Name: Polaris GENERAL 2016 Service manual
Brand: Polaris
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7. Table of Contents
8. GENERAL INFORMATION
9. PUBLICATION PART NUMBERS
10. SPECIAL TOOLS WEBSITE
11. SPECIAL TOOLS INDEX
14. MASTER TORQUE TABLE
20. VEHICLE IDENTIFICATION
21. VEHICLE SPECIFICATIONS
22. 2016 POLARIS GENERAL SPECIFICATIONS
23. 2017 POLARIS GENERAL
25. 2017 POLARIS GENERAL
31. 2018 POLARIS GENERAL OVERVIEW (INTL)
32. 2018 POLARIS GENERAL SPECIFICATIONS (INT...
39. MISC SPECIFICATIONS AND CHARTS
40. SAE TAP / DRILL SIZES
41. DECIMAL EQUIVALENTS
45. MAINTENANCE
46. SERVICE SPECIFICATIONS - MAINTENANCE
47. PERIODIC MAINTENANCE
48. PRE-RIDE INSPECTION
50. PERIODIC MAINTENANCE CHART
52. MAINTENANCE QUICK REFERENCE
54. GREASE LUBRICATION POINTS
55. MAINTENANCE LUBRICANTS
56. GENERAL VEHICLE INSPECTION AND MAINTENAN...
57. HEAT SHIELD INSPECTION
58. ENGINE MAINTENANCE
59. ENGINE OIL AND FILTER CHANGE
60. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
62. CAM CHAIN TENSIONER INSPECTION
63. COOLING SYSTEM MAINTENANCE
64. COOLING SYSTEM HOSES
65. RADIATOR INSPECTION / CLEANING
66. FUEL SYSTEM AND AIR INTAKE MAINTENANCE
67. FUEL PUMP / FUEL FILTERS
68. FUEL TANK VENT LINE
69. INTAKE DUCT DRAIN INSPECTION
70. PVT SYSTEM MAINTENANCE
71. TRANSMISSION AND FRONT GEARCASE MAINTENA...
72. FRONT GEARCASE LUBRICATION
73. FINAL DRIVE MAINTENANCE
74. TIRE INSPECTION
75. STEERING MAINTENANCE
76. TIE ROD END / WHEEL HUB INSPECTION
77. WHEEL TOE ADJUSTMENT
78. SUSPENSION MAINTENANCE
79. SPRING ADJUSTMENT - GENERAL 4
80. BRAKE SYSTEM MAINTENANCE
81. PARKING BRAKE INSPECTION (INTL)
83. ELECTRICAL MAINTENANCE
84. BATTERY REMOVAL (INTL)
85. ENGINE / CHASSIS ELECTRICAL GROUND
86. THROTTLE PEDAL INSPECTION
90. GENERAL INFORMATION - ENGINE
91. TORQUE SPECIFICATIONS - ENGINE / COOLING...
92. SERVICE SPECIFICATIONS - ENGINE / COOLIN...
94. ASSEMBLY VIEWS - ENGINE
98. BALANCE SHAFT / CONNECTING RODS / CRANKC...
99. CYLINDER / OIL COOLER / OIL FILTER / OIL...
100. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / I...
101. SPARK PLUGS / STARTER / THERMOSTAT HOUSI...
102. EXHAUST SYSTEM ASSEMBLY VIEW (2016-2018)
103. EXHAUST SYSTEM ASSEMBLY VIEW (2019)
104. EXHAUST SYSTEM ASSEMBLY VIEW (INTL)
105. ENGINE SERVICE
106. ENGINE OIL AND FILTER CHANGE
107. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
109. TOP END SERVICE (ENGINE IN CHASSIS)
110. CRANKSHAFT PTO SEAL REPLACEMENT
112. ENGINE REMOVAL
115. ENGINE INSTALLATION
118. ENGINE BREAK-IN PERIOD
120. ENGINE OIL FLOW CHART
121. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
122. CAMSHAFT SPROCKET INSPECTION
123. CAMSHAFT / CAMSHAFT BORE INSPECTION (100...
124. CYLINDER HEAD REMOVAL
125. CYLINDER HEAD WARP INSPECTION
126. VALVE INSPECTION
127. COMBUSTION CHAMBER CLEANING
128. VALVE SEALING TEST
131. ENGINE DISASSEMBLY / INSPECTION - BOTTOM...
132. WATER PUMP HOUSING REMOVAL
133. STARTER ONE-WAY CLUTCH DISASSEMBLY
134. CRANKCASE DISASSEMBLY / INSPECTION
136. BALANCE SHAFT REMOVAL / INSPECTION
137. CRANKSHAFT REMOVAL / INSPECTION
139. CRANKCASE INSPECTION
140. CYLINDER INSPECTION
141. CYLINDER / PISTON REMOVAL
142. PISTON RING REMOVAL
143. PISTON RING TO GROOVE CLEARANCE INSPECTI...
144. PISTON-TO-CYLINDER CLEARANCE
146. ENGINE ASSEMBLY - BOTTOM END
147. CONNECTING ROD BEARING SELECTION
148. UPPER CRANKCASE PREPARATION
150. PISTON / CONNECTING ROD ASSEMBLY
151. CYLINDER / PISTON INSTALLATION
152. CRANKSHAFT INSTALLATION
153. BALANCE SHAFT INSTALLATION
154. LOWER CRANKCASE PREPARATION
158. STARTER ONE-WAY CLUTCH ASSEMBLY
159. STATOR COVER INSTALLATION
160. ENGINE ASSEMBLY - TOP END
161. CYLINDER HEAD INSTALLATION
162. CAMSHAFT INSTALLATION / TIMING
166. CAMSHAFT TIMING - QUICK REFERENCE
167. VALVE CLEARANCE ADJUSTMENT
168. VALVE COVER INSTALLATION
169. INTAKE VALVE LASH - TAPPET SELECTION MAT...
170. EXHAUST VALVE LASH - TAPPET SELECTION MA...
171. INTAKE / EXHAUST SERVICE
172. INTAKE INSTALLATION
173. EXHAUST REMOVAL
174. EXHAUST INSTALLATION
175. COOLING SYSTEM SERVICE
176. ENGINE COOLING SYSTEM SPECIFICATIONS
177. COOLING SYSTEM PRESSURE CAP TEST
178. RADIATOR REPLACEMENT
179. THERMOSTAT REPLACEMENT
180. COOLING SYSTEM BLEEDING
181. WATER PUMP REMOVAL
183. WATER PUMP SERVICE
186. TROUBLESHOOTING - ENGINE / COOLING SYSTE...
190. GENERAL INFORMATION - FUEL SYSTEM
191. SPECIAL TOOLS - FUEL SYSTEM
192. ASSEMBLY VIEWS - FUEL SYSTEM
193. EVAP FUEL SYSTEM ASSEMBLY VIEW
194. FUEL PUMP ASSEMBLY VIEW
195. EVAP SYSTEM
196. EVAP CONDITIONS AND SYMPTOMS
197. CARBON CANISTER FILTER REPLACEMENT
198. PURGE VALVE REPLACEMENT
199. FUEL LINES
207. FUEL LINE ROUTING - GENERAL 4
211. VENT LINE TERMINATION FITTING
213. FUEL INJECTOR
214. FUEL INJECTOR TROUBLESHOOTING
215. FUEL INJECTOR REPLACEMENT
218. FUEL TANK SERVICE
220. FUEL TANK INSTALLATION
221. FUEL PUMP SERVICE
222. FUEL PUMP REPLACEMENT
226. TROUBLESHOOTING - FUEL SYSTEM
229. GENERAL INFORMATION - PVT SYSTEM
230. TORQUE SPECIFICATIONS - PVT SYSTEM
231. ASSEMBLY VIEWS - PVT SYSTEM
232. DRIVE CLUTCH ASSEMBLY VIEW
234. DRIVEN CLUTCH ASSEMBLY VIEW
235. PVT SYSTEM OVERVIEW
236. PVT BREAK
237. PVT SYSTEM OVERHEATING / DIAGNOSIS
238. PVT SYSTEM SERVICE
239. PVT ASSEMBLY
241. DRIVE BELT SERVICE
242. DRIVE BELT INSTALLATION
243. DRIVE CLUTCH SERVICE
244. NEEDLE BEARING INSPECTION
245. SHIFT WEIGHT INSPECTION
246. SPIDER REMOVAL
247. CLUTCH INSPECTION
248. MOVEABLE SHEAVE BUSHING INSPECTION
250. DRIVE CLUTCH ASSEMBLY
253. DRIVEN CLUTCH SERVICE
255. DRIVEN CLUTCH ASSEMBLY
257. DRIVEN CLUTCH SERVICE (INTL)
259. DRIVEN CLUTCH ASSEMBLY
261. TROUBLESHOOTING - PVT SYSTEM
264. GENERAL INFORMATION - TRANSMISSION
265. ASSEMBLY VIEWS - TRANSMISSION
267. TRANSMISSION ASSEMBLY VIEW (2019)
268. TRANSMISSION VENT LINE 2017-2018
269. TRANSMISSION VENT LINE ROUTING / RETENTI...
270. SHIFT CABLE SERVICE
271. SHIFT CABLE ADJUSTMENT
272. TRANSMISSION SERVICE
274. TRANSMISSION INSTALLATION
278. TRANSMISSION MOUNTING TORQUE VALUES
279. DIFFERENTIAL OPERATION
281. TRANSMISSION DISASSEMBLY
283. GEAR CLUSTER DISASSEMBLY
284. SNORKEL SHAFT REMOVAL / DISASSEMBLY
286. PLANETARY DIFFERENTIAL DISASSEMBLY
287. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
289. PLANETARY DIFFERENTIAL ASSEMBLY
290. BEVEL DIFFERENTIAL DISASSEMBLY (2019)
293. GEAR / SHAFT / BEARING INSPECTION
294. SNORKEL GEAR BACKLASH PROCEDURE
297. TRANSMISSION ASSEMBLY
302. TROUBLESHOOTING - TRANSMISSION
305. GENERAL INFORMATION - FINAL DRIVE
306. ASSEMBLY VIEWS - FINAL DRIVE
308. PROPSHAFT ASSEMBLY VIEW (2018-2019)
310. DRIVE SHAFT ASSEMBLY VIEW
311. DRIVE SHAFT ASSEMBLY VIEW (INTL)
313. FRONT GEARCASE ASSEMBLY VIEW
314. GEARCASE VENT LINE
315. PROPSHAFT SERVICE
318. PROPSHAFT REMOVAL (2016-2017)
319. PROPSHAFT REMOVAL - GENERAL 4 (2017)
321. U-JOINT DISASSEMBLY
322. U-JOINT ASSEMBLY
327. PROPSHAFT INSTALLATION (2016-2017)
328. PROPSHAFT INSTALLATION - GENERAL 4 (2017...
331. DRIVE SHAFT SERVICE
332. FRONT DRIVE SHAFT INSTALLATION
333. REAR DRIVE SHAFT REMOVAL
334. REAR DRIVE SHAFT INSTALLATION
336. DRIVE SHAFT / CV JOINT HANDLING TIPS
339. INNER PLUNGING JOINT / BOOT REPLACEMENT
342. BEARING CARRIER SERVICE
343. FRONT BEARING REPLACEMENT
344. FRONT BEARING CARRIER INSTALLATION
345. REAR BEARING CARRIER REMOVAL / INSPECTIO...
346. REAR BEARING REPLACEMENT
347. BEARING INSTALLATION
349. FRONT GEARCASE SERVICE
351. FRONT GEARCASE DISASSEMBLY / INSPECTION
354. FRONT GEARCASE ASSEMBLY
357. FRONT GEARCASE INSTALLATION
359. TROUBLESHOOTING - FINAL DRIVE
363. GENERAL INFORMATION - STEERING / SUSPENS...
364. SERVICE SPECIFICATIONS - STEERING / SUSP...
365. ASSEMBLY VIEWS - STEERING / SUSPENSION
366. FRONT SUSPENSION ASSEMBLY VIEW
367. REAR SUSPENSION ASSEMBLY VIEW
368. STEERING ASSEMBLY SERVICE
369. STEERING WHEEL REMOVAL
370. STEERING SHAFT REMOVAL - LOWER
371. STEERING SHAFT BEARING REPLACEMENT
372. POWER STEERING UNIT INSTALLATION
373. STEERING SHAFT INSTALLATION - UPPER
375. TIE ROD END / WHEEL HUB INSPECTION
376. STEERING RACK INSTALLATION
377. WHEEL TOE ADJUSTMENT
378. STEERING WHEEL FREE-PLAY
380. SHOCK SERVICE
381. SHOCK SPECIFICATIONS - GENERAL 4
382. SHOCK COMPRESSION ADJUSTMENT
383. SPRING ADJUSTMENT
384. SPRING ADJUSTMENT - GENERAL 4
385. SHOCK DISASSEMBLY (FOX)
391. EYELET-MOUNTED REBOUND ADJUSTER
392. DX BUSHING AND SEAL STYLE EYELET
393. SHOCK ASSEMBLY (FOX)
394. EYELET-MOUNTED REBOUND ADJUSTER
395. ASSEMBLY CONTINUED
402. SHOCK DISASSEMBLY (WALKER EVANS)
403. SHOCK ASSEMBLY (WALKER EVANS)
405. SUSPENSION SERVICE
406. CONTROL ARM INSTALLATION - FRONT
409. CONTROL ARM REMOVAL - REAR
410. CONTROL ARM INSTALLATION - REAR
413. STABILIZER BAR REMOVAL - FRONT
414. STABILIZER BAR REMOVAL - REAR
415. STABILIZER BAR INSTALLATION - REAR
416. BALL JOINT SERVICE
417. TROUBLESHOOTING - STEERING / SERVICE
418. POWER STEERING NON-FUNCTIONAL WITH MIL O...
419. EPAS TROUBLESHOOTING USING DIGITAL WRENC...
423. GENERAL INFORMATION - BRAKE SYSTEM
424. SERVICE SPECIFICATIONS - BRAKE SYSTEM
425. SERVICE SPECIFICATIONS - BRAKE SYSTEM (I...
426. ANTILOCK BRAKE SYSTEM (ABS) (INTL)
427. BRAKE SYSTEM ASSEMBLY VIEW (INTL)
428. BRAKE LINE ROUTING AND RETENTION (INTL)
432. BRAKE LINE ROUTING AND RETENTION NON-ABS...
435. BRAKE PEDAL REMOVAL (INTL)
436. BRAKE PRESSURE SWITCH REPLACEMENT (INTL)
437. TONE RING INSPECTION (INTL)
438. WHEEL SPEED SENSOR AIR GAP ADJUSTMENT (I...
439. ABS HECU REMOVAL (INTL)
440. ABS HECU INSTALLATION (INTL)
441. ABS TROUBLESHOOTING (INTL)
442. ASSEMBLY VIEWS - BRAKE SYSTEM
443. BRAKE SYSTEM ASSEMBLY VIEW - GENERAL 4
444. LINE ROUTING AND RETENTION
447. GENERAL 4 BRAKE LINE ROUTING AND RETENTI...
450. BRAKE LINE ROUTING AND RETENTION (2019) ...
453. BRAKE CALIPER ASSEMBLY VIEW
454. REAR CALIPER
455. BRAKE SYSTEM SERVICE
456. BRAKE BURNISHING PROCEDURE
457. MASTER CYLINDER SERVICE
458. BRAKE PEDAL SERVICE
459. FRONT PAD SERVICE
460. BRAKE PAD INSPECTION
462. FRONT CALIPER SERVICE
463. BRAKE CALIPER INSPECTION - FRONT
464. BRAKE CALIPER ASSEMBLY - FRONT
466. DISC SERVICE
468. REAR PAD SERVICE
469. BRAKE PAD INSPECTION
470. REAR CALIPER SERVICE
471. BRAKE CALIPER INSPECTION - REAR
472. BRAKE CALIPER INSTALLATION - REAR
473. PARKING BRAKE (INT
474. PARKING BRAKE INSPECTION (INTL)
475. CALIPER REMOVAL
477. TROUBLESHOOTING - BRAKE SYSTEM
481. GENERAL INFORMATION - BODY / FRAME
482. ASSEMBLY VIEWS - BODY / FRAME
483. EXTERIOR BODY COMPONENT ASSEMBLY VIEW - ...
484. EXTERIOR BODY COMPONENT ASSEMBLY VIEW (I...
485. INTERIOR BODY COMPONENT ASSEMBLY VIEW
486. INTERIOR BODY COMPONENT ASSEMBLY VIEW - ...
487. SEAT ASSEMBLY VIEW
488. CARGO BOX ASSEMBLY VIEW
489. DOOR ASSEMBLY VIEW
493. DOOR ASSEMBLY VIEW - GENERAL 4
495. ROPS ASSEMBLY VIEW
496. ROPS ASSEMBLY VIEW - GENERAL 4
497. FRAME ASSEMBLY VIEW
498. FRAME ASSEMBLY VIEW - GENERAL 4
501. BODY COMPONENT REMOVAL
502. REAR VIEW MIRROR REMOVAL
503. DOOR REMOVAL - GENERAL 4
504. FRONT BUMPER REMOVAL
509. EXTERIOR BODY COMPONENT REMOVAL - GENERA...
516. INTERIOR BODY COMPONENT REMOVAL
519. CARGO BOX REMOVAL
520. DECAL REPLACEMENT
521. BODY COMPONENT INSTALLATION
524. INTERIOR BODY COMPONENT INSTALLATION
528. EXTERIOR BODY COMPONENT INSTALLATION
531. EXTERIOR BODY COMPONENT INSTALLATION - G...
533. FRONT BUMPER INSTALLATION
534. HOOD INSTALLATION
535. DOOR INSTALLATION
536. DOOR INSTALLATION - GENERAL 4
539. DOOR CABLE ADJUSTMENT
543. AUDIO SYSTEM INSTALLATION
545. REAR VIEW MIRROR INSTALLATION
546. ROOF INSTALLATION
547. FRAME COMPONENT INSTALLATION
548. ROPS INSTALLATION
549. ROPS INSTALLATION - GENERAL 4
551. SKID PLATE REPLACEMENT
558. ASSEMBLY VIEWS
559. HARNESS ROUTING / RETENTION - GENERAL 4
562. HARNESS ROUTING / RETENTION ABS (2018 IN...
564. HARNESS ROUTING / RETENTION NON-ABS (201...
566. HARNESS ROUTING / RETENTION (2019)
568. HARNESS ROUTING / RETENTION 2019 - GENER...
570. HARNESS ROUTING / RETENTION 2019 (EVAP)
572. GENERAL INFORMATION - ELECTRICAL SYSTEM
573. SPECIAL TOOLS - ELECTRICAL SYSTEM
574. SERVICE SPECIFICATIONS - ELECTRICAL SYST...
575. ELECTRICAL DIAGNOSTICS
576. CONNECTOR PROBING GUIDELINES
577. TESTING CONTINUITY/RESISTANCE
578. TESTING FOR A SHORT TO VOLTAGE
579. TESTING FOR INTERMITTENT CONDITIONS
580. TESTING VOLTAGE DROP
581. INSTRUMENT CLUSTER SERVICE
582. INSTRUMENT CLUSTER OVERVIEW (INTL)
583. RIDER INFORMATION DISPLAY
585. INFORMATION DISPLAY AREA
586. GAUGE SETTINGS MENU
587. TRIP METER
588. INSTRUMENT CLUSTER PINOUTS (INTL)
589. INSTRUMENT CLUSTER REPLACEMENT
590. ADJUSTABLE SPEED LIMITING DEVICE (ASLD) ...
591. RIDE COMMAND SYSTEM
593. RIDE COMMAND TROUBLESHOOTING
595. ELECTRONIC CONTROL UNIT (ECU)
596. DIAGNOSTIC TROUBLE CODES OVERVIEW
597. DIAGNOSTIC TROUBLE CODE LIST
601. ABS TROUBLE CODES (INTL)
604. CYLINDER MISFIRE DETECTION
605. BATTERY SERVICE
606. BATTERY INSTALLATION
607. BATTERY TESTING
609. FUSE / RELAY SERVICE
612. FUSE / RELAY OPERATION OVERVIEW
613. FUSE BOX REPLACEMENT
616. FUSE / CIRCUIT BREAKER CIRCUITS (2017-20...
617. FUSE / CIRCUIT BREAKER CIRCUITS (2019)
619. CHARGING SYSTEM SERVICE
620. TEST 3: MEASURE AC VOLTAGE OUTPUT OF EAC...
621. BATTERY CONDUCTANCE ANALYZER
622. CHARGING SYSTEM TESTING
623. STARTING SYSTEM SERVICE
624. STARTER MOTOR INSTALLATION
625. STARTING SYSTEM TROUBLESHOOTING
626. IGNITION SYSTEM SERVICE
627. SPARK PLUG SERVICE
628. ELECTRONIC POWER-ASSISTED STEERING
629. LIGHTING SYSTEM SERVICE
630. HEADLIGHT REMOVAL
631. TAIL LIGHT REPLACEMENT
632. WINCH SERVICE
634. SWITCH SERVICE
635. HEADLIGHT SWITCH
636. IGNITION (KEY) SWITCH
637. AWD / 2WD SWITCH
638. AWD / 2WD / TURF SWITCH
639. SEAT BELT SWITCH
640. WINCH SWITCH
641. CRANKSHAFT POSITION SENSOR (CPS)
642. CPS REPLACEMENT
643. ELECTRONIC THROTTLE CONTROL (ETC)
644. ETC LEARN PROCEDURE
645. THROTTLE POSITION SENSOR (TPS)
646. HEATED OXYGEN SENSOR (O2)
647. TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR...
648. ENGINE COOLANT TEMPERATURE (ECT) SENSOR
649. VEHICLE SPEED SENSOR (VSS)
650. MISC ELECTRICAL SERVICE
651. PULSE BAR
652. DIGITAL WRENCH
653. DIGITAL WRENCH® VERSION AND UPDATE ID
655. DIGITAL WRENCH® COMMUNICATION ERRORS
656. DIGITAL WRENCH® FEATURE MAP
657. ENGINE CONTROLLER REPROGRAMMING (REFLASH...
660. POLARIS MOBILE DIGITAL WRENCH (PMDW)
661. BREAKOUT DIAGRAMS
662. STARTING SYSTEM BREAKOUT
663. UNSWITCHED CHASSIS POWER BREAKOUT
664. KEY-ON BATTERY POWER BREAKOUT
665. AWD BREAKOUT
666. VEHICLE SPEED SENSOR BREAKOUT
667. LIGHTS BREAKOUT
668. EPAS BREAKOUT
669. RIDE COMMAND BREAKOUT

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7. Table of Contents
8. GENERAL INFORMATION
9. PUBLICATION PART NUMBERS
10. SPECIAL TOOLS WEBSITE
11. SPECIAL TOOLS INDEX
14. MASTER TORQUE TABLE
20. VEHICLE IDENTIFICATION
21. VEHICLE SPECIFICATIONS
22. 2016 POLARIS GENERAL SPECIFICATIONS
23. 2017 POLARIS GENERAL
25. 2017 POLARIS GENERAL
31. 2018 POLARIS GENERAL OVERVIEW (INTL)
32. 2018 POLARIS GENERAL SPECIFICATIONS (INT...
39. MISC SPECIFICATIONS AND CHARTS
40. SAE TAP / DRILL SIZES
41. DECIMAL EQUIVALENTS
45. MAINTENANCE
46. SERVICE SPECIFICATIONS - MAINTENANCE
47. PERIODIC MAINTENANCE
48. PRE-RIDE INSPECTION
50. PERIODIC MAINTENANCE CHART
52. MAINTENANCE QUICK REFERENCE
54. GREASE LUBRICATION POINTS
55. MAINTENANCE LUBRICANTS
56. GENERAL VEHICLE INSPECTION AND MAINTENAN...
57. HEAT SHIELD INSPECTION
58. ENGINE MAINTENANCE
59. ENGINE OIL AND FILTER CHANGE
60. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
62. CAM CHAIN TENSIONER INSPECTION
63. COOLING SYSTEM MAINTENANCE
64. COOLING SYSTEM HOSES
65. RADIATOR INSPECTION / CLEANING
66. FUEL SYSTEM AND AIR INTAKE MAINTENANCE
67. FUEL PUMP / FUEL FILTERS
68. FUEL TANK VENT LINE
69. INTAKE DUCT DRAIN INSPECTION
70. PVT SYSTEM MAINTENANCE
71. TRANSMISSION AND FRONT GEARCASE MAINTENA...
72. FRONT GEARCASE LUBRICATION
73. FINAL DRIVE MAINTENANCE
74. TIRE INSPECTION
75. STEERING MAINTENANCE
76. TIE ROD END / WHEEL HUB INSPECTION
77. WHEEL TOE ADJUSTMENT
78. SUSPENSION MAINTENANCE
79. SPRING ADJUSTMENT - GENERAL 4
80. BRAKE SYSTEM MAINTENANCE
81. PARKING BRAKE INSPECTION (INTL)
83. ELECTRICAL MAINTENANCE
84. BATTERY REMOVAL (INTL)
85. ENGINE / CHASSIS ELECTRICAL GROUND
86. THROTTLE PEDAL INSPECTION
90. GENERAL INFORMATION - ENGINE
91. TORQUE SPECIFICATIONS - ENGINE / COOLING...
92. SERVICE SPECIFICATIONS - ENGINE / COOLIN...
94. ASSEMBLY VIEWS - ENGINE
98. BALANCE SHAFT / CONNECTING RODS / CRANKC...
99. CYLINDER / OIL COOLER / OIL FILTER / OIL...
100. CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / I...
101. SPARK PLUGS / STARTER / THERMOSTAT HOUSI...
102. EXHAUST SYSTEM ASSEMBLY VIEW (2016-2018)
103. EXHAUST SYSTEM ASSEMBLY VIEW (2019)
104. EXHAUST SYSTEM ASSEMBLY VIEW (INTL)
105. ENGINE SERVICE
106. ENGINE OIL AND FILTER CHANGE
107. ENGINE CRANKCASE BREATHER HOSE INSPECTIO...
109. TOP END SERVICE (ENGINE IN CHASSIS)
110. CRANKSHAFT PTO SEAL REPLACEMENT
112. ENGINE REMOVAL
115. ENGINE INSTALLATION
118. ENGINE BREAK-IN PERIOD
120. ENGINE OIL FLOW CHART
121. ENGINE DISASSEMBLY / INSPECTION - TOP EN...
122. CAMSHAFT SPROCKET INSPECTION
123. CAMSHAFT / CAMSHAFT BORE INSPECTION (100...
124. CYLINDER HEAD REMOVAL
125. CYLINDER HEAD WARP INSPECTION
126. VALVE INSPECTION
127. COMBUSTION CHAMBER CLEANING
128. VALVE SEALING TEST
131. ENGINE DISASSEMBLY / INSPECTION - BOTTOM...
132. WATER PUMP HOUSING REMOVAL
133. STARTER ONE-WAY CLUTCH DISASSEMBLY
134. CRANKCASE DISASSEMBLY / INSPECTION
136. BALANCE SHAFT REMOVAL / INSPECTION
137. CRANKSHAFT REMOVAL / INSPECTION
139. CRANKCASE INSPECTION
140. CYLINDER INSPECTION
141. CYLINDER / PISTON REMOVAL
142. PISTON RING REMOVAL
143. PISTON RING TO GROOVE CLEARANCE INSPECTI...
144. PISTON-TO-CYLINDER CLEARANCE
146. ENGINE ASSEMBLY - BOTTOM END
147. CONNECTING ROD BEARING SELECTION
148. UPPER CRANKCASE PREPARATION
150. PISTON / CONNECTING ROD ASSEMBLY
151. CYLINDER / PISTON INSTALLATION
152. CRANKSHAFT INSTALLATION
153. BALANCE SHAFT INSTALLATION
154. LOWER CRANKCASE PREPARATION
158. STARTER ONE-WAY CLUTCH ASSEMBLY
159. STATOR COVER INSTALLATION
160. ENGINE ASSEMBLY - TOP END
161. CYLINDER HEAD INSTALLATION
162. CAMSHAFT INSTALLATION / TIMING
166. CAMSHAFT TIMING - QUICK REFERENCE
167. VALVE CLEARANCE ADJUSTMENT
168. VALVE COVER INSTALLATION
169. INTAKE VALVE LASH - TAPPET SELECTION MAT...
170. EXHAUST VALVE LASH - TAPPET SELECTION MA...
171. INTAKE / EXHAUST SERVICE
172. INTAKE INSTALLATION
173. EXHAUST REMOVAL
174. EXHAUST INSTALLATION
175. COOLING SYSTEM SERVICE
176. ENGINE COOLING SYSTEM SPECIFICATIONS
177. COOLING SYSTEM PRESSURE CAP TEST
178. RADIATOR REPLACEMENT
179. THERMOSTAT REPLACEMENT
180. COOLING SYSTEM BLEEDING
181. WATER PUMP REMOVAL
183. WATER PUMP SERVICE
186. TROUBLESHOOTING - ENGINE / COOLING SYSTE...
190. GENERAL INFORMATION - FUEL SYSTEM
191. SPECIAL TOOLS - FUEL SYSTEM
192. ASSEMBLY VIEWS - FUEL SYSTEM
193. EVAP FUEL SYSTEM ASSEMBLY VIEW
194. FUEL PUMP ASSEMBLY VIEW
195. EVAP SYSTEM
196. EVAP CONDITIONS AND SYMPTOMS
197. CARBON CANISTER FILTER REPLACEMENT
198. PURGE VALVE REPLACEMENT
199. FUEL LINES
207. FUEL LINE ROUTING - GENERAL 4
211. VENT LINE TERMINATION FITTING
213. FUEL INJECTOR
214. FUEL INJECTOR TROUBLESHOOTING
215. FUEL INJECTOR REPLACEMENT
218. FUEL TANK SERVICE
220. FUEL TANK INSTALLATION
221. FUEL PUMP SERVICE
222. FUEL PUMP REPLACEMENT
226. TROUBLESHOOTING - FUEL SYSTEM
229. GENERAL INFORMATION - PVT SYSTEM
230. TORQUE SPECIFICATIONS - PVT SYSTEM
231. ASSEMBLY VIEWS - PVT SYSTEM
232. DRIVE CLUTCH ASSEMBLY VIEW
234. DRIVEN CLUTCH ASSEMBLY VIEW
235. PVT SYSTEM OVERVIEW
236. PVT BREAK
237. PVT SYSTEM OVERHEATING / DIAGNOSIS
238. PVT SYSTEM SERVICE
239. PVT ASSEMBLY
241. DRIVE BELT SERVICE
242. DRIVE BELT INSTALLATION
243. DRIVE CLUTCH SERVICE
244. NEEDLE BEARING INSPECTION
245. SHIFT WEIGHT INSPECTION
246. SPIDER REMOVAL
247. CLUTCH INSPECTION
248. MOVEABLE SHEAVE BUSHING INSPECTION
250. DRIVE CLUTCH ASSEMBLY
253. DRIVEN CLUTCH SERVICE
255. DRIVEN CLUTCH ASSEMBLY
257. DRIVEN CLUTCH SERVICE (INTL)
259. DRIVEN CLUTCH ASSEMBLY
261. TROUBLESHOOTING - PVT SYSTEM
264. GENERAL INFORMATION - TRANSMISSION
265. ASSEMBLY VIEWS - TRANSMISSION
267. TRANSMISSION ASSEMBLY VIEW (2019)
268. TRANSMISSION VENT LINE 2017-2018
269. TRANSMISSION VENT LINE ROUTING / RETENTI...
270. SHIFT CABLE SERVICE
271. SHIFT CABLE ADJUSTMENT
272. TRANSMISSION SERVICE
274. TRANSMISSION INSTALLATION
278. TRANSMISSION MOUNTING TORQUE VALUES
279. DIFFERENTIAL OPERATION
281. TRANSMISSION DISASSEMBLY
283. GEAR CLUSTER DISASSEMBLY
284. SNORKEL SHAFT REMOVAL / DISASSEMBLY
286. PLANETARY DIFFERENTIAL DISASSEMBLY
287. PLANETARY DIFFERENTIAL BUSHING REPLACEME...
289. PLANETARY DIFFERENTIAL ASSEMBLY
290. BEVEL DIFFERENTIAL DISASSEMBLY (2019)
293. GEAR / SHAFT / BEARING INSPECTION
294. SNORKEL GEAR BACKLASH PROCEDURE
297. TRANSMISSION ASSEMBLY
302. TROUBLESHOOTING - TRANSMISSION
305. GENERAL INFORMATION - FINAL DRIVE
306. ASSEMBLY VIEWS - FINAL DRIVE
308. PROPSHAFT ASSEMBLY VIEW (2018-2019)
310. DRIVE SHAFT ASSEMBLY VIEW
311. DRIVE SHAFT ASSEMBLY VIEW (INTL)
313. FRONT GEARCASE ASSEMBLY VIEW
314. GEARCASE VENT LINE
315. PROPSHAFT SERVICE
318. PROPSHAFT REMOVAL (2016-2017)
319. PROPSHAFT REMOVAL - GENERAL 4 (2017)
321. U-JOINT DISASSEMBLY
322. U-JOINT ASSEMBLY
327. PROPSHAFT INSTALLATION (2016-2017)
328. PROPSHAFT INSTALLATION - GENERAL 4 (2017...
331. DRIVE SHAFT SERVICE
332. FRONT DRIVE SHAFT INSTALLATION
333. REAR DRIVE SHAFT REMOVAL
334. REAR DRIVE SHAFT INSTALLATION
336. DRIVE SHAFT / CV JOINT HANDLING TIPS
339. INNER PLUNGING JOINT / BOOT REPLACEMENT
342. BEARING CARRIER SERVICE
343. FRONT BEARING REPLACEMENT
344. FRONT BEARING CARRIER INSTALLATION
345. REAR BEARING CARRIER REMOVAL / INSPECTIO...
346. REAR BEARING REPLACEMENT
347. BEARING INSTALLATION
349. FRONT GEARCASE SERVICE
351. FRONT GEARCASE DISASSEMBLY / INSPECTION
354. FRONT GEARCASE ASSEMBLY
357. FRONT GEARCASE INSTALLATION
359. TROUBLESHOOTING - FINAL DRIVE
363. GENERAL INFORMATION - STEERING / SUSPENS...
364. SERVICE SPECIFICATIONS - STEERING / SUSP...
365. ASSEMBLY VIEWS - STEERING / SUSPENSION
366. FRONT SUSPENSION ASSEMBLY VIEW
367. REAR SUSPENSION ASSEMBLY VIEW
368. STEERING ASSEMBLY SERVICE
369. STEERING WHEEL REMOVAL
370. STEERING SHAFT REMOVAL - LOWER
371. STEERING SHAFT BEARING REPLACEMENT
372. POWER STEERING UNIT INSTALLATION
373. STEERING SHAFT INSTALLATION - UPPER
375. TIE ROD END / WHEEL HUB INSPECTION
376. STEERING RACK INSTALLATION
377. WHEEL TOE ADJUSTMENT
378. STEERING WHEEL FREE-PLAY
380. SHOCK SERVICE
381. SHOCK SPECIFICATIONS - GENERAL 4
382. SHOCK COMPRESSION ADJUSTMENT
383. SPRING ADJUSTMENT
384. SPRING ADJUSTMENT - GENERAL 4
385. SHOCK DISASSEMBLY (FOX)
391. EYELET-MOUNTED REBOUND ADJUSTER
392. DX BUSHING AND SEAL STYLE EYELET
393. SHOCK ASSEMBLY (FOX)
394. EYELET-MOUNTED REBOUND ADJUSTER
395. ASSEMBLY CONTINUED
402. SHOCK DISASSEMBLY (WALKER EVANS)
403. SHOCK ASSEMBLY (WALKER EVANS)
405. SUSPENSION SERVICE
406. CONTROL ARM INSTALLATION - FRONT
409. CONTROL ARM REMOVAL - REAR
410. CONTROL ARM INSTALLATION - REAR
413. STABILIZER BAR REMOVAL - FRONT
414. STABILIZER BAR REMOVAL - REAR
415. STABILIZER BAR INSTALLATION - REAR
416. BALL JOINT SERVICE
417. TROUBLESHOOTING - STEERING / SERVICE
418. POWER STEERING NON-FUNCTIONAL WITH MIL O...
419. EPAS TROUBLESHOOTING USING DIGITAL WRENC...
423. GENERAL INFORMATION - BRAKE SYSTEM
424. SERVICE SPECIFICATIONS - BRAKE SYSTEM
425. SERVICE SPECIFICATIONS - BRAKE SYSTEM (I...
426. ANTILOCK BRAKE SYSTEM (ABS) (INTL)
427. BRAKE SYSTEM ASSEMBLY VIEW (INTL)
428. BRAKE LINE ROUTING AND RETENTION (INTL)
432. BRAKE LINE ROUTING AND RETENTION NON-ABS...
435. BRAKE PEDAL REMOVAL (INTL)
436. BRAKE PRESSURE SWITCH REPLACEMENT (INTL)
437. TONE RING INSPECTION (INTL)
438. WHEEL SPEED SENSOR AIR GAP ADJUSTMENT (I...
439. ABS HECU REMOVAL (INTL)
440. ABS HECU INSTALLATION (INTL)
441. ABS TROUBLESHOOTING (INTL)
442. ASSEMBLY VIEWS - BRAKE SYSTEM
443. BRAKE SYSTEM ASSEMBLY VIEW - GENERAL 4
444. LINE ROUTING AND RETENTION
447. GENERAL 4 BRAKE LINE ROUTING AND RETENTI...
450. BRAKE LINE ROUTING AND RETENTION (2019) ...
453. BRAKE CALIPER ASSEMBLY VIEW
454. REAR CALIPER
455. BRAKE SYSTEM SERVICE
456. BRAKE BURNISHING PROCEDURE
457. MASTER CYLINDER SERVICE
458. BRAKE PEDAL SERVICE
459. FRONT PAD SERVICE
460. BRAKE PAD INSPECTION
462. FRONT CALIPER SERVICE
463. BRAKE CALIPER INSPECTION - FRONT
464. BRAKE CALIPER ASSEMBLY - FRONT
466. DISC SERVICE
468. REAR PAD SERVICE
469. BRAKE PAD INSPECTION
470. REAR CALIPER SERVICE
471. BRAKE CALIPER INSPECTION - REAR
472. BRAKE CALIPER INSTALLATION - REAR
473. PARKING BRAKE (INT
474. PARKING BRAKE INSPECTION (INTL)
475. CALIPER REMOVAL
477. TROUBLESHOOTING - BRAKE SYSTEM
481. GENERAL INFORMATION - BODY / FRAME
482. ASSEMBLY VIEWS - BODY / FRAME
483. EXTERIOR BODY COMPONENT ASSEMBLY VIEW - ...
484. EXTERIOR BODY COMPONENT ASSEMBLY VIEW (I...
485. INTERIOR BODY COMPONENT ASSEMBLY VIEW
486. INTERIOR BODY COMPONENT ASSEMBLY VIEW - ...
487. SEAT ASSEMBLY VIEW
488. CARGO BOX ASSEMBLY VIEW
489. DOOR ASSEMBLY VIEW
493. DOOR ASSEMBLY VIEW - GENERAL 4
495. ROPS ASSEMBLY VIEW
496. ROPS ASSEMBLY VIEW - GENERAL 4
497. FRAME ASSEMBLY VIEW
498. FRAME ASSEMBLY VIEW - GENERAL 4
501. BODY COMPONENT REMOVAL
502. REAR VIEW MIRROR REMOVAL
503. DOOR REMOVAL - GENERAL 4
504. FRONT BUMPER REMOVAL
509. EXTERIOR BODY COMPONENT REMOVAL - GENERA...
516. INTERIOR BODY COMPONENT REMOVAL
519. CARGO BOX REMOVAL
520. DECAL REPLACEMENT
521. BODY COMPONENT INSTALLATION
524. INTERIOR BODY COMPONENT INSTALLATION
528. EXTERIOR BODY COMPONENT INSTALLATION
531. EXTERIOR BODY COMPONENT INSTALLATION - G...
533. FRONT BUMPER INSTALLATION
534. HOOD INSTALLATION
535. DOOR INSTALLATION
536. DOOR INSTALLATION - GENERAL 4
539. DOOR CABLE ADJUSTMENT
543. AUDIO SYSTEM INSTALLATION
545. REAR VIEW MIRROR INSTALLATION
546. ROOF INSTALLATION
547. FRAME COMPONENT INSTALLATION
548. ROPS INSTALLATION
549. ROPS INSTALLATION - GENERAL 4
551. SKID PLATE REPLACEMENT
558. ASSEMBLY VIEWS
559. HARNESS ROUTING / RETENTION - GENERAL 4
562. HARNESS ROUTING / RETENTION ABS (2018 IN...
564. HARNESS ROUTING / RETENTION NON-ABS (201...
566. HARNESS ROUTING / RETENTION (2019)
568. HARNESS ROUTING / RETENTION 2019 - GENER...
570. HARNESS ROUTING / RETENTION 2019 (EVAP)
572. GENERAL INFORMATION - ELECTRICAL SYSTEM
573. SPECIAL TOOLS - ELECTRICAL SYSTEM
574. SERVICE SPECIFICATIONS - ELECTRICAL SYST...
575. ELECTRICAL DIAGNOSTICS
576. CONNECTOR PROBING GUIDELINES
577. TESTING CONTINUITY/RESISTANCE
578. TESTING FOR A SHORT TO VOLTAGE
579. TESTING FOR INTERMITTENT CONDITIONS
580. TESTING VOLTAGE DROP
581. INSTRUMENT CLUSTER SERVICE
582. INSTRUMENT CLUSTER OVERVIEW (INTL)
583. RIDER INFORMATION DISPLAY
585. INFORMATION DISPLAY AREA
586. GAUGE SETTINGS MENU
587. TRIP METER
588. INSTRUMENT CLUSTER PINOUTS (INTL)
589. INSTRUMENT CLUSTER REPLACEMENT
590. ADJUSTABLE SPEED LIMITING DEVICE (ASLD) ...
591. RIDE COMMAND SYSTEM
593. RIDE COMMAND TROUBLESHOOTING
595. ELECTRONIC CONTROL UNIT (ECU)
596. DIAGNOSTIC TROUBLE CODES OVERVIEW
597. DIAGNOSTIC TROUBLE CODE LIST
601. ABS TROUBLE CODES (INTL)
604. CYLINDER MISFIRE DETECTION
605. BATTERY SERVICE
606. BATTERY INSTALLATION
607. BATTERY TESTING
609. FUSE / RELAY SERVICE
612. FUSE / RELAY OPERATION OVERVIEW
613. FUSE BOX REPLACEMENT
616. FUSE / CIRCUIT BREAKER CIRCUITS (2017-20...
617. FUSE / CIRCUIT BREAKER CIRCUITS (2019)
619. CHARGING SYSTEM SERVICE
620. TEST 3: MEASURE AC VOLTAGE OUTPUT OF EAC...
621. BATTERY CONDUCTANCE ANALYZER
622. CHARGING SYSTEM TESTING
623. STARTING SYSTEM SERVICE
624. STARTER MOTOR INSTALLATION
625. STARTING SYSTEM TROUBLESHOOTING
626. IGNITION SYSTEM SERVICE
627. SPARK PLUG SERVICE
628. ELECTRONIC POWER-ASSISTED STEERING
629. LIGHTING SYSTEM SERVICE
630. HEADLIGHT REMOVAL
631. TAIL LIGHT REPLACEMENT
632. WINCH SERVICE
634. SWITCH SERVICE
635. HEADLIGHT SWITCH
636. IGNITION (KEY) SWITCH
637. AWD / 2WD SWITCH
638. AWD / 2WD / TURF SWITCH
639. SEAT BELT SWITCH
640. WINCH SWITCH
641. CRANKSHAFT POSITION SENSOR (CPS)
642. CPS REPLACEMENT
643. ELECTRONIC THROTTLE CONTROL (ETC)
644. ETC LEARN PROCEDURE
645. THROTTLE POSITION SENSOR (TPS)
646. HEATED OXYGEN SENSOR (O2)
647. TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR...
648. ENGINE COOLANT TEMPERATURE (ECT) SENSOR
649. VEHICLE SPEED SENSOR (VSS)
650. MISC ELECTRICAL SERVICE
651. PULSE BAR
652. DIGITAL WRENCH
653. DIGITAL WRENCH® VERSION AND UPDATE ID
655. DIGITAL WRENCH® COMMUNICATION ERRORS
656. DIGITAL WRENCH® FEATURE MAP
657. ENGINE CONTROLLER REPROGRAMMING (REFLASH...
660. POLARIS MOBILE DIGITAL WRENCH (PMDW)
661. BREAKOUT DIAGRAMS
662. STARTING SYSTEM BREAKOUT
663. UNSWITCHED CHASSIS POWER BREAKOUT
664. KEY-ON BATTERY POWER BREAKOUT
665. AWD BREAKOUT
666. VEHICLE SPEED SENSOR BREAKOUT
667. LIGHTS BREAKOUT
668. EPAS BREAKOUT
669. RIDE COMMAND BREAKOUT

Description

The Service Manual of the Polaris GENERAL 2016, 2017, 2018, and 2019, as well as the GENERAL 4 2016, 2017, 2018, and 2019 Offroad Vehicle is designed to help maintain and repair your Polaris GENERAL vehicle. It includes detailed instructions on how to use the special tools required for the repair, along with a list of spare parts and a troubleshooting guide. The manual is divided into sections with detailed information on general information, publication part numbers, special tools and website, special tools and inventory, maintenance, and troubleshooting. The Service Manual provides information on performing routine maintenance such as changing the oil and air filter, replacing the spark plugs, and checking the brakes. It also covers more intricate repairs such as replacing the shocks, adjusting the clutch belt, and troubleshooting the electric start system. The manual also includes safety information, a warranty guide, and a list of frequently asked questions. The Polaris GENERAL Service Manual is essential for anyone who owns a Polaris GENERAL, ensuring that your vehicle runs smoothly and efficiently.

Also for: GENERAL 2017, GENERAL 2018, GENERAL 2019, GENERAL 4 2016, GENERAL 4 2017, GENERAL 4 2018, GENERAL 4 2019

File size: 79.13 MB

Created: January 30, 2023

Last updated: March 23, 2023