Polaris General XP 2021 User Manual

IX.2
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
Non-ABS (INTL)................................................... 10.80
Brake Master Cylinder
Installation .......................................................... 10.47
Removal............................................................. 10.47
Brake Pad
Inspection.................................................. 10.50, 10.60
Brake Pad Inspection, .............................................. 10.50
Brake Pedal
Installation .......................................................... 10.48
Removal............................................................. 10.48
Brake Pedal installation ............................................ 10.83
Brake System
Assembly View - General .........................................10.9
Assembly View - General 4..................................... 10.14
Assembly View - General XP .................................. 10.23
Assembly View - General XP 4 ................................ 10.34
Brake Bleeding / Fluid Change ..................................10.7
Brake Burnishing Procedure .....................................10.8
Brake Hose and Fitting Inspection..............................2.51
Fluid Inspection .....................................................2.51
Operation Overview ................................................10.7
Pad / Disc Inspection ..............................................2.51
Service Notes........................................................10.3
Service Specifications (General / General 4) ................10.4
Service Specifications (General XP / General XP 4) .......10.5
Service Specifications (INTL) ....................................10.6
Special Tools .........................................................10.3
Brakes
Brake Vibration ......................................................1.78
Brakes Lock ..........................................................1.79
Front Caliper Assembly ......................................... 10.58
Front Caliper Disassembly / Inspection ..................... 10.56
Overheating ..........................................................1.79
Performance Issues................................................1.79
Troubleshooting Brake Noise ....................................1.78
Break-In Period.......................................................... 2.6
C
Caliper
Assembly (front)................................................... 10.58
Caliper, Front
Disassembly / Inspection ....................................... 10.56
Cam Chain Tensioner
Inspection.............................................................2.31
Camshaft
Inspection (1000) ...................................................3.22
Installation / Timing.................................................3.62
Removal...............................................................3.20
Sprocket Inspection ................................................3.21
Camshaft Timing - Quick Reference ..............................3.66
Carbon Canister
Replacement.......................................................... 5.9
Cargo Box
Assembly View - GENERAL ................................... 11.22
Assembly View - GENERAL XP............................... 11.26
Cargo Box Harness
Component Locations
Domestic Models............................................... 12.14
INTL ............................................................... 12.24
Routing / Retention
Domestic Models............................................... 12.15
INTL Models..................................................... 12.25
Center Console
Assembly View - GENERAL / GENERAL XP .............. 11.10
Assembly View - GENERAL 4 / GENERAL XP 4 ......... 11.14
Charging System..................................................... 12.56
Break Even Test................................................... 12.55
Operation Overview .............................................. 12.55
Stator (Alternator) Replacement .............................. 12.56
Stator (Alternator) Tests ......................................... 12.55
Testing ............................................................... 12.58
Chassis Heat Shield...................................................2.26
Closeoff & Rear Fender
Assembly View - GENERAL ................................... 11.11
Assembly View - GENERAL XP............................... 11.12
Clutch
Starter One Way ....................................................3.58
Combustion Chamber ................................................3.26
Connecting Rod Assembly ..........................................3.50
Connecting Rod Inspection..........................................3.44
Coolant Flow Diagram ................................................3.79
Coolant Hose
Routing / Retention
2 Seat...............................................................3.80
4 Seat...............................................................3.83
Coolant Overflow Line
Routing / Retention .................................................3.86
Cooling System
Assembly View ......................................................3.79
Bleeding Procedure ................................................3.91
Coolant Drain / Fill ..................................................2.34
Coolant Level Inspection..........................................2.32
Coolant Strength ....................................................2.32
Hose Replacement .................................................3.88
Hoses ..................................................................2.33
Overview ..............................................................2.32
Pressure Cap Test ..................................................3.88
Pressure Test ........................................................3.87
Radiator Inspection / Cleaning ..................................2.34
Specifications ........................................................3.87
Thermostat Replacement.........................................3.90
Troubleshooting .....................................................1.48
Crankcase
Assembly .............................................................3.55
Disassembly / Inspection .........................................3.33
Crankshaft
Connecting Rod Bearing Selection.............................3.47
Connecting Rod Inspection.......................................3.44
Installation ............................................................3.52
Main Bearing Selection............................................3.47
Removal / Inspection...............................................3.37
Crankshaft Position Sensor (CPS)
Operation Overview ................................................. 4.5
Replacement.......................................................... 4.6
Test ...................................................................... 4.5
Crankshaft PTO Seal
Installation ............................................................ 3.11
Removal............................................................... 3.11
Replacement......................................................... 3.11
Cylinder
Inspection.............................................................3.39
Installation ............................................................3.51
Misfire..................................................................1.69
Removal...............................................................3.40
Cylinder Head
Assembly .............................................................3.60
Disassembly .........................................................3.24
Installation ............................................................3.61
Removal...............................................................3.23
Warp ...................................................................3.24
INDEX

Polaris General XP 2021 Specifications

General

Brand	Polaris
Model	General XP 2021
Category	Offroad Vehicle
Language	English