Polaris General and XP (2020-2021) - Service Manual - Repair Manual

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POLARIS GENERAL & GENERAL XP (2020-2021) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for ATV Polaris General and XP (2020-2021).

 
CONTENTS:


CHAPTER 1 : GENERAL INFORMATION
- VEHICLE IDENTIFICATION
- Model Number Designation
- Vehicle Identification Number (VIN) Designation
- Vehicle and Engine Serial Number Location
- REFERENCE INFORMATION
- Service Rules
- Publication Part Numbers
- Replacement Keys
- Special Tools Website
- Special Tools Index
- VEHICLE SPECIFICATIONS (Model Year 2021)
- Model Specifications - 2 Seat
- Model Specifications - 4 Seat
- Model Specifications - INTL
- MISC SPECIFICATIONS AND CHARTS
- Master Torque Table
- Conversion Table
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
- GENERAL DIAGNOSTICS
- General Diagnostics Information Overview
- Guided Symptom Diagnostic
- Guided Symptom References
- Engine and Drivability Diagnostic Procedures
- Engine Cranks but does Not Start
- No Crank No Start or Slow Crank
- Over Heating
- Warning Lights
- Engine Troubleshooting
- Cooling Troubleshooting
- Digital Wrench® Software Overview
- Special Tools
- Guided Diagnostics
- Digital Wrench® Software Installation and 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)
- Diagnostic Trouble Codes Overview
- Master Trouble Code List
- Cylinder Misfire Detection
- Fluid Leaks
- Fluid Inspection
- Fuel System Troubleshooting
- PVT System Troubleshooting
- PVT System Overheating / Diagnosis
- Hard Shifting
- Transmission Isolation
- All Wheel Drive (AWD) Concerns
- Driveshaft (Half Shaft) Diagnostics
- BRAKE NOISE TROUBLESHOOTING
- Brake Vibration
- Caliper Overheats (Brakes Drag)
- Poor Brake Performance
- Brakes Lock
- EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
- EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
- EPS Troubleshooting (Using Digital Wrench®)
- Shock Analysis
- Electrical Service Notes
- Digital Multi-Meter (DMM) Notes
- Static and Dynamic Testing
- Connector Probing Guidelines
- Testing Continuity / Resistance
- Testing For A Short To Ground
- Testing For A Short To Voltage
- Testing for Intermittent Conditions
- Testing Current Flow (Amperage)
- Current Draw - Key Off
- Testing Voltage Drop

CHAPTER 2 : MAINTENANCE
- GENERAL INFORMATION - MAINTENANCE
- Service Notes - Maintenance
- Special Tools - Maintenance
- Service Specifications - Maintenance
- PERIODIC MAINTENANCE
- Periodic Maintenance Overview
- Break-In Period
- Pre-Ride Inspection
- Maintenance Interval 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
- Heat Shield Inspection
- 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
- Coolant Drain / Fill
- FUEL SYSTEM AND AIR INTAKE MAINTENANCE
- Fuel Pump / Fuel Filters
- Fuel Tank Vent Line
- Vent Line Termination Fitting
- Air Filter Service
- Intake Duct Drain Inspection
- PVT SYSTEM MAINTENANCE
- PVT Drying
- TRANSMISSION AND FRONT GEARCASE MAINTENANCE
- Transmission Lubrication
- Front Gearcase Lubrication
- FINAL DRIVE MAINTENANCE
- Drive Shaft Boot Inspection
- Wheel Removal
- Wheel installation
- Tire Inspection
- Tire Inspection (INTL)
- STEERING MAINTENANCE
- Steering Inspection
- Steering Wheel Free-Play
- Tie Rod End / Wheel Hub Inspection
- Wheel Toe Alignment Inspection
- Wheel Toe Adjustment
- SUSPENSION MAINTENANCE - GENERAL / GENERAL 4
- Spring Adjustment
- Spring Adjustment - GENERAL 4
- Shock Compression Adjustment
- SUSPENSION MAINTENANCE - GENERAL XP / GENERAL XP 4
- Spring Adjustment - General XP
- Spring Adjustment - General XP 4
- 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
- Battery Removal (INTL)
- Battery Installation (INTL)
- 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
- Engine Cylinder Leakdown Test
- Oil Pressure Test
- Engine Oil Flow Chart
- Engine Break-In Period
- ENGINE SERVICE SPECIFICATIONS
- Service Specifications - Engine / Cooling System
- ENGINE SERVICE
- Top End Service (Engine In Chassis)
- Crankshaft PTO Seal Replacement
- Engine Removal
- Engine Installation
- ENGINE DISASSEMBLY / INSPECTION - TOP END
- Camshaft Sprocket Inspection
- ENGINE DISASSEMBLY / INSPECTION - BOTTOM END
- Piston-to-Cylinder Clearance
- ENGINE ASSEMBLY - BOTTOM END
- Bearing Selection Identification Letters and Numbers
- Connecting Rod Bearing Selection
- Crankshaft Main Bearing Selection
- ENGINE ASSEMBLY - TOP END
- Camshaft Timing - Quick Reference
- Valve Lash - Tappet Selection
- INTAKE SERVICE
- Intake Assembly View - General / General XP
- Intake Assembly View - General 4 / General XP 4
- Intake Removal
- Intake Installation
- EXHAUST SERVICE
- Exhaust System Assembly View
- Exhaust Removal
- Exhaust Installation
- COOLING SYSTEM SERVICE
- Cooling System Assembly View
- Coolant Hose Routing / Retention - 2 Seat
- Coolant Hose Routing / Retention - 4 Seat
- Coolant Overflow Line Routing / Retention
- Cooling System Specifications
- Cooling System Pressure Cap Test
- Cooling System Hose Replacement
- Radiator Replacement
- Thermostat Replacement
- Cooling System Bleeding
- Water Pump Installation

CHAPTER 4 : ENGINE ELECTRICAL
- ELECTRONIC CONTROL UNIT (ECU)
- ECU Operation Overview
- ECU Service
- ECU Replacement
- ADJUSTABLE SPEED LIMITING DEVICE (ASLD) - ABS Models
- ASLD Overview - ABS Models
- 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
- ACCELERATOR POSITION SENSOR (APS)
- APS Operation Overview
- APS Test
- APS 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
- IGNITION SYSTEM SERVICE
- Ignition System Operation Overview
- Ignition Coil / HT Lead Replacement
- Ignition Coil Tests
- Spark Plug Service

CHAPTER 5 : FUEL SYSTEM
- GENERAL INFORMATION - FUEL SYSTEM
- Service Notes - Fuel System
- Special Tools - Fuel System
- Service Specifications - Fuel System
- ASSEMBLY VIEWS - FUEL SYSTEM
- Fuel System Assembly View
- EVAP Fuel System Assembly View
- Fuel Pump Assembly View
- EVAP SYSTEM
- EVAP System Overview
- EVAP Conditions and Symptoms
- Carbon Canister Filter Replacement
- Carbon Canister Replacement
- Purge Valve Replacement
- Purge Valve Ohm Test
- FUEL LINES
- Fuel Line Routing
- Fuel Line Routing - GENERAL 4
- Fuel Line Routing (EVAP Models)
- Fuel Line Routing - GENERAL 4 (EVAP Models)
- Fuel Line Quick Connect Removal
- Fuel Line Replacement
- Vent Line Termination Fitting
- FUEL INJECTOR
- Fuel Injector Operation Overview
- Fuel Injector O-Rings
- Fuel Injector Test
- Fuel Injector Replacement
- Fuel Injector Troubleshooting
- FUEL TANK SERVICE
- Fuel Tank Removal
- Fuel Tank Installation
- FUEL PUMP SERVICE
- Fuel Pump Operation Overview
- Fuel Pump Test
- Fuel Pump Replacement

CHAPTER 6 : PVT SYSTEM
- GENERAL INFORMATION - PVT SYSTEM
- Service Notes - PVT System
- Special Tools - PVT System
- Service Specifications - PVT System
- PVT SYSTEM OVERVIEW
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In
- PVT System Maintenance / Inspection
- ASSEMBLY VIEWS - PVT SYSTEM
- PVT Covers / Duct Assembly View - General
- PVT Covers / Duct Assembly View - General 4
- Inner Clutch Cover Assembly View
- PVT SYSTEM SERVICE
- PVT Disassembly
- PVT Assembly
- DRIVE BELT SERVICE
- Drive Belt Removal
- Drive Belt Inspection
- Drive Belt Installation
- DRIVE CLUTCH SERVICE
- Drive Clutch Assembly View
- Moveable Sheave Bushing Inspection
- DRIVEN CLUTCH SERVICE
- Driven Clutch Assembly View
- Driven Clutch Alignment Procedure
- Driven Clutch Disassembly
- Driven Clutch Assembly
- Driven Clutch Slider Inspection

CHAPTER 7 : TRANSMISSION
- GENERAL INFORMATION - TRANSMISSION
- Service Notes - Transmission
- Special Tools - Transmission
- Service Specifications - Transmission
- SHIFT CABLE SERVICE
- Shift Lever / Cable Assembly View - General
- Shift Cable Routing - General
- Shift Lever / Cable Assembly View - General 4
- Shift Cable Routing - General 4
- Shift Lever Replacement
- Shift Cable Inspection
- Shift Cable Adjustment
- ASSEMBLY VIEWS - TRANSMISSION
- Transmission Assembly View
- Transmission Mounting Torque Values
- TRANSMISSION VENT LINE
- Transmission Vent Line Routing
- Vent Line Termination Fitting
- TRANSMISSION SERVICE
- Transmission Removal
- Differential Operation
- Transmission Disassembly
- Gear Cluster Disassembly
- Snorkel Shaft Removal / Disassembly
- Bevel Differential Disassembly
- Bevel Differential Assembly
- Gear / Shaft / Bearing Inspection
- Transmission Assembly
- Transmission Installation

CHAPTER 8 : FINAL DRIVE
- GENERAL INFORMATION - FINAL DRIVE
- Service Notes - Final Drive
- Special Tools - Final Drive
- Service Specifications - Final Drive
- ASSEMBLY VIEWS - FINAL DRIVE
- Propshaft Assembly View - 2 Seat
- Propshaft Assembly View - 4 Seat
- Drive Shaft Assembly View
- Drive Shaft Assembly View (INTL ABS Models)
- Front Gearcase Assembly View
- Gearcase Vent Line
- PROPSHAFT SERVICE
- Propshaft Removal - 2 Seat
- Propshaft Removal - 4 Seat
- U-Joint Disassembly
- U-Joint Assembly
- Propshaft Installation - 2 Seat
- Propshaft Installation - 4 Seat
- DRIVE SHAFT SERVICE - General / General 4
- 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
- DRIVE SHAFT SERVICE - General XP / General XP 4
- 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 - General / General 4
- Front Bearing Carrier Removal / Inspection
- Front Bearing Replacement
- Front Bearing Carrier Installation
- Rear Bearing Carrier Removal / Inspection
- Rear Bearing Replacement
- Rear Bearing Carrier Installation
- BEARING CARRIER SERVICE - General XP / General XP 4
- Front Bearing Carrier Removal / Inspection
- Front Bearing Replacement
- Front Bearing Carrier Installation
- Rear Bearing Carrier Removal / Inspection
- Rear Bearing Replacement
- Rear Bearing Carrier Installation
- FRONT GEARCASE SERVICE
- All-Wheel Drive Operation
- Front Gearcase Removal
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- Front Gearcase Installation
- WHEEL HUBS - General / General 4
- Front Hub Assembly View
- Rear Hub Assembly View
- WHEEL HUBS - General XP / General XP 4
- Front Hub Assembly View
- Rear Hub Assembly View

CHAPTER 9 : STEERING / SUSPENSION
- GENERAL INFORMATION - STEERING / SUSPENSION
- Service Notes - Steering / Suspension
- Special Tools - Steering / Suspension
- Service Specifications - Steering
- Service Specifications - Suspension
- ASSEMBLY VIEWS - STEERING / SUSPENSION GENERAL / GENERAL 4
- Steering Assembly View
- Front Suspension Assembly View
- Front Stabilizer Bar Assembly View
- Rear Suspension Assembly View
- Rear Stabilizer Bar Assembly View
- ASSEMBLY VIEWS - STEERING / SUSPENSION GENERAL XP / GENERAL XP 4
- Steering Assembly View
- Front Suspension Assembly View
- Front Stabilizer Bar Assembly View
- Rear Suspension Assembly View
- Rear Stabilizer Bar 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
- SUSPENSION SERVICE - General / General 4
- Front Control Arm Removal
- Front Control Arm Installation
- Front Stabilizer Bar Removal
- Front Stabilizer Bar Installation
- Rear Control Arm Removal
- Rear Control Arm Installation
- Rear Stabilizer Bar Removal
- Rear Stabilizer Bar Installation
- SUSPENSION SERVICE - General XP / General XP 4
- Front Control Arm Removal
- Front Control Arm Installation
- Front Stabilizer Bar Removal
- Front Stabilizer Bar Installation
- Rear Control Arm Removal
- Rear Control Arm Installation
- Rear Stabilizer Bar Removal
- Rear Stabilizer Bar Installation
- BALL JOINT SERVICE
- Ball Joint Preparation
- Ball Joint Installation
- SHOCK SERVICE - General / General 4
- Shock Specifications - General
- Shock Specifications - General 4
- Shock Removal
- Spring Replacement
- Spring Adjustment
- Spring Adjustment - GENERAL 4
- Shock Compression Adjustment
- Shock Installation
- Shock Disassembly (FOX)
- Shock Assembly (FOX)
- SHOCK SERVICE - General XP / General XP 4
- Shock Specifications - General XP
- Shock Specifications - General XP 4
- Shock Removal
- Spring Replacement
- Spring Adjustment - General XP
- Spring Adjustment - General XP 4
- Shock Compression Adjustment
- Shock Installation
- Shock Disassembly (Walker Evans)
- Shock Assembly (Walker Evans)

CHAPTER 10 : BRAKE SYSTEM
- GENERAL INFORMATION - BRAKE SYSTEM
- Service Notes - Brake System
- Special Tools - Brake System
- Service Specifications - Brake System (General / General 4)
- Service Specifications - Brake System (General XP / General XP 4)
- Service Specifications - Brake System (INTL)
- BRAKE SYSTEM SERVICE
- Brake System Operation Overview
- Brake Bleeding / Fluid Change
- Brake Burnishing Procedure
- ASSEMBLY VIEWS - BRAKE SYSTEM (General / General 4)
- Brake System Assembly View - General
- Brake Line Routing - General
- Brake System Assembly View - GENERAL 4
- Brake Line Routing - GENERAL 4
- Brake Caliper Assembly View - General / General 4
- Brake Line Fitting Orientation - General / General 4
- ASSEMBLY VIEWS - BRAKE SYSTEM (General XP / General XP 4)
- Brake System Assembly View - General XP
- Brake Line Routing - General XP
- Brake Caliper Assembly View - General XP
- Brake System Assembly View - General XP 4
- Brake Line Routing - General XP 4
- Brake Caliper Assembly View - General XP 4
- Brake Line Fitting Orientation - General XP / General XP 4
- MASTER CYLINDER SERVICE
- Master Cylinder Removal
- Master Cylinder Installation
- BRAKE PEDAL SERVICE
- Brake Pedal Removal
- Brake Pedal Installation
- FRONT PAD SERVICE
- Front Brake Pad Removal
- Brake Pad Inspection
- Brake Pad Inspection (INTL)
- Front Brake Pad Installation
- FRONT CALIPER SERVICE - General / General XP / General 4
- Front Caliper Removal
- Front Caliper Disassembly
- Front Caliper Inspection
- Front Caliper Assembly
- Front Caliper Installation
- FRONT CALIPER SERVICE - General XP 4
- Front Caliper Removal
- Front Caliper Disassembly / Inspection
- Front Caliper Assembly
- Front Caliper Installation
- REAR PAD SERVICE
- Rear Brake Pad Removal
- Brake Pad Inspection
- Rear Brake Pad Installation
- REAR CALIPER SERVICE - General / General 4 / General XP 4
- Rear Caliper Removal
- Rear Caliper Disassembly
- Rear Caliper Inspection
- Rear Caliper Assembly
- Rear Caliper Installation
- REAR CALIPER SERVICE - General XP
- Rear Caliper Removal
- Rear Caliper Disassembly
- Rear Caliper Inspection
- Rear Caliper Assembly
- Rear Caliper Installation
- DISC SERVICE
- Brake Disc Runout
- Brake Disc Inspection
- Brake Disc Replacement
- Brake Disc Replacement
- INTERNATIONAL (INTL) BRAKE SERVICE
- Antilock Braking System (ABS) Overview (INTL)
- Brake System Assembly View (INTL ABS)
- Brake Line Routing And Retention (INTL ABS)
- Brake Line Fitting Orientation - ABS
- Brake Line Routing And Retention Non-ABS (INTL)
- Brake Pedal Removal (INTL)
- Brake Pedal Installation (INTL)
- Brake Pressure Switch Replacement (INTL)
- Tone Ring Inspection (INTL ABS)
- Tone Ring Replacement (INTL ABS)
- Wheel Speed Sensor Replacement (INTL ABS)
- Wheel Speed Sensor Air Gap Adjustment (INTL ABS)
- ABS HECU Removal (INTL ABS)
- ABS HECU Installation (INTL ABS)
- ABS Troubleshooting (INTL ABS)
- PARKING BRAKE (INTL)
- Parking Brake Assembly View

CHAPTER 11 : BODY / FRAME
- GENERAL INFORMATION - BODY / FRAME
- Service Notes - Body / Frame
- Special Tools - Body / Frame
- Decal Replacement
- ASSEMBLY VIEWS - BODY / FRAME
- Front Facia Assembly View
- Hood & Front Fender Assembly View - GENERAL / GENERAL 4
- Hood & Front Fender Assembly View - GENERAL XP / GENERAL XP 4
- Dash Assembly View
- Floor & Rocker Assembly View - GENERAL
- Floor & Rocker Assembly View - GENERAL XP
- Center Console Assembly View - GENERAL / GENERAL XP
- Closeoff & Rear Fender Assembly View - GENERAL
- Closeoff & Rear Fender Assembly View - GENERAL XP
- Front Closeoff & Floor Assembly View - GENERAL 4 / GENERAL XP 4
- Center Console Assembly View - GENERAL 4 / GENERAL XP 4
- Rear Closeoff, Fenders, & Floor Assembly View - GENERAL 4
- Rear Closeoff, Fenders, & Floor Assembly View - GENERAL XP 4
- Seat Assembly View - GENERAL
- Seat Assembly View - GENERAL 4
- Cargo Box Assembly View - GENERAL
- Cargo Box Assembly View - GENERAL XP
- Door Assembly View - Front
- Door Assembly View - Rear
- ROPS Assembly View - GENERAL
- ROPS Assembly View - GENERAL 4
- Frame Assembly View - GENERAL
- Frame Assembly View - GENERAL 4
- Frame Assembly View - GENERAL XP
- Frame Assembly View - GENERAL XP 4
- BODY COMPONENT REMOVAL
- Door Removal
- Door Removal - GENERAL 4
- Seat Removal
- Hood Removal
- Exterior Body Component Removal
- Exterior Body Component Removal - GENERAL 4
- Interior Body Component Removal
- Interior Body Component Removal - GENERAL 4
- Cargo Box Removal
- 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
- Hood Installation
- Seat Installation
- Door Installation
- Door Installation - GENERAL 4
- Door Cable Adjustment
- FRAME COMPONENT INSTALLATION
- ROPS Removal
- ROPS Installation

AND MORE....