Polaris General XP 2021

9
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
9.1
STEERING / SUSPENSION
CHAPTER 9
STEERING / SUSPENSION
GENERAL INFORMATION - STEERING / SUSPENSION . . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... 9.3
SERVICE NOTES - STEERING / SUSPENSION . . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . 9.3
SPECIAL TOOLS - STEERING / SUSPENSION . . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. 9.3
SERVICE SPECIFICATIONS - STEERING . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 9.3
SERVICE SPECIFICATIONS - SUSPENSION . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . . 9.3
ASSEMBLY VIEWS - STEERING / SUSPENSION GENERAL / GENERAL 4 . .. . . .. . . .. . . .. . . .. . . .. . . 9.4
STEERING ASSEMBLY VIEW . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . 9.4
FRONT SUSPENSION ASSEMBLY VIEW. ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . . 9.5
FRONT STABILIZER BAR ASSEMBLY VIEW . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 9.7
REAR SUSPENSION ASSEMBLY VIEW . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... 9.8
REAR STABILIZER BAR ASSEMBLY VIEW . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..9.10
ASSEMBLY VIEWS - STEERING / SUSPENSION GENERAL XP / GENERAL XP 4 . . .. . . .. . . .. . . .. 9.11
STEERING ASSEMBLY VIEW . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... 9.11
FRONT SUSPENSION ASSEMBLY VIEW. ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .9.12
FRONT STABILIZER BAR ASSEMBLY VIEW . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . .9.14
REAR SUSPENSION ASSEMBLY VIEW . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..9.15
REAR STABILIZER BAR ASSEMBLY VIEW . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..9.17
STEERING ASSEMBLY SERVICE . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .9.18
STEERING SHAFT REMOVAL - UPPER . . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . .9.18
STEERING WHEEL REMOVAL . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..9.19
POWER STEERING UNIT REMOVAL.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..9.19
STEERING SHAFT REMOVAL - LOWER . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .9.20
STEERING SHAFT BEARING REPLACEMENT . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..9.21
STEERING SHAFT INSTALLATION - LOWER. ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .9.21
POWER STEERING UNIT INSTALLATION . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. .9.22
STEERING SHAFT INSTALLATION - UPPER .. . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ..9.23
TIE ROD END / WHEEL HUB INSPECTION. .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..9.25
STEERING RACK REMOVAL . . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ...9.25
STEERING RACK INSTALLATION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . ... . .9.26
WHEEL TOE ALIGNMENT INSPECTION . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..9.27
WHEEL TOE ADJUSTMENT .. . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .9.28
STEERING WHEEL FREE-PLAY . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .9.28
SUSPENSION SERVICE - GENERAL / GENERAL 4. .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .9.29
FRONT CONTROL ARM REMOVAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . ... . .9.29
FRONT CONTROL ARM INSTALLATION . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .9.30
FRONT STABILIZER BAR REMOVAL . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .9.33
FRONT STABILIZER BAR INSTALLATION . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..9.33
REAR CONTROL ARM REMOVAL. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .9.34
REAR CONTROL ARM INSTALLATION ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . ...9.35
REAR STABILIZER BAR REMOVAL . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .9.38
REAR STABILIZER BAR INSTALLATION . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . .9.38