Polaris General 2020

2
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
2.1
MAINTENANCE
CHAPTER 2
MAINTENANCE
GENERAL INFORMATION - MAINTENANCE . . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 2.3
SERVICE NOTES - MAINTENANCE . . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . . 2.3
SPECIAL TOOLS - MAINTENANCE. .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... 2.3
SERVICE SPECIFICATIONS - MAINTENANCE .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 2.4
PERIODIC MAINTENANCE. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . . 2.6
PERIODIC MAINTENANCE OVERVIEW . . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . . 2.6
BREAK-IN PERIOD.. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . . 2.6
PRE-RIDE INSPECTION . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . . 2.7
MAINTENANCE INTERVAL CHART . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . .. 2.8
MAINTENANCE QUICK REFERENCE . . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..2.21
GREASE LUBRICATION POINTS.. . ... . ... . . .. . . .. . ... . ... . .. . . ... . ... . . .. . ... . ... . .. . . .. . . ... . ... . ..2.23
MAINTENANCE LUBRICANTS . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..2.24
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..2.25
PRE-RIDE / DAILY INSPECTION . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .2.25
FRAME, NUTS, BOLTS, AND FASTENERS . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . ..2.25
SHIFT CABLE INSPECTION / ADJUSTMENT . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .2.25
HEAT SHIELD INSPECTION.. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. .2.26
ENGINE MAINTENANCE . . ... . ... . ... . ... . . .. . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .2.27
ENGINE OIL LEVEL . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..2.27
ENGINE OIL AND FILTER CHANGE . . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . .2.28
ENGINE CRANKCASE BREATHER HOSE INSPECTION . . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..2.29
ENGINE CYLINDER LEAKDOWN TEST .. . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. .2.29
VALVE CLEARANCE INSPECTION .. . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . .2.29
CAM CHAIN TENSIONER INSPECTION .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..2.31
COOLING SYSTEM MAINTENANCE .. . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...2.32
COOLING SYSTEM OVERVIEW. . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .2.32
COOLANT STRENGTH.. . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .2.32
COOLANT LEVEL INSPECTION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..2.32
COOLANT DRAIN / FILL . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .2.34
FUEL SYSTEM AND AIR INTAKE MAINTENANCE . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...2.35
FUEL PUMP / FUEL FILTERS . . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . .2.35
FUEL TANK VENT LINE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . .2.36
VENT LINE TERMINATION FITTING.. . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. .2.36
AIR FILTER SERVICE . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ...2.37
INTAKE DUCT DRAIN INSPECTION . . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .2.37
PVT SYSTEM MAINTENANCE .. . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ..2.38
PVT DRYING . . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..2.38
TRANSMISSION AND FRONT GEARCASE MAINTENANCE .. . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .2.39
TRANSMISSION LUBRICATION . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .2.39
FRONT GEARCASE LUBRICATION . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .2.40
FINAL DRIVE MAINTENANCE .. . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..2.41