Polaris General XP 2021

IX
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
IX.3
D
Dash
Assembly View ...................................................... 11.7
Diagnostic ...............................................................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
Differential
Bevel Differential Assembly ......................................7.28
Operation .............................................................7.19
Digital Wrench
Diagnostic Connector ..............................................1.51
Digital Wrench®
Communication Errors.............................................1.51
ECU Reprogramming ..............................................1.55
Feature Map..........................................................1.53
Guided Diagnostics ................................................1.49
Polaris Mobile Digital Wrench® (PMDW) .....................1.55
Serial Number Location ...........................................1.52
Software Installation and Updates..............................1.50
Software Overview .................................................1.49
Special Tools .........................................................1.49
Disc Inspection
Parking Brake...................................................... 10.93
Door ..................................................................... 11.50
Assembly View - Front........................................... 11.30
Assembly View - Rear ........................................... 11.34
door alignment........................................................ 11.77
Door alignment ....................................................... 11.78
door installation ...................................................... 11.77
Door Installation ...................................................... 11.78
Door Removal ........................................................ 11.50
Drive Belt
Inspection............................................................. 6.11
Installation ............................................................6.12
Removal............................................................... 6.11
Drive Clutch .............................................................6.13
Assembly .............................................................6.21
Bearing Inspection..................................................6.15
Bushing Service .....................................................6.19
Button to Tower Clearance .......................................6.16
Cover Bushing .......................................................6.19
Disassembly .........................................................6.14
Moveable Sheave Inspection ....................................6.19
Operation .............................................................. 6.4
Roller and Pin Inspection .........................................6.17
Shift Weights .........................................................6.16
Spider Removal .....................................................6.17
Spring..................................................................6.14
Drive Clutch Assembly View ........................................6.13
Drive Shaft
Assembly View ....................................................... 8.6
Assembly View (INTL ABS Models)............................. 8.7
Boot Inspection ......................................................2.41
CV Joint Handling........................................... 8.25, 8.36
Inner Plunging Joint / Boot Replacement ............. 8.28, 8.39
Outer CV Joint / Boot Replacement .................... 8.26, 8.37
Driven Clutch
Alignment Procedure ..............................................6.25
Assembly .............................................................6.27
Assembly View ......................................................6.24
Disassembly .........................................................6.25
Operation .............................................................. 6.4
Slider Inspection ....................................................6.29
Driveshaft (Half Shaft)
Diagnostics ...........................................................1.77
Dynamic
Testing .................................................................1.84
E
ECU
Diagnostic Trouble Codes Overview ...........................1.57
ETC Learn Procedure .............................................. 4.8
Operation Overview ................................................. 4.2
Replacement.......................................................... 4.2
Service ................................................................. 4.2
Electrical
Connector Probing Guidelines...................................1.85
Continuity / Resistance ............................................1.86
Current Draw - Key Off ...................................1.89, 12.57
Digital Multi-Meter (DMM) ........................................1.84
Engine / Chassis Electrical Ground ............................2.56
Service Notes ........................................................1.84
Static and Dynamic Testing ......................................1.84
Testing Current Flow (Amperage) ..............................1.88
Testing For A Short To Ground ..................................1.86
Testing For A Short To Voltage ..................................1.87
Testing for Intermittent Conditions ..............................1.88
Testing Voltage Drop ...............................................1.89
Throttle Pedal Inspection .........................................2.58
Electrical System
12V Receptacle ................................................... 12.76
AWD Coil............................................................ 12.76
Chassis Ground ................................................... 12.77
Diagnostic Plug.................................................... 12.77
Service Notes ........................................................12.4
Service Specifications .............................................12.5
Special Tools .........................................................12.5
Electronic Power Steering (EPS)
Operation ........................................................... 12.61
Troubleshooting - EPS Non-Functional MIL Off .............1.81
Troubleshooting - EPS Non-Functional MIL On .............1.80
Troubleshooting - Using Digital Wrench® ....................1.82
Electronic Throttle Body
Learn Procedure ..................................................... 4.8
Electronic Throttle Control (ETC)
Operation Overview ................................................. 4.7
Replacement.......................................................... 4.7
Test ...................................................................... 4.7
Engine
Balance Shaft Removal / Inspection ...........................3.36
Bearing Selection Identification .................................3.46
Break-In Period....................................................... 3.8
Breather Hose Inspection.........................................2.29
Camshaft Installation / Timing ...................................3.62
Camshaft Removal .................................................3.20
Camshaft Sprocket Inspection...................................3.21
Connecting Rod Bearing Selection.............................3.47
Crankcase Assembly ..............................................3.55
Crankcase Disassembly / Inspection ..........................3.33
Crankshaft Installation .............................................3.52
Crankshaft Main Bearing Selection ............................3.47
Crankshaft Removal / Inspection ...............................3.37
Cylinder / Piston Installation......................................3.51
Cylinder / Piston Removal ........................................3.40
Cylinder Head Assembly..........................................3.60
Cylinder Head Disassmebly......................................3.24
Cylinder Head Installation ........................................3.61
Cylinder Head Removal ...........................................3.23
Cylinder Head Warp................................................3.24
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