SERVICE
- Starting System Operation Overview
- Voltage Drop Test
- Starter Motor Removal
- Starter Motor Installation
- Starter Solenoid Service
- Starting System Troubleshooting
- IGNITION SYSTEM SERVICE
- Ignition System Operation Overview
- Ignition Coil / Ht Lead Replacement
- Ignition Coil Tests
- Spark Plug Service
- ELECTRONIC POWER-ASSISTED STEERING
- Epas Operation Overview
- Epas System Diagnostics
- Eps Torque Offset Procedure
- LIGHTING SYSTEM SERVICE
- Headlight Adjustment
- Headlight Bulb Replacement
- Headlight Removal
- Headlight Installation
- Tail Light Replacement
- Dash Led Light
- SWITCH SERVICE
- Brake Pressure Switch
- Headlight Switch
- Ignition (Key) Switch
- Awd / 2wd Switch
- Awd / 2wd / Turf Switch
- Transmission / Gear Position Switch
- Seat Belt Switch
- Winch Switch
- CRANKSHAFT POSITION SENSOR (CPS)
- Cps Operation Overview
- Cps Test
- Cps Replacement
- ELECTRONIC THROTTLE CONTROL (ETC)
- Etc Operation Overview
- Etc Test
- Etc Replacement
- Etc Learn Procedure
- THROTTLE POSITION SENSOR (TPS)
- Tps Operation Overview
- Tps Test
- Tps Replacement
- HEATED OXYGEN SENSOR (O2)
- O2 Operation Overview
- O2 Test
- O2 Replacement
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- T-Map Operation Overview
- T-Map Test
- T-Map Replacement
- ENGINE COOLANT TEMPERATURE (ECT) SENSOR
- Ect Operation Overview
- Ect Test
- Ect Replacement
- VEHICLE SPEED SENSOR (VSS)
- Vss Operation Overview
- Vss Test
- Vss Replacement
- MISC ELECTRICAL SERVICE
- 12v Receptacle
- Awd Coil
- Operation Overview
- Testing
- Terminal Block
- Chassis Ground
- Diagnostic Plug
- DIGITAL WRENCH
- Digital Wrench® Diagnostic Software Overview
- Special Tools
- Guided Diagnostic Available
- Digital Wrench® Version And Update Id
- Digital Wrench® Updates
- Digital Wrench® Communication Errors
- Digital Wrench Diagnostic Connector
- Digital Wrench® Serial Number Location
- Digital Wrench® Feature Map
- Engine Controller Reprogramming (Reflash)
- Polaris Mobile Digital Wrench (Pmdw)
- BREAKOUT DIAGRAMS
- Cooling System Breakout
- Starting System Breakout
- Unswitched Chassis Power Breakout
- Key-On Battery Power Breakout
- Awd Breakout
- Vehicle Speed Sensor Breakout
- Lights Breakout
- Epas Breakout

WIRING DIAGRAMS