Polaris General 2020

3
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
3.1
ENGINE / COOLING SYSTEM
CHAPTER 3
ENGINE / COOLING SYSTEM
GENERAL INFORMATION - ENGINE . . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . . 3.3
SERVICE NOTES - ENGINE / COOLING SYSTEM ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . . 3.3
SPECIAL TOOLS - ENGINE / COOLING SYSTEM. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . 3.3
ENGINE CYLINDER LEAKDOWN TEST .. . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . 3.4
OIL PRESSURE TEST. . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . 3.6
ENGINE OIL FLOW CHART . . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . . 3.7
ENGINE BREAK-IN PERIOD . . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . 3.8
ENGINE SERVICE SPECIFICATIONS . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . 3.9
SERVICE SPECIFICATIONS - ENGINE / COOLING SYSTEM . . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . 3.9
ENGINE SERVICE . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .3.11
TOP END SERVICE (ENGINE IN CHASSIS) . . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . 3.11
CRANKSHAFT PTO SEAL REPLACEMENT . . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . 3.11
ENGINE REMOVAL .. . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...3.13
ENGINE INSTALLATION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..3.16
ENGINE DISASSEMBLY / INSPECTION - TOP END .. . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ..3.20
CAMSHAFT SPROCKET INSPECTION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. .3.21
ENGINE DISASSEMBLY / INSPECTION - BOTTOM END . . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ..3.30
PISTON-TO-CYLINDER CLEARANCE ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .3.43
ENGINE ASSEMBLY - BOTTOM END . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .3.46
BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..3.46
CONNECTING ROD BEARING SELECTION . ... . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .3.47
CRANKSHAFT MAIN BEARING SELECTION . . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ...3.47
ENGINE ASSEMBLY - TOP END . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..3.60
CAMSHAFT TIMING - QUICK REFERENCE .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . ..3.66
VALVE LASH - TAPPET SELECTION . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .3.69
INTAKE SERVICE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..3.71
INTAKE ASSEMBLY VIEW - GENERAL / GENERAL XP . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . .. . . ..3.71
INTAKE ASSEMBLY VIEW - GENERAL 4 / GENERAL XP 4 . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..3.72
INTAKE REMOVAL . . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .3.73
INTAKE INSTALLATION . . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... .3.74
EXHAUST SERVICE . . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . .. . . ... . ... . ..3.76
EXHAUST SYSTEM ASSEMBLY VIEW . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ..3.76
EXHAUST REMOVAL .. . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . ... . ... . ... . .3.77
EXHAUST INSTALLATION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. .3.77
COOLING SYSTEM SERVICE . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .3.79
COOLING SYSTEM ASSEMBLY VIEW . ... . ... . . .. . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ..3.79
COOLANT HOSE ROUTING / RETENTION - 2 SEAT. .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .3.80
COOLANT HOSE ROUTING / RETENTION - 4 SEAT. .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .3.83
COOLANT OVERFLOW LINE ROUTING / RETENTION . . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .3.86
COOLING SYSTEM SPECIFICATIONS . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..3.87
COOLING SYSTEM PRESSURE CAP TEST . ... . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .3.88