Polaris General XP 2021

1
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
1.1
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION .. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .. 1.3
MODEL NUMBER DESIGNATION . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . 1.3
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 1.3
VEHICLE AND ENGINE SERIAL NUMBER LOCATION. . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... 1.4
REFERENCE INFORMATION . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. 1.5
SERVICE RULES. . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . 1.5
PUBLICATION PART NUMBERS .. . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 1.6
REPLACEMENT KEYS . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . 1.7
SPECIAL TOOLS WEBSITE . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .. 1.8
SPECIAL TOOLS INDEX. . . .. . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . . 1.9
VEHICLE SPECIFICATIONS (MODEL YEAR 2021) . . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .1.13
MODEL SPECIFICATIONS - 2 SEAT . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .1.13
MODEL SPECIFICATIONS - 4 SEAT . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .1.18
MODEL SPECIFICATIONS - INTL. . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .1.22
MISC SPECIFICATIONS AND CHARTS . . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .1.26
MASTER TORQUE TABLE . . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .1.26
CONVERSION TABLE . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .1.33
SAE TAP / DRILL SIZES . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .1.34
METRIC TAP / DRILL SIZES .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ...1.34
DECIMAL EQUIVALENTS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1.35
GENERAL DIAGNOSTICS.. . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .1.36
GENERAL DIAGNOSTICS INFORMATION OVERVIEW . . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .1.36
GUIDED SYMPTOM DIAGNOSTIC . . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . .1.36
GUIDED SYMPTOM REFERENCES .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..1.37
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES . . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . .1.38
ENGINE CRANKS BUT DOES NOT START . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ..1.41
NO CRANK NO START OR SLOW CRANK . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .1.43
OVER HEATING. ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .1.44
WARNING LIGHTS . . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. .1.45
ENGINE TROUBLESHOOTING.. . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...1.46
COOLING TROUBLESHOOTING . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ..1.48
DIGITAL WRENCH® SOFTWARE OVERVIEW . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ..1.49
SPECIAL TOOLS . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .1.49
GUIDED DIAGNOSTICS.. . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..1.49
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES . . ... . ... . ... . ... . . .. . ... . ... . .1.50
DIGITAL WRENCH® COMMUNICATION ERRORS. . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .1.51
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR.. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . ..1.51
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .1.52
DIGITAL WRENCH® FEATURE MAP . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .1.53
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . ... . ... . ... . ... . .. . . .. . . .. . . .. . . ... . .1.55
POLARIS MOBILE DIGITAL WRENCH® (PMDW) . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1.55