Polaris General XP 2021

IX.6
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
Assembly View - General / General XP .......................3.71
Assembly View - General 4 / General XP 4 ..................3.72
International ........................................................... 10.50
INTL ..................................................................... 10.83
K
Key Switch............................................................. 12.67
Keys
Replacement.......................................................... 1.7
L
Lights
Headlight Adjustment ............................................ 12.62
Headlight Installation............................................. 12.63
Headlight Removal ............................................... 12.63
Interior LED Lights................................................ 12.64
Tail Light Replacement .......................................... 12.64
M
Maintenance
Battery .................................................................2.54
Lubricants.............................................................2.24
Pre-Ride / Daily Inspection .......................................2.25
Quick Reference Chart ............................................2.21
Service Notes......................................................... 2.3
Service specifications............................................... 2.4
Special Tools .......................................................... 2.3
Steering System.....................................................2.43
Maintenance Interval Chart
Periodic Maintenance............................................... 2.8
Master Torque Table ..................................................1.26
Misc. Specifications / Charts
Conversion Table ...................................................1.33
Decimal Equivalents ...............................................1.35
Tap / Drill Sizes (Metric) ...........................................1.34
Tap / Drill Sizes (SAE) .............................................1.34
Model Specifications
2 Seat Models .......................................................1.13
4 Seat Models .......................................................1.18
International Models ...............................................1.22
Module
Flasher Module .................................................... 12.73
N
ne
Valve Clearance Adjustment .....................................3.67
O
Oil Pressure Test........................................................ 3.6
P
Parking Brake
Assembly View .................................................... 10.90
Caliper Removal (INT’L) ........................................ 10.92
Disc Inspection/Replacement.................................. 10.93
Switch................................................................ 12.73
Parking Brake Caliper
Installation (INT’L) ................................................ 10.93
Parking Brake, Adjustment (INT’L) .......................2.52, 10.91
Parking Brake, Inspection (INT’L) ........................2.52, 10.91
Periodic Maintenance
Overview ............................................................... 2.6
Piston
Disassembly / Inspection (1000) ................................3.41
Installation ............................................................3.51
Removal...............................................................3.40
Ring Groove Clearance ...........................................3.42
Ring Installation .....................................................3.48
Ring Installed Gap (1000) ........................................3.43
Ring Removal / Inspection........................................3.42
Piston to Cylinder Clearance........................................3.43
Pre-Ride Inspection .................................................... 2.7
Prop Shaft
U-Joint Assembly ...................................................8.15
U-Joint Disassembly ...............................................8.14
Propshaft
Assembly View
2 Seat................................................................ 8.4
4 Seat................................................................ 8.5
Installation
2 Seat...............................................................8.16
4 Seat...............................................................8.18
Removal
2 Seat............................................................... 8.11
4 Seat...............................................................8.12
Publication Part Numbers............................................. 1.6
Pulse Bar
Replacement....................................................... 12.77
Purge Valve
Ohm Test..............................................................5.10
Replacement.........................................................5.10
PVT Covers / Duct
Assembly View - General .......................................... 6.5
Assembly View - General 4........................................ 6.6
PVT system..............................................................6.13
PVT System
Belt Break-In .......................................................... 6.4
Disassembly ..................................................... 6.8-6.9
Drive Clutch Operation ............................................. 6.4
Driven Clutch Assembly...........................................6.27
Driven Clutch Disassembly.......................................6.25
Driven Clutch Operation............................................ 6.4
Maintenance .......................................................... 6.4
Overheating / Diagnosis...........................................1.75
PVT Drying ...........................................................2.38
Service Notes......................................................... 6.2
Service Specifications .............................................. 6.3
Special Tools .......................................................... 6.2
Troubleshooting .....................................................1.73
R
Radiator ..................................................................3.89
Radiator installation ...................................................3.89
Rear Bearing Carrier
Bearing Replacement...................................... 8.47, 8.53
Installation
General / General 4 .............................................8.48
General XP / General XP 4 ....................................8.54
Removal / Inspection
General / General 4 .............................................8.46
INDEX