Polaris General 2020

10.2
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
FRONT CALIPER INSTALLATION . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . . 10.55
FRONT CALIPER SERVICE - GENERAL XP 4 . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 10.56
FRONT CALIPER REMOVAL . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... 10.56
FRONT CALIPER DISASSEMBLY / INSPECTION. .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . 10.56
FRONT CALIPER ASSEMBLY . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 10.58
FRONT CALIPER INSTALLATION . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . . 10.58
REAR PAD SERVICE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 10.59
REAR BRAKE PAD REMOVAL. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . . 10.59
BRAKE PAD INSPECTION . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . . 10.60
REAR BRAKE PAD INSTALLATION.. . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... 10.60
REAR CALIPER SERVICE - GENERAL / GENERAL 4 / GENERAL XP 4 . .. . . .. . . .. . . .. . . ... . ... . .. . . .. 10.61
REAR CALIPER REMOVAL.. . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... 10.61
REAR CALIPER DISASSEMBLY . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. 10.61
REAR CALIPER INSPECTION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. 10.62
REAR CALIPER ASSEMBLY . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . 10.62
REAR CALIPER INSTALLATION . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 10.63
REAR CALIPER SERVICE - GENERAL XP. ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. 10.64
REAR CALIPER REMOVAL.. . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... 10.64
REAR CALIPER DISASSEMBLY . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. 10.64
REAR CALIPER INSPECTION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. 10.65
REAR CALIPER ASSEMBLY . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . 10.66
REAR CALIPER INSTALLATION . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 10.66
DISC SERVICE . . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 10.68
BRAKE DISC RUNOUT. .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . . 10.68
BRAKE DISC INSPECTION. . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . 10.68
BRAKE DISC REPLACEMENT . . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... 10.69
BRAKE DISC REPLACEMENT . . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... 10.70
INTERNATIONAL (INTL) BRAKE SERVICE . . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . 10.71
ANTILOCK BRAKING SYSTEM (ABS) OVERVIEW (INTL). . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . .. 10.71
BRAKE SYSTEM ASSEMBLY VIEW (INTL ABS) .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.72
BRAKE LINE ROUTING AND RETENTION (INTL ABS) . . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . 10.73
BRAKE LINE FITTING ORIENTATION - ABS .. . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. 10.77
BRAKE LINE ROUTING AND RETENTION NON-ABS (INTL). .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . 10.80
BRAKE PEDAL REMOVAL (INTL). . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... 10.83
BRAKE PEDAL INSTALLATION (INTL). ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . . 10.83
BRAKE PRESSURE SWITCH REPLACEMENT (INTL) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.84
TONE RING INSPECTION (INTL ABS).. . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . 10.85
TONE RING REPLACEMENT (INTL ABS). .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . 10.85
WHEEL SPEED SENSOR REPLACEMENT (INTL ABS) . . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... 10.85
WHEEL SPEED SENSOR AIR GAP ADJUSTMENT (INTL ABS) . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . . 10.86
ABS HECU REMOVAL (INTL ABS). ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. 10.87
ABS HECU INSTALLATION (INTL ABS) . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . 10.88
ABS TROUBLESHOOTING (INTL ABS) . . .. . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . 10.89
PARKING BRAKE (INTL). . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . 10.90
PARKING BRAKE ASSEMBLY VIEW . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. 10.90
BRAKE SYSTEM