Polaris General XP 2021

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed August 2020 (PN 9850067 R01)
© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2020-2021 GENERAL / GENERAL XP
Service Manual

Polaris General XP 2021 Specifications

General

Brand	Polaris
Model	General XP 2021
Category	Offroad Vehicle
Language	English

Summary

General Information

Vehicle Identification

Details on model number and VIN designation for identifying the vehicle.

Reference Information and Service Rules

Key information on service rules, part numbers, replacement keys, and special tools.

General Diagnostics and Troubleshooting Procedures

Covers diagnostic overview, guided symptoms, warning lights, engine/cooling troubleshooting, and Digital Wrench.

Maintenance

Engine Maintenance

Procedures for checking engine oil level, changing oil/filter, and inspecting breather hose.

Cooling System Maintenance

Procedures for checking coolant level, strength, hoses, radiator, and bleeding the system.

Engine Cooling System

Engine Service Procedures

Procedures for top end and bottom end service, including removal and installation.

Crankshaft and Piston Service

Specifications and procedures for pistons, rings, connecting rods, and crankshafts.

Cylinder Head Service

Procedures for cylinder head removal, inspection, and valve service.

Cooling System Service

Procedures for inspecting hoses, radiator, thermostat, and bleeding the system.

Engine Electrical

Electronic Control Unit (ECU) Service

ECU operation, service, and replacement procedures.

Sensors and Electronic Throttle Control

Overview, testing, and replacement of CPS, ETC, APS, O2, T-MAP, and ECT sensors.

Ignition System Service

Ignition system operation, coil/HT lead replacement, and coil tests.

Fuel System

EVAP System and Fuel Lines

Fuel Injector and Fuel Pump Service

Procedures for fuel injector operation, testing, replacement, and fuel pump service.

PVT System

PVT System Overview and Maintenance

Drive Clutch Service

Driven Clutch Service

Transmission

Transmission Service Procedures

Procedures for transmission removal, differential operation, disassembly, and installation.

Final Drive

Drive Shaft Service

Bearing Carrier Service

Steering Suspension

Steering Assembly Views and Service

Suspension Service - General and XP Models

Shock Service and Specifications

Shock specifications and procedures for removal, spring replacement, and compression adjustment.

Brake System

Brake System Operation and Bleeding

Front Brake Service

Rear Brake Service

Body Frame

Body Component Installation

Chassis Body Electrical

Instrument Cluster and Battery Service

Fuse, Relay, and Charging System Service

Starting System and Electrical Component Service

Procedures for starter motor, solenoid, EPS, lighting, switches, sensors, and AWD system.