Polaris General 2020

1.2
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
DIAGNOSTIC TROUBLE CODES OVERVIEW . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1.57
MASTER TROUBLE CODE LIST. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .1.58
CYLINDER MISFIRE DETECTION .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . .1.69
FLUID LEAKS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. .1.70
FLUID INSPECTION.. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. .1.70
FUEL SYSTEM TROUBLESHOOTING. .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. .1.71
PVT SYSTEM TROUBLESHOOTING . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .1.73
PVT SYSTEM OVERHEATING / DIAGNOSIS . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. .1.75
HARD SHIFTING . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . .1.76
TRANSMISSION ISOLATION . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .1.76
ALL WHEEL DRIVE (AWD) CONCERNS . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .1.77
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . .1.77
BRAKE NOISE TROUBLESHOOTING .. . ... . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .1.78
BRAKE VIBRATION . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . .1.78
CALIPER OVERHEATS (BRAKES DRAG) .. . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .1.79
POOR BRAKE PERFORMANCE. . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .1.79
BRAKES LOCK.. . . .. . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... .1.79
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . .. . ... . . .. . . .. . .1.80
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . .. . . .. . . ... . .1.81
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .1.82
SHOCK ANALYSIS . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ..1.83
ELECTRICAL SERVICE NOTES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1.84
DIGITAL MULTI-METER (DMM) NOTES . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .1.84
STATIC AND DYNAMIC TESTING . . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .1.84
CONNECTOR PROBING GUIDELINES .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ...1.85
TESTING CONTINUITY / RESISTANCE . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . .1.86
TESTING FOR A SHORT TO GROUND. .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . ..1.86
TESTING FOR A SHORT TO VOLTAGE . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ..1.87
TESTING FOR INTERMITTENT CONDITIONS. . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1.88
TESTING CURRENT FLOW (AMPERAGE) . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .1.88
CURRENT DRAW - KEY OFF. .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . .1.89
TESTING VOLTAGE DROP ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . ..1.89
GENERAL INFORMATION