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9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
2.25
GENERAL VEHICLE INSPECTION AND MAINTENANCE
PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance.
• Engine Oil - Check for proper level on dipstick, refer to
“Engine Oil Level” page 2.27
• Tires - check condition and pressures
• Fuel tank - fill to proper level
• Brakes - check operation and fluid level and
adjustment
• Headlights/Taillights/Brakelights - also check operation
of all indicator lights, instrument cluster and switches
• Ignition switch - check for proper function
• Wheels - check for tightness of wheel nuts and axle
nuts; check to be sure axle nuts are secured by cotter
pins
• Engine Intake Pre-Filter - Inspect pre-filter and clean
with soapy water and low pressure compressed air if
necessary
• PVT Intake Pre-Filter - Inspect pre-filter and clean with
soapy water and low pressure compressed air if
necessary
• Steering - check for free operation noting any unusual
looseness in any area
• Loose parts - visually inspect vehicle for any damaged
or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery
bottle
• Drive Shaft Boots - Inspect inner and outer boots for
tears or damage on both front and rear drive shafts
• Check all front and rear suspension components for
wear or damage.
• Heat Shields - ensure they are not damaged and are
properly secured. If any heat shields are found to be
damaged or missing, they must be replaced.
FRAME, NUTS, BOLTS, AND
FASTENERS
Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check that
all cotter pins are in place. Refer to specific fastener
torques listed in each chapter.
SHIFT CABLE INSPECTION /
ADJUSTMENT
Shift cable adjustment may be necessary if:
• No gear position or AWD display on instrument cluster
• Ratcheting noise on deceleration
• Inability to engage into a gear
• Excessive gear lash (noise)
• Gear selector moving out of desired range
1. Locate the shift cable
q
attached to the transmission
case in the right rear wheel well area.
2. Inspect shift cable, clevis pin, pivot bushings
r
, and
dust boot
e
. Replace if worn or damaged.
3. If adjustment is required, loosen the lower jam nut
y
and pull the cable out of the mount
w
to move the
upper jam nut
t
.
4. Adjust the shift cable so there is the same amount of
cable travel when shifting slightly past HIGH gear and
PARK.
5. Thread the upper or lower jam nut as required to
obtain proper cable adjustment.
NOTICE
This procedure may require a few attempts to obtain
the proper adjustment.
6. Once the proper adjustment is obtained, place the
shift cable and upper jam nut into the mount. Tighten
the lower jam nut against the mount.
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.
MAINTENANCE
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