Polaris GENERAL 2016 Service Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. GENERAL 2016
  6. Service manual

Polaris GENERAL 2016 Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
Table of Contents

Advertisement

Quick Links

Download this manual
2016-2019 GENERAL / GENERAL 4
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed July 2018 (PN 9929375 R02)
© Copyright 2018 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Advertisement

Table of Contents
loading

Related Manuals for Polaris GENERAL 2016

Summary of Contents for Polaris GENERAL 2016

  • Page 1 Publication Printed July 2018 (PN 9929375 R02) © Copyright 2018 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 4 REVISION INDEX (TRADEMARKLIST) DATE CHANGES 07/27/2018 Initial Release Driven Clutch Alignment Procedure added 09/05/2018...
  • Page 5 FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video. This feedback form is viewable on a mobile...
  • Page 6 2016-2019 GENERAL / GENERAL 4 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10:...

  • Page 7: Table Of Contents

    ........... . .1.27 2018 POLARIS GENERAL EU OVERVIEW (INTL) .

  • Page 8: General Information

    Always replace locking hardware such as lock nuts or lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual with genuine Polaris hardware from an authorized Polaris dealer. Working with batteries can be hazardous. Review all battery warnings and cautions.

  • Page 9: Publication Part Numbers

    GENERAL INFORMATION PUBLICATION PART NUMBERS Some vehicle publications, such as the Owner’s Manual and Parts Manual are available on-line and can be downloaded from the Polaris website (www.polarisindustries.com). MODEL MODEL NUMBER OWNER’S MANUAL 2016 GENERAL R16RGE99A7 / AV / AE...

  • Page 10: Special Tools Website

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/...

  • Page 11: Special Tools Index

    2.375” Bore PU-50562 PU-50625 Stand) PW-47054 CHAPTER 4 — FUEL SYSTEM Fuel Pressure Fuel Pressure Fuel Pump Gauge Kit Gauge Adapter Service Tool PU-43506-A PA-48838 PU-50326 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 12 Replacement Roll Pin Axle Boot Clamp CV Boot Clamp Tool Kit Tool Removal Tool Tool Pliers 2871226 PA-47336 2872608 PU-48951 8700226 Universal Clutch Compressor PU-50518 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 13 CHAPTER 9 — BRAKE SYSTEM Mityvac® Wireless Vehicle Digital Wrench® Digital Wrench® Pressure Test Vehicle SmartLink Link (WVL) Tool Interface Cable Module PU-51435 2870975 PU-47469 PU-47468 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 14: Master Torque Table

    26 ft-lb (35 Nm) (M8) Screws Crankcase Bolts (Upper) Plunger Bolt 15 ft-lb (20 Nm) 9 ft-lb (12 Nm) (M6) Spark Plug 7 lb-ft (10 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 15 72 in-lbs (8 Nm) Retaining Screws Fastener Oil Sump Cover Bolts 26 ft-lb (35 Nm) Seat Base Frame Front 10 lb-ft (14 Nm) (M8) Fasteners 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 16 5 lb-ft (7 Nm) Mounting Bolts Step 3 Engine / Transmission 44 lb-ft (60 Nm) Mounting Bolts Step 4–7 Intake Plenum Hose 17 lb-in (2 Nm) Clamps 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.10 © Copyright Polaris Industries Inc.
  • Page 17 Master Cylinder Mounting 22 lb-ft (30 Nm) Fasteners Tie Rod Jam Nut 15 lb-ft (20 Nm) Parking Brake Caliper 37 lb-ft (50 Nm) Fasteners (INTL) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.11 © Copyright Polaris Industries Inc.
  • Page 18 40 lb-ft (54 Nm) Fastener M10 x 1.5 x 55 Frame, Seat Base Rear 10 ft-lbs (14 Nm) Fastener M8 x 1.25 x 55 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.12 © Copyright Polaris Industries Inc.
  • Page 19 7 lb-ft (10 Nm) Speed Sensor 12 lb-ft (16 Nm) 7 lb-ft (10 Nm) Starter Motor Fasteners Tail Light Fasteners 4 lb-ft (5 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.13 © Copyright Polaris Industries Inc.

  • Page 20: Vehicle Identification

    The engine serial number can be found on a decal applied to the front of the engine crankcase (A) or stamped into the crankcase on the PTO side of the engine (B). Refer to Figure 1-2. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.14 © Copyright Polaris Industries Inc.

  • Page 21: Vehicle Specifications

    Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.15 © Copyright Polaris Industries Inc.

  • Page 22: 2016 Polaris General Specifications

    5.44 Qt (5.1 L) 12.25 in (31 cm) Front Travel Independent Dual A-Arm Rear Suspension FUEL SYSTEM Polaris 2.0 in / FOX™ 2.5 in Type 13.25 in (33.7 cm) Bosch ME17 EFI Rear Travel Fuel Delivery Electronic Fuel Pump (in-tank)

  • Page 23: 2017 Polaris General

    Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.17 © Copyright Polaris Industries Inc.
  • Page 24 12.25 in (31 cm) Front Travel Oil Capacity 2.5 Qt (2.4 L) Independent Dual A-Arm Rear Suspension Polaris 2.0 in / FOX™ 2.5 in Coolant Capacity 5.44 Qt (5.1 L) 13.25 in (33.7 cm) Rear Travel Spring Adjustment Threaded Spanner Wrench...

  • Page 25: 2017 Polaris General

    Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.19 © Copyright Polaris Industries Inc.
  • Page 26 GENERAL INFORMATION 2017 POLARIS GENERAL 4 SPECIFICATIONS DRIVETRAIN ENGINE Reverse 4-Stroke, DOHC, Twin Cylinder Platform Front Drive Ratio 3.182:1 Engine Displacement 61 ci (999 cc) Front Gearcase Lubricant Demand Drive Fluid Number of Cylinders Requirement 8.5 oz (250 mL) Bore & Stroke 93 x 73.5 mm...
  • Page 27 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.21 © Copyright Polaris Industries Inc.
  • Page 28 Front Travel Wet Sump Lubrication Independent Dual A-Arm Oil Requirements PS-4 5W-50 Full Synthetic Rear Suspension Polaris 2.0 in / FOX™ 2.5 in Oil Capacity 2.5 Qt (2.4 L) 13.25 in (33.7 cm) Rear Travel Coolant Capacity 5.36 Qt (5.0 L)
  • Page 29 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 2000 lb / 907 kg 150 lb / 68 kg Hitch Tongue Capacity 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.23 © Copyright Polaris Industries Inc.
  • Page 30 5A Brake Light 1800-3700 M 29-59 Black / White 20A Accessory Fuses 7044505 (6000-12000 Ft) (5633319) (7044465) 10A Drive 10A Lights 20A EPS (if appl.) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.24 © Copyright Polaris Industries Inc.

  • Page 31: 2018 Polaris General Overview (Intl)

    GENERAL INFORMATION 2018 POLARIS GENERAL OVERVIEW (INTL) CATEGORY DIMENSION / CAPACITY Length 116 in / 295 cm Width 63 in / 160 cm Height 76 in / 193 cm Wheel Base 81 in / 206 cm Ground Clearance 12 in / 30.5 cm...

  • Page 32: 2018 Polaris General Specifications (Intl)

    12.25 in (31 cm) Lubrication Front Travel Independent Dual A-Arm Oil Requirements PS-4 5W-50 Full Synthetic Rear Suspension Polaris 2.0 in / FOX™ 2.5 in Oil Capacity 2.5 Qt (2.4 L) 13.25 in (33.7 cm) Rear Travel Coolant Capacity 5.36 Qt (5.0 L)
  • Page 33 GENERAL INFORMATION 2018 POLARIS GENERAL EU OVERVIEW (INTL) CATEGORY DIMENSION / CAPACITY Length 116 in / 295 cm Width 63 in / 160 cm Height 76 in / 193 cm Wheel Base 81 in / 206 cm Ground Clearance 12 in / 30.5 cm...
  • Page 34 5.36 Qt (5.0 L) 12.25 in (31 cm) Front Travel Independent Dual A-Arm Rear Suspension FUEL SYSTEM Polaris 2.0 in / FOX™ 2.5 in Type Bosch ME17 EFI 13.25 in (33.7 cm) Rear Travel Fuel Delivery Electronic Fuel Pump (in-tank)
  • Page 35 Maximum Weight Capacity (Includes riders, cargo and (Payload) accessories) Hitch Towing Capacity 2000 lb / 907 kg Hitch Tongue Capacity 150 lb / 68 kg 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.29 © Copyright Polaris Industries Inc.
  • Page 36 Front Travel Wet Sump Lubrication Independent Dual A-Arm Oil Requirements PS-4 5W-50 Full Synthetic Rear Suspension Polaris 2.0 in / FOX™ 2.5 in Oil Capacity 2.5 Qt (2.4 L) 13.25 in (33.7 cm) Rear Travel Coolant Capacity 5.36 Qt (5.0 L)
  • Page 37 GENERAL INFORMATION 2019 POLARIS GENERAL 4 OVERVIEW CATEGORY DIMENSION / CAPACITY Length 150 in / 382 cm Width 63 in / 160 cm Height 76 in / 193 cm Wheel Base 113 in / 287 cm Ground Clearance 12 in / 30.5 cm...
  • Page 38 5A Brake Light 1800-3700 M 29-59 Black / White 20A Accessory Fuses 7044505 (6000-12000 Ft) (5633319) (7044465) 10A Drive 10A Lights 20A EPS (if appl.) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.32 © Copyright Polaris Industries Inc.

  • Page 39: Misc Specifications And Charts

    π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.33 © Copyright Polaris Industries Inc.

  • Page 40: Sae Tap / Drill Sizes

    1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.34 © Copyright Polaris Industries Inc.

  • Page 41: Decimal Equivalents

    0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.35 © Copyright Polaris Industries Inc.
  • Page 42 GENERAL INFORMATION NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 1.36 © Copyright Polaris Industries Inc.
  • Page 43 PVT SYSTEM MAINTENANCE ............... . .2.28 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 44 ............... . .2.44 THROTTLE PEDAL INSPECTION 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 45: Maintenance

    TORQUE SPECIFICATIONS - MAINTENANCE Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for TORQUE replacement parts, use genuine Polaris parts available PART DESCRIPTION SPECIFICATION from your Polaris dealer. Inspection, adjustment and lubrication of important...

  • Page 46: Service Specifications - Maintenance

    AGL Gearcase Lubricant Brake Fluid DOT 4 Grease Fittings Premium All-Season Grease U-Joint Lubricant Premium U-Joint Lubricant 87 Octane (minimum) 9.5 Gal (36 L) Fuel 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 47: Periodic Maintenance

    Improperly performing the procedures marked ■ could cause or see your dealer. result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual...

  • Page 48: Pre-Ride Inspection

    • Verify coolant level is filled to the FULL COLD mark on Coolant Level coolant reservoir (if engine is cold) • Inspect hoses and radiator for leaks Auxiliary Brake (if equipped) Inspect / adjust as needed 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 49 Inspect / clean often Power Steering Unit Inspect / clean often Clean when driving in mud and water; replace a cracked Spark Arrester or damaged arrester before operating 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 50: Periodic Maintenance Chart

    500 (800) Inspect; clean external surfaces ▶ Radiator 50 H 1000 Engine Oil Lines/Fasteners Inspect for leaks and loose fittings ▶ 50 H (1600) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 51 Inspect; adjust as needed Valve Clearance (8000) Replace coolant ▶ Coolant 60 M Inspect periodically; adjust when parts are ■ Toe Adjustment replaced Headlight Aim Adjust as needed 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 52: Maintenance Quick Reference

    - Under Front Hood / Access Panel Coolant bottle * More often under severe use, such as operation in water or under severe loads. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.10 © Copyright Polaris Industries Inc.
  • Page 53 Add lubricant until it is visible at first Transmission Polaris AGL the fill hole threads * More often under severe use, such as operation in water or under severe loads. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.11 © Copyright Polaris Industries Inc.

  • Page 54: Grease Lubrication Points

    Propshaft Yokes Premium U-Joint Lubricant fittings submerging the vehicle Propshaft Yokes Grease middle and rear Premium U-Joint Lubricant (GENERAL 4) fittings 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.12 © Copyright Polaris Industries Inc.

  • Page 55: Maintenance Lubricants

    50/50 EL Anti-Free (Gal) (4 count) 2880513 50/50 EL Anti-Free (55 Gal Drum) 2880512 NOTICE Each item can be purchased separately at your local Polaris dealer. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.13 © Copyright Polaris Industries Inc.

  • Page 56: General Vehicle Inspection And Maintenance

    7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.14 © Copyright Polaris Industries Inc.

  • Page 57: Heat Shield Inspection

    Chassis Heat Shield Box Heat Shield Headpipe Heat Shield Silencer Outer Heat Shield, Elbow Midpipe Heat Shield Silencer Heat Shield, Main 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.15 © Copyright Polaris Industries Inc.

  • Page 58: Engine Maintenance

    Lower the cargo box and secure in position. dipstick tube to keep the depth of the dipstick consistent. 5. Remove the dipstick and check the oil level. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.16 © Copyright Polaris Industries Inc.

  • Page 59: Engine Oil And Filter Change

    Component Installation”page 10.50 procedure. 16. Dispose of used oil and filter properly. 6. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.17 © Copyright Polaris Industries Inc.

  • Page 60: Engine Crankcase Breather Hose Inspection

    1. Remove the driver’s seat and access panel. Disconnect the negative (-) battery cable. 2. Remove eight screws retaining the outer clutch cover. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.18 © Copyright Polaris Industries Inc.
  • Page 61 16. Connect the negative (-) battery cable to the battery, access panel, and install the seat. 17. Start the engine to ensure proper operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.19 © Copyright Polaris Industries Inc.

  • Page 62: Cam Chain Tensioner Inspection

    It should move freely. If it does not move freely, replace the tensioner assembly. 5. Retract the plunger all the way in and install into the cylinder. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.20 © Copyright Polaris Industries Inc.

  • Page 63: Cooling System Maintenance

    Overheating of engine could occur if air is not fully purged from system. Polaris Premium 50/50 Antifreeze is premixed and ready to use. Do not dilute with water. With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle.

  • Page 64: Cooling System Hoses

    3. Check tightness and condition of all hose spring clamps. Replace if necessary. Recovery Bottle Engine Hoses Radiator Hoses To Thermostat Housing To Water Pump To Radiator 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.22 © Copyright Polaris Industries Inc.

  • Page 65: Radiator Inspection / Cleaning

    MAX level. Refer to “Cooling System Bleeding”page 3.94 procedure. Recommended Coolant: 50 / 50 Extended Life Antifreeze 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.23 © Copyright Polaris Industries Inc.

  • Page 66: Fuel System And Air Intake Maintenance

    NOTICE damage, or leakage. Replace line(s) if necessary. Ensure all lines are not kinked or pinched. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.24 © Copyright Polaris Industries Inc.

  • Page 67: Fuel Pump / Fuel Filters

    EFI system. 3. The engine uses a high-volume, high-pressure, fuel pump that includes a preliminary pickup filter an internal filter located before the pump regulator. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.25 © Copyright Polaris Industries Inc.

  • Page 68: Fuel Tank Vent Line

    3. Be sure the vent line is routed properly and secured with appropriate retention components. NOTICE Ensure vent line is not kinked or pinched. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.26 © Copyright Polaris Industries Inc.

  • Page 69: Intake Duct Drain Inspection

    Be sure the lower tabs on the air box cover are properly engaged into the airbox. 6. Install the cover and engage the cover latches. 7. Lower the cargo box and secure in position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.27 © Copyright Polaris Industries Inc.

  • Page 70: Pvt System Maintenance

    PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.28 © Copyright Polaris Industries Inc.

  • Page 71: Transmission And Front Gearcase Maintenance

    Transmission Fill / Drain Plug Torque: Transmission Fill / Drain Plug Torque: 14 lb-ft (19 Nm) 14 lb-ft (19 Nm) 8. Check for leaks. Dispose of used lubricant properly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.29 © Copyright Polaris Industries Inc.

  • Page 72: Front Gearcase Lubrication

    10 lb-ft (14 Nm) Front Gearcase Fill / Drain Plug Torque: 10 lb-ft (14 Nm) 8. Check for leaks. Dispose of used fluid properly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.30 © Copyright Polaris Industries Inc.

  • Page 73: Final Drive Maintenance

    3. Attach the wheel nuts and finger tighten them. 4. Carefully lower the vehicle to the ground. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.31 © Copyright Polaris Industries Inc.

  • Page 74: Tire Inspection

    Failure to use specified tire and wheel specifications will effect vehicle handling and cause an ABS failure. • Ensure wheels are balanced to prevent an ABS failure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.32 © Copyright Polaris Industries Inc.

  • Page 75: Steering Maintenance

    • Steering Gearbox WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.33...

  • Page 76: Tie Rod End / Wheel Hub Inspection

    Position chalk marks facing rearward, even with the wheel nuts or loose front hub nut). Refer to Final hub/axle center line. Drive chapter for service procedures. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.34 © Copyright Polaris Industries Inc.

  • Page 77: Wheel Toe Adjustment

    To adjust toe alignment: 1. Hold tie rod end to keep it from rotating. 2. Loosen jam nuts at both end of the tie rod. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.35 © Copyright Polaris Industries Inc.

  • Page 78: Suspension Maintenance

    SPRING ADJUSTMENT - FACTORY SETTING FRONT REAR 6.625 in (16.828 cm) 1.625 in (4.128 cm) NOTICE Models with base suspension use softest setting for factory setting. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.36 © Copyright Polaris Industries Inc.

  • Page 79: Spring Adjustment - General 4

    The DAMPING increased suspension height will negatively impact Softest Position 1 vehicle stability when operating without a load. Factory Position 2 Firmest Position 3 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.37 © Copyright Polaris Industries Inc.

  • Page 80: Brake System Maintenance

    MEASUREMENT Brake Disc Thickness Service Limit 0.170 (4.32 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.38 © Copyright Polaris Industries Inc.

  • Page 81: Parking Brake Inspection (Intl)

    After 8 full clicks of lever travel, the vehicle should not roll while parked. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.39 © Copyright Polaris Industries Inc.
  • Page 82 MAINTENANCE 10. If additional adjustment is needed, the cable can be adjust on the parking brake handle side jam nut 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.40 © Copyright Polaris Industries Inc.

  • Page 83: Electrical Maintenance

    10-30% of full potential. Charge battery according to “Battery Charging Procedure”page 11.55. Do not use the vehicle’s stator/alternator to charge a new battery. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.41 © Copyright Polaris Industries Inc.

  • Page 84: Battery Removal (Intl)

    1. Place the battery in the battery holder and secure with hold-down strap. Torque fastener specification. TORQUE Battery Bracket: 3.5 lb-ft (5 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.42 © Copyright Polaris Industries Inc.

  • Page 85: Engine / Chassis Electrical Ground

    5. Remove spark plugs using spark plug socket with an extension. 2. Inspect the chassis ground terminals. Be sure the grounds are clean and tight. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.43 © Copyright Polaris Industries Inc.

  • Page 86: Throttle Pedal Inspection

    Ensure wires are pushed down all the way so they engage onto the spark plugs. 13. Lower the cargo box and secure in position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 2.44 © Copyright Polaris Industries Inc.
  • Page 87 ............3.45 STATOR COVER REMOVAL / INSPECTION 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 88 ............3.90 ENGINE COOLING SYSTEM SPECIFICATIONS 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 89 ..................3.101 COOLING SYSTEM 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 90: General Information - Engine

    • Oil Pump / Oil Pump Sprocket or Chain Piston Ring Compressor Pliers PV-43570-1 • Piston / Rings Water Pump Mechanical Seal PU-50564 Installer Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 91: Torque Specifications - Engine / Cooling System

    Oil Pump Mounting Bolts 7 lb-ft (10 Nm) Oil Pump Pick-Up Retaining 7 lb-ft (10 Nm) Screws Oil Sump Cover Bolts (M8) 26 lb-ft (35 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 92: Service Specifications - Engine / Cooling System

    Valve Seat - Contacting Width - Exhaust .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm) Valve Seat 30.0° ± 1.5° Valve Seat Angles 45.0° ± 0.5° 60.0° ± 1.5° 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 93 Ambient Temp Range: -35° F to 100° F PS-4 10W-40 Extreme Duty Full Synthetic Ambient Temp Range: 0° F to 120° F Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature) 10 PSI (69 kPa) @ 1200 RPM 40 PSI (276 kPa) @ 7000 RPM *Additional oil may be required after complete engine disassembly.

  • Page 94: Assembly Views - Engine

    ENGINE / COOLING SYSTEM ASSEMBLY VIEWS - ENGINE MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE Cam Carrier 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 95 ENGINE / COOLING SYSTEM Crankcase Split-Line (Bottom) Crankcase Split-Line (Top) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 96 ENGINE / COOLING SYSTEM Cylinder Head Sump Cover 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.10 © Copyright Polaris Industries Inc.
  • Page 97 ENGINE / COOLING SYSTEM Stator Cover 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.11 © Copyright Polaris Industries Inc.

  • Page 98: Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons

    ENGINE / COOLING SYSTEM BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.12 © Copyright Polaris Industries Inc.

  • Page 99: Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump

    ENGINE / COOLING SYSTEM CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.13 © Copyright Polaris Industries Inc.

  • Page 100: Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

    ENGINE / COOLING SYSTEM CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.14 © Copyright Polaris Industries Inc.

  • Page 101: Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover

    ENGINE / COOLING SYSTEM SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.15 © Copyright Polaris Industries Inc.

  • Page 102: Exhaust System Assembly View (2016-2018)

    Headpipe fasteners, 18 lb-ft (24 Nm) Double Spherical Gasket Oxygen Sensor, 13 lb-ft (18 Nm) Exhaust Spring Isolator Mount Exhaust Stud, 21 lb-ft (28 Nm) Spring Silencer 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.16 © Copyright Polaris Industries Inc.

  • Page 103: Exhaust System Assembly View (2019)

    Headpipe fasteners, 18 lb-ft (24 Nm) Double Spherical Gasket Oxygen Sensor, 13 lb-ft (18 Nm) Exhaust Spring Isolator Mount Exhaust Stud, 21 lb-ft (28 Nm) Spring Silencer 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.17 © Copyright Polaris Industries Inc.

  • Page 104: Exhaust System Assembly View (Intl)

    Headpipe fasteners, 18 lb-ft (24 Nm) Double Spherical Gasket Oxygen Sensor, 13 lb-ft (18 Nm) Exhaust Spring Isolator Mount Exhaust Stud, 21 lb-ft (28 Nm) Spring Silencer 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.18 © Copyright Polaris Industries Inc.

  • Page 105: Engine Service

    Lower the cargo box and secure in position. dipstick tube to keep the depth of the dipstick consistent. 5. Remove the dipstick and check the oil level. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.19 © Copyright Polaris Industries Inc.

  • Page 106: Engine Oil And Filter Change

    Component Installation”page 10.50 procedure. 16. Dispose of used oil and filter properly. 6. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.20 © Copyright Polaris Industries Inc.

  • Page 107: Engine Crankcase Breather Hose Inspection

    1. Remove the driver’s seat and access panel. Disconnect the negative (-) battery cable. 2. Remove eight screws retaining the outer clutch cover. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.21 © Copyright Polaris Industries Inc.
  • Page 108 16. Connect the negative (-) battery cable to the battery, access panel, and install the seat. 17. Start the engine to ensure proper operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.22 © Copyright Polaris Industries Inc.

  • Page 109: Top End Service (Engine In Chassis)

    To service the top-end of the engine refer to “Valve Clearance Inspection”page 3.21, which provides detailed steps to access the valve cover. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.23 © Copyright Polaris Industries Inc.

  • Page 110: Crankshaft Pto Seal Replacement

    3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.24 © Copyright Polaris Industries Inc.
  • Page 111 5. Field test the vehicle before putting back into service. Inspect for any leaks. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.25 © Copyright Polaris Industries Inc.

  • Page 112: Engine Removal

    14. Disconnect fuel lines and remove throttle body and air inlet assembly. Refer “Fuel Line Replacement”page procedure. Make note of line routing for installation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.26 © Copyright Polaris Industries Inc.
  • Page 113 Remove exhaust head pipe towards the front of the vehicle. Discard exhaust gaskets NOTICE It is not necessary to remove the bolts that retain the bracket to the transmission. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.27 © Copyright Polaris Industries Inc.
  • Page 114 • Sleeve adapter for a 2″ bore engine stand: (PU-50625) • Sleeve adapter for a 2.375″ bore engine stand: (PW-47054) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.28 © Copyright Polaris Industries Inc.

  • Page 115: Engine Installation

    6. Align transmission joint mounting holes with the transmission front mounting holes. TORQUE Starter Motor Bolts: 7 lb-ft (10 Nm) Trans Joint Bracket Bolts: 44 lb-ft (60 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.29 © Copyright Polaris Industries Inc.
  • Page 116 Hand tighten the bolts so they remain loose at this time. NOTICE DO NOT torque fasteners at this time. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.30 © Copyright Polaris Industries Inc.
  • Page 117 15. Remove the lifting straps and overhead or portable / coolant. engine hoist. 16. Install the two coolant hoses onto the engine. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.31 © Copyright Polaris Industries Inc.

  • Page 118: Engine Break-In Period

    Test results are based on the use of the recommended idle or sustained high speed. engine oil (Polaris PS-4 or PS-4 Extreme Duty) at 5. Perform regular checks on fluid levels, controls and operating temperature, and may vary considerably if all important bolt torques.
  • Page 119 6. Upon assembly, torque the crankcase gallery plug to specification. TORQUE Crankcase Oil Gallery Plug (M20): 22 ft-lbs (30 Nm) TORQUE Crankcase Oil Gallery Plug (1/2 NPT): 16 ft-lbs (22 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.33 © Copyright Polaris Industries Inc.

  • Page 120: Engine Oil Flow Chart

    ENGINE / COOLING SYSTEM ENGINE OIL FLOW CHART 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.34 © Copyright Polaris Industries Inc.

  • Page 121: Engine Disassembly / Inspection - Top End

    3. Remove the two bolts retaining the fixed cam chain and the slots on the end of the camshafts should guide and remove the assembly from the engine. line up. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.35 © Copyright Polaris Industries Inc.

  • Page 122: Camshaft Sprocket Inspection

    NOTICE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.36 © Copyright Polaris Industries Inc.

  • Page 123: Camshaft / Camshaft Bore Inspection (1000)

    Service Limit: 1.5122" (38.41 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.37 © Copyright Polaris Industries Inc.

  • Page 124: Cylinder Head Removal

    .0000 - .0026" (0.001 - 0.067 mm) without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Service Limit: Removalpage 3.55. .0039" (0.1 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.38 © Copyright Polaris Industries Inc.

  • Page 125: Cylinder Head Warp Inspection

    1. Remove the valve tappet from the cylinder head. Note the tappet size engraved on the underside of the bucket. MEASUREMENT Cylinder Head Warp Limit: .0039″ (0.1 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.39 © Copyright Polaris Industries Inc.

  • Page 126: Valve Inspection

    8. Clean the combustion chamber and head gasket surface. 9. Check the condition of each valve spring. Replace if wear or cracking is present on the spring. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.40 © Copyright Polaris Industries Inc.

  • Page 127: Combustion Chamber Cleaning

    .2165 - .2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.41 © Copyright Polaris Industries Inc.

  • Page 128: Valve Sealing Test

    If seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.42 © Copyright Polaris Industries Inc.
  • Page 129 Look for an even and continuous contact Exhaust Seat Cutter Diameter: 1.364″ (34.65 mm) point all the way around the valve face 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.43 © Copyright Polaris Industries Inc.
  • Page 130 12. Thoroughly clean cylinder head and valves. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.44 © Copyright Polaris Industries Inc.

  • Page 131: Engine Disassembly / Inspection - Bottom End

    3. Inspect the condition of the stator windings output wires . If replacement is required, refer to the Electrical chapter. 4. Inspect the ball bearing that supports the starter motor shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.45 © Copyright Polaris Industries Inc.

  • Page 132: Water Pump Housing Removal

    Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.46 © Copyright Polaris Industries Inc.

  • Page 133: Starter One-Way Clutch Disassembly

    Grasp clutch gear and rotate clockwise. It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.47 © Copyright Polaris Industries Inc.

  • Page 134: Crankcase Disassembly / Inspection

    M8 bolts CRANKCASE DISASSEMBLY / INSPECTION retaining the sump cover to the crankcase. 1. Remove the four screws retaining the oil cooler the crankcase. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.48 © Copyright Polaris Industries Inc.
  • Page 135 If unable to extract the dowel pins from the oil pump, the oil pump sprocket must be removed. Access the sprocket bolt by removing the case plug. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.49 © Copyright Polaris Industries Inc.

  • Page 136: Balance Shaft Removal / Inspection

    Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.50 © Copyright Polaris Industries Inc.

  • Page 137: Crankshaft Removal / Inspection

    . Remove the end caps from the crankshaft. 8. If the crankshaft gear or sprocket is damaged, the crankshaft assembly must be replaced. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.51 © Copyright Polaris Industries Inc.
  • Page 138 If worn past the service limit, replace the crankshaft assembly. CRANKSHAFT BEARING JOURNAL DIAMETERS 1.6140 - 1.6143" Main (40.996 - 41.004 Standard Bearing 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.52 © Copyright Polaris Industries Inc.

  • Page 139: Crankcase Inspection

    14. Whether installing a new crankshaft or re-installing the original, refer to the bearing selection chart provided Crankshaft Main Bearing Selectionpage 3.61 and Connecting Rod Bearing Selectionpage 3.61 procedures. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.53 © Copyright Polaris Industries Inc.

  • Page 140: Cylinder Inspection

    .002″ (0.05 mm) Inspect cylinder for wear, scratches, or damage. NOTICE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.54 © Copyright Polaris Industries Inc.

  • Page 141: Cylinder / Piston Removal

    1. Note location of the piston circlip gap at the top (12:00 position) or bottom (6:00 position). 4. Carefully lift the cylinder and pistons from the upper crankcase. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.55 © Copyright Polaris Industries Inc.

  • Page 142: Piston Ring Removal

    Do not scratch ring lands. MEASUREMENT Piston Pin Bore I.D.: .7877 - .7881" (20.009 - 20.018 mm) Service Limit: .7893" (20.05 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.56 © Copyright Polaris Industries Inc.

  • Page 143: Piston Ring To Groove Clearance Inspection

    Oil Control Rails: .008 - .028" (0.20 - 0.70 mm) Service Limit: .0354" (0.9 mm) NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.57 © Copyright Polaris Industries Inc.

  • Page 144: Piston-To-Cylinder Clearance

    5. Install matching rod cap on connecting rod (without bearings) and install the bolts. 6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm). 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.58 © Copyright Polaris Industries Inc.
  • Page 145 44.010 mm) 10. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided Connecting Bearing Selectionpage 3.61 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.59 © Copyright Polaris Industries Inc.

  • Page 146: Engine Assembly - Bottom End

    *Some engines may only have 4 digits. The extra two digits will refer to the balance shaft bearings which should now all be standard. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.60 © Copyright Polaris Industries Inc.

  • Page 147: Connecting Rod Bearing Selection

    Bearing Selection Chart — Main Bearings Blue Green Yellow Crankshaft Green Yellow Yellow Code Blue Blue Green Case Blue Green Yellow Green Yellow Yellow 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.61 © Copyright Polaris Industries Inc.

  • Page 148: Upper Crankcase Preparation

    NOTICE Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.62 © Copyright Polaris Industries Inc.
  • Page 149 4. Install second ring with marking facing top of piston. Rotate ring to position the end gap toward intake side of piston as shown below. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.63 © Copyright Polaris Industries Inc.

  • Page 150: Piston / Connecting Rod Assembly

    (there is no piston pin offset in the rod), however it is recommended they be installed with rods facing the same direction. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.64 © Copyright Polaris Industries Inc.

  • Page 151: Cylinder / Piston Installation

    9. Verify piston orientation (arrow pointing toward exhaust) one last time prior to installation. NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.65 © Copyright Polaris Industries Inc.

  • Page 152: Crankshaft Installation

    (PU-50563) onto the cylinder. The cylinder holding 5. Install oil drain diverter into the upper crankcase. tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each rod bearing journal and main bearing journal of crankshaft. CRANKSHAFT INSTALLATION...

  • Page 153: Balance Shaft Installation

    ENGINE / COOLING SYSTEM 8. Apply Polaris PS-4 engine oil to the new crankshaft 13. Install new bolts and tighten evenly until snug. oil seal and install the seal on the PTO end of the crankshaft. 14. Torque connecting rod bolts to specification.

  • Page 154: Lower Crankcase Preparation

    ENGINE / COOLING SYSTEM 3. Apply Polaris PS-4 engine oil to both balance shaft 5. Refer to Engine Oil Flow Chartpage 3.34 at the journals beginning of this chapter and trace the oil paths through the crankcase and cylinder. 6. Flush all oil passages with solvent and then warm soapy water.
  • Page 155 12. Install the eleven M6 and two M8 upper crankcase bolts. Tighten all bolts lightly by hand. NOTICE Install new M10 lower crankcase bolts. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.69 © Copyright Polaris Industries Inc.
  • Page 156 NOTICE Gasket surfaces must be DRY and oil free. Use care upon assembly to keep oil away. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.70 © Copyright Polaris Industries Inc.
  • Page 157 TORQUE Oil Cooler bolts: 7 ft-lbs (10 Nm) 27. Proceed to Flywheel Installationpage 3.72 and then Cylinder Head Installationpage 3.75. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.71 © Copyright Polaris Industries Inc.

  • Page 158: Starter One-Way Clutch Assembly

    6. After assembly, be sure the starter gear rotates in the Loctite cures with time, the longer the unit is let stand clockwise direction only. before engine starting the better the joint will be. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.72 © Copyright Polaris Industries Inc.

  • Page 159: Stator Cover Installation

    / installation process or injury could result. 3. Install stator cover and thirteen screws. Torque screws in sequence to specification. TORQUE Stator Cover Screws: 9 ft-lb (12 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.73 © Copyright Polaris Industries Inc.

  • Page 160: Engine Assembly - Top End

    9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.74 © Copyright Polaris Industries Inc.

  • Page 161: Cylinder Head Installation

    5. Carefully set the cylinder head in place on alignment pins. 6. Install new bolts and finger tighten the six cylinder head bolts evenly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.75 © Copyright Polaris Industries Inc.

  • Page 162: Camshaft Installation / Timing

    3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head.
  • Page 163 “E” marks aligned with gasket surface. Install the exhaust cam sprocket first (opposite the cam chain tensioner) to ensure proper cam timing. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.77 © Copyright Polaris Industries Inc.
  • Page 164 18. Install the front camshaft carrier and two outer retaining bolts. 19. Install the fixed cam chain guide and two retaining bolts. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.78 © Copyright Polaris Industries Inc.
  • Page 165 Camshaft Carrier Bolts: • Install the two mounting bolts. Torque fasteners to 7 ft-lb (10 Nm) specification. 21. Apply Polaris PS-4 engine oil to the cam chain TORQUE tensioner bore prior to assembly. Use a new Tensioner Mounting Bolts: tensioner sealing washer 7 ft-lb (10 Nm) 22.

  • Page 166: Camshaft Timing - Quick Reference

    DO NOT use the “V” mark located on the flywheel opposite of the “I” mark. Only the “I” mark should be used as a TDC reference 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.80 © Copyright Polaris Industries Inc.

  • Page 167: Valve Clearance Adjustment

    2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes should face out as shown.

  • Page 168: Valve Cover Installation

    16. Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification. TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.82 © Copyright Polaris Industries Inc.

  • Page 169: Intake Valve Lash - Tappet Selection Matrix

    4 (i. e. 459 should be rounded to 460 since there is a 460 tappet). Available Tappets 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.83 © Copyright Polaris Industries Inc.

  • Page 170: Exhaust Valve Lash - Tappet Selection Matrix

    0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545 0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.84 © Copyright Polaris Industries Inc.

  • Page 171: Intake / Exhaust Service

    (2) holding the floor intake duct to the vehicle and remove from floor intake duct. 9. Remove the hood from the vehicle. Refer to “Hood Removal”page 10.25 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.85 © Copyright Polaris Industries Inc.

  • Page 172: Intake Installation

    3 lb-ft (4 Nm) Intake Duct Clamps: 3 lb-ft (4 Nm) 3. Install the hood onto the vehicle. Refer to “Hood Installation”page 10.56 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.86 © Copyright Polaris Industries Inc.

  • Page 173: Exhaust Removal

    49 lb-in (5.5 Nm) 10. Lower the cargo box and secure in position. 6. Remove the exhaust assembly out the RH side of the vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.87 © Copyright Polaris Industries Inc.

  • Page 174: Exhaust Installation

    3. Connect the oxygen sensor to the wiring harness. 4. If necessary, install the fasteners holding the headpipe silencer. Torque fasteners specification. TORQUE Exhaust Headpipe to Silencer Fasteners: 21 lb-lb (28 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.88 © Copyright Polaris Industries Inc.

  • Page 175: Cooling System Service

    Oil Cooler Outlet Hose Engine Hoses Pressure Cap Bypass Hose Lower Radiator Hose Upper Radiator Hose Water Pump Outlet Hose Fan Assembly Recovery Bottle 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.89 © Copyright Polaris Industries Inc.

  • Page 176: Engine Cooling System Specifications

    Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

  • Page 177: Cooling System Pressure Cap Test

    3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification. TORQUE Coolant Hose Mounting Bracket Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.91 © Copyright Polaris Industries Inc.

  • Page 178: Radiator Replacement

    Lower Radiator Hose Fan Motor Assembly Recovery Bottle Radiator 4. Disconnect cooling fan electrical connector. 5. Remove the upper radiator hose from the radiator. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.92 © Copyright Polaris Industries Inc.

  • Page 179: Thermostat Replacement

    7. Using an 8 mm swivel socket and long extension, remove the front bolt retaining the thermostat 11. Be sure to properly fill and bleed cooling system as cover. outlined in this chapter. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.93 © Copyright Polaris Industries Inc.

  • Page 180: Cooling System Bleeding

    (see CAUTION). to the MAX line. 10. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck. 11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

  • Page 181: Water Pump Removal

    14. Plug the water pump drive access hole in the engine block with a clean shop towel. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.95 © Copyright Polaris Industries Inc.
  • Page 182 16. Install the hood, engine service panel and seats. NOTICE Install different bolt lengths as shown. TORQUE Water Pump Mounting Bolts: 7 lb-ft (10 Nm) (Apply Loctite® 204™ to bolt threads) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.96 © Copyright Polaris Industries Inc.

  • Page 183: Water Pump Service

    13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure. 5. Remove impeller from water pump shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.97 © Copyright Polaris Industries Inc.
  • Page 184 7 lb-ft (10 Nm) (Apply Loctite® 204™ to bolt threads) 18. Clean cover and housing gasket surfaces 19. Install a new water pump cover gasket 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.98 © Copyright Polaris Industries Inc.
  • Page 185 ENGINE / COOLING SYSTEM Water Pump Assembly View Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.99 © Copyright Polaris Industries Inc.

  • Page 186: Troubleshooting - Engine / Cooling System

    Engine Idles But Will Not Accelerate • Air filter dirty or contaminated • Spark plug fouled/weak spark Low Compression • Broken throttle cable • Obstruction in air intake 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.100 © Copyright Polaris Industries Inc.
  • Page 187 • Thermostat stuck open Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.101 © Copyright Polaris Industries Inc.
  • Page 188 ENGINE / COOLING SYSTEM NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 3.102 © Copyright Polaris Industries Inc.
  • Page 189 ..............4.38 FUEL SYSTEM TROUBLESHOOTING 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 190: General Information - Fuel System

    • For the purpose of troubleshooting difficult running * Never drain the fuel system when the engine is hot. issues, a known-good ECU from another POLARIS of Severe burns may result. the same model and year may be used without damaging system or engine components.

  • Page 191: Special Tools - Fuel System

    70 lb-ft (95 Nm) Fuel Rail Mounting Bolts 3.5 lb-ft (5 Nm) Intake Plenum Hose 3 lb-ft (4 Nm) Clamps Lower Intake Plenum 22 lb-ft (30 Nm) Fastener 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 192: Assembly Views - Fuel System

    Fuel Tank Assembly Fuel Vent Line PFA Nut Fuel Feed Line Fuel Pump Cap Harness Clip Fuel Sender Routing Clip Fuel Vent Fuel Fill Neck 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 193: Evap Fuel System Assembly View

    Vent Rollover Valve Carbon Canister Filter Fastener Purge Valve to Throttle Body Line 2& Hinged Routing Clip Carbon Canister to Purge Valve Panduit Strap Line 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 194: Fuel Pump Assembly View

    FUEL SYSTEM FUEL PUMP ASSEMBLY VIEW Fuel Pump Fuel Level Sensor Fuel Pressure Regulator Float Arm Assembly Wire Harness Connector Pickup Filter 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 195: Evap System

    Fuel Cap: On EVAP equipped vehicles, the fuel cap will have a ratcheting style fuel cap with a tether. It is important to note that Polaris does not use an enhanced EVAP control system. This means the system does not detect a gross leak, or restrictions in the EVAP system such as a missing or loose fuel cap.

  • Page 196: Evap Conditions And Symptoms

    Excessive carbon monoxide emissions may be caused by any of the following: • Rich air/fuel mixture • Dirty air filter • Leaking fuel injectors • Fuel pressure too high/bad regulator 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 197: Carbon Canister Filter Replacement

    6. Installation is performed by reversing the removal procedure. procedure. TORQUE TORQUE Carbon Canister Fasteners: Carbon Canister Filter Fasteners: 72 in-lbs (8 Nm) 72 in-lbs (8 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 198: Purge Valve Replacement

    7. Installation is performed by reversing the removal procedure. 8. Reinstall rear lower close off panel and center council. Reference page 10.43 9. Reinstall seats. See page 10.56. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.10 © Copyright Polaris Industries Inc.

  • Page 199: Fuel Lines

    FUEL SYSTEM FUEL LINES FUEL LINE ROUTING Fuel Feed Line Routing Fuel Pump Assembly Harness Clip, Interlock Routing Clip Fuel Rail 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.11 © Copyright Polaris Industries Inc.
  • Page 200 FUEL SYSTEM Fuel Vent Line Routing Fuel Vent Routing Clip, Hinged Routing Clip Vent Line Termination Fitting Harness Clip, Interlock 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.12 © Copyright Polaris Industries Inc.
  • Page 201 FUEL SYSTEM FUEL LINE ROUTING - GENERAL 4 Fuel Feed Line Routing Routing Clip Harness Clip Fuel Rail Fitting 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.13 © Copyright Polaris Industries Inc.
  • Page 202 FUEL SYSTEM Fuel Vent Line Routing Routing Clip Harness Clip Routing Clip, Hinged Vent Termination Fitting 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.14 © Copyright Polaris Industries Inc.
  • Page 203 FUEL SYSTEM FUEL LINE ROUTING (EVAP MODELS) Fuel Feed Line Routing Fuel Pump Assembly Panduit Strap Routing Clip, Hinged Fuel Rail 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.15 © Copyright Polaris Industries Inc.
  • Page 204 FUEL SYSTEM Purge Line Routing 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.16 © Copyright Polaris Industries Inc.
  • Page 205 FUEL SYSTEM Fuel Vent Purge Valve Routing Clip, Hinged Panduit Strap Carbon Canister Throttle Body Panduit Strap 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.17 © Copyright Polaris Industries Inc.
  • Page 206 Fuel Vent Canister Filter Routing Clip, Hinged Panduit Strap Carbon Canister Routing Clip, Hinged Carbon Canister to Canister Filter 5/16” Hose Vent Line Termination Fitting 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.18 © Copyright Polaris Industries Inc.

  • Page 207: Fuel Line Routing - General 4

    FUEL SYSTEM FUEL LINE ROUTING - GENERAL 4 (EVAP MODELS) Fuel Feed Line Routing Fuel Pump Assembly Panduit Strap Routing Clip, Hinged Fuel Rail 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.19 © Copyright Polaris Industries Inc.
  • Page 208 FUEL SYSTEM Purge Line Routing 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.20 © Copyright Polaris Industries Inc.
  • Page 209 FUEL SYSTEM Fuel Vent Purge Valve Routing Clip, Hinged Panduit Strap Carbon Canister Throttle Body Panduit Strap 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.21 © Copyright Polaris Industries Inc.
  • Page 210 Fuel Vent Canister Filter Routing Clip, Hinged Panduit Strap Carbon Canister Routing Clip, Hinged Carbon Canister to Canister Filter 5/16” Hose Vent Line Termination Fitting 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.22 © Copyright Polaris Industries Inc.

  • Page 211: Vent Line Termination Fitting

    Screwdriver Method: 3. Remove quick connect from the fuel fitting. Hand Method: 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.23 © Copyright Polaris Industries Inc.
  • Page 212 4. Quick connect has been twisted from its original inserted position, or the connector has been 6. Remove quick connect from the fuel fitting. damaged. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.24 © Copyright Polaris Industries Inc.

  • Page 213: Fuel Injector

    2. Always lubricate NEW injector o-rings with clean, silicone-free motor oil. NOTICE Apply oil sparingly and avoid contaminating the pintle valve / jet surface and upper inlet port. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.25 © Copyright Polaris Industries Inc.

  • Page 214: Fuel Injector Troubleshooting

    NOTICE Take note of PTO and MAG fuel injector harness connectors before disconnecting them. The harness leads are marked with PTO and MAG identifiers. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.26 © Copyright Polaris Industries Inc.

  • Page 215: Fuel Injector Replacement

    5. Remove the driver’s seat and disconnect the negative injector and the MAG harness lead to the MAG injector battery cable. to ensure proper engine operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.27 © Copyright Polaris Industries Inc.
  • Page 216 5 mm Allen wrench. 11. Upon installation of the new fuel injectors, lightly lubricate the injector O-rings to aid installation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.28 © Copyright Polaris Industries Inc.
  • Page 217 20. Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks. 26. Lower the cargo box and secure in position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.29 © Copyright Polaris Industries Inc.

  • Page 218: Fuel Tank Service

    Verify the connector tabs snap back into place. 7. Be sure fuel line is routed and retained properly. 8. Ensure PFA cap is fully seated over PFA nut. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.30 © Copyright Polaris Industries Inc.
  • Page 219 Refer to “Interior Body Component Removal”page 10.35 procedure. 8. Remove the fasteners holding the seat base assembly to the vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.31 © Copyright Polaris Industries Inc.

  • Page 220: Fuel Tank Installation

    9. Install both seats and access panels. Test the fuel pump by turning the ignition key on and listening for the pump to activate. Check the fuel line fittings for leaks. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.32 © Copyright Polaris Industries Inc.

  • Page 221: Fuel Pump Service

    POSITION READING EMPTY position 450 Ω ± 5% FULL position 100 Ω ± 3% Measure between — the two pins 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.33 © Copyright Polaris Industries Inc.

  • Page 222: Fuel Pump Replacement

    Excessive debris in fuel tank may cause premature wear of fuel pump and/or clogging of internal fuel filters. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.34 © Copyright Polaris Industries Inc.
  • Page 223 A small amount of fuel may come out of the fuel lines or pump fitting. Properly drain fuel into a suitable container. 7. Disconnect the fuel pump electrical harness 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.35 © Copyright Polaris Industries Inc.
  • Page 224 Do not use water or any other chemicals to remove debris. WARNING Failure to align the orientation marks may lead to interferences with the fuel level float armand cause incorrect function. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.36 © Copyright Polaris Industries Inc.
  • Page 225 25. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 26. Install the passenger seat / storage box. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.37 © Copyright Polaris Industries Inc.

  • Page 226: Troubleshooting - Fuel System

    • Leaking injector (rich condition) • Belt dragging • Throttle stop screw tampering Symptom: Erratic Idle. • Throttle cable incorrectly adjusted • Air Leaks, dirty injector 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 4.38 © Copyright Polaris Industries Inc.
  • Page 227 .............5.31 DRIVEN CLUTCH SLIDER INSPECTION 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 228 ..............5.35 PVT SYSTEM TROUBLESHOOTING 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 229: General Information - Pvt System

    (initial vehicle movement), Bosch Automotive Service Solutions: 1-800-345-2233 clutch upshift and backshift. During the development of or http://polaris.service-solutions.com/ the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions SPECIAL SUPPLIES PART vehicle’s...

  • Page 230: Torque Specifications - Pvt System

    0.000-0.012 in (0.000-0.304 mm) Clearance Drive Clutch Shaft Diameter 1.3725-1.3712 in (34.8615-34.8488 1.3704 in (34.8088 mm) Vespel® Thrust Washer Thickness 0.030 in (0.76 mm) 0.025 in (0.64 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 231: Assembly Views - Pvt System

    Inner Clutch Cover Outer Clutch Cover Inner Cover Seal Outer Cover Screws Intake Duct Outer Cover Seal Inlet Hose Guard Plate Clutch Cover Drain Screw Outlet Hose 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 232: Drive Clutch Assembly View

    Nut, Jam Spacer, Clutch Short Spring, Clutch Bolt, Shoulder Cover, Bearing Weight, Shift Screw Nut, Flex Lock Washer Button, Clutch Screw Washer, Clutch Spider Roller 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 233 DRIVEN CLUTCH ASSEMBLY VIEW Shoulder Sleeve Flanged Bearing Ball Bearing Spring Roller Pin Retaining Ring Puck Thrust Washer Stationary Sheave Clutch Roller Spring Pin Spider Moveable Sheave Screw 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 234: Driven Clutch Assembly View

    Spring Shoulder Sleeve Bearing Spider Spring Pin Roller Slider Washer E-clip Slider Pin Stationary Sheave Helix (Cam) Helix Screws Moveable Sheave 48 in-lb (5 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 235: Pvt System Overview

    During the development of optimum engine RPM. At full throttle a perfectly matched the Polaris vehicle, the PVT system is matched first to the PVT system should hold engine RPM at the peak of the engine power curve; then to average riding conditions power curve.

  • Page 236: Pvt Break

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.10 © Copyright Polaris Industries Inc.

  • Page 237: Pvt System Overheating / Diagnosis

    CLUTCH DRIVE BELT & COVER RELATED occurs. ISSUES: DIAGNOSIS Clutch component inspection Clutch POSSIBLE should be performed by a Polaris SOLUTIONS / WHAT TO DO malfunction. MSD certified technician. CAUSES Fouled spark plugs, foreign Loading the...

  • Page 238: Pvt System Service

    2872085) to prevent damage to crankshaft. 13. Remove the seven bolts that retain inner clutch cover to engine and transmission. Remove inner clutch cover. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.12 © Copyright Polaris Industries Inc.

  • Page 239: Pvt Assembly

    12. Clean the end of the taper on the crankshaft and the tapered bore inside the drive clutch. 13. Install the drive clutch onto the engine. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.13 © Copyright Polaris Industries Inc.
  • Page 240 4.5 lb-ft (6 Nm) 18. Install inlet and outlet ducts and tighten hose clamps. 19. Install the left rear wheel. Refer to “Wheel Installation”page procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.14 © Copyright Polaris Industries Inc.

  • Page 241: Drive Belt Service

    Removal of left rear wheel or left rear shock is NOT necessary for belt replacement. 3. Mark the drive belt direction of rotation so that it can be installed in the same direction. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.15 © Copyright Polaris Industries Inc.

  • Page 242: Drive Belt Installation

    5-7 times to properly seat the belt in the driven clutch. 5. Install the outer clutch cover and eight screws. Torque screws to specification. TORQUE Outer Clutch Cover Screws: 4.5 lb-ft (6 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.16 © Copyright Polaris Industries Inc.

  • Page 243: Drive Clutch Service

    2 are not in alignment, the clutch will not be in balance and the assembly MUST be replaced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.17 © Copyright Polaris Industries Inc.

  • Page 244: Needle Bearing Inspection

    Check to see that spring coils are parallel to one another using a straight-edge. Distortion of the spring indicates stress fatigue, requiring replacement. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.18 © Copyright Polaris Industries Inc.

  • Page 245: Shift Weight Inspection

    A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Drive Clutch Roller Pin and Button Service”. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.19 © Copyright Polaris Industries Inc.

  • Page 246: Spider Removal

    Rollers, pins, thrust washers and buttons are not using Clutch Spider Removal / Installation Tool serviceable at the time of this publication. Spider Removal / Installation Tool: 2870341-A 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.20 © Copyright Polaris Industries Inc.

  • Page 247: Clutch Inspection

    3. Lift bearing and thrust washers off the shaft. Replace as an assembly if worn, damaged, or if operational problems were noted prior disassembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.21 © Copyright Polaris Industries Inc.

  • Page 248: Moveable Sheave Bushing Inspection

    Bushing Removal /Installation Tool P-90 Driven Clutch 5020631 Cover Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.22 © Copyright Polaris Industries Inc.
  • Page 249 3. Remove nut from puller rod and set aside. Moveable Sheave - Bushing Installation 12. Place main adapter on puller. 4. Install puller adapter from kit PN 2871226. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.23 © Copyright Polaris Industries Inc.

  • Page 250: Drive Clutch Assembly

    29. Remove bushing and bushing removal tool from puller. Discard bushing. Cover Bushing Installation 30. Apply Loctite® 648 evenly to bushing bore in the cover. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.24 © Copyright Polaris Industries Inc.
  • Page 251 Loctite® 7088™ Primer in 90° apart to the threads of the spider jamb nut. Install spider jam nut onto stationary shaft threads. Moveable Sheave Spider 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.25 © Copyright Polaris Industries Inc.
  • Page 252 10. Install the limiter spacer and the clutch spring CAUTION DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.26 © Copyright Polaris Industries Inc.

  • Page 253: Driven Clutch Service

    6. Test the vehicle to ensure proper operation. DRIVEN CLUTCH DISASSEMBLY Universal Clutch Compressor: PU-50518-A DISASSEMBLY 1. Remove driven clutch from the transmission input shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.27 © Copyright Polaris Industries Inc.
  • Page 254 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTICE Spring is compression only and has no torsional wind. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.28 © Copyright Polaris Industries Inc.

  • Page 255: Driven Clutch Assembly

    12. Inspect the sheaves for excessive wear or damage. 3. Install the spring pins to retain the slider pins. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.29 © Copyright Polaris Industries Inc.
  • Page 256 10. Install the drive clutch on the vehicle. See PVT 6. Align the X’s on the spider and moveable sheave. Assemblypage 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.30 © Copyright Polaris Industries Inc.

  • Page 257: Driven Clutch Service (Intl)

    3. Place the driven clutch (helix side up) into the Slider to Sheave Clearance Universal Clutch Compressor. Service Limit: 0.175″ (4.5 mm) Slider Width Service Limit: 0.975″ (24.8 mm) Universal Clutch Compressor: PU-50518-A 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.31 © Copyright Polaris Industries Inc.
  • Page 258 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTICE Spring is compression only and has no torsional wind. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.32 © Copyright Polaris Industries Inc.

  • Page 259: Driven Clutch Assembly

    1. Align the X’s on the moveable and stationary sheaves. 4. If removed, install the rollers , washers and E- clips onto the spider. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.33 © Copyright Polaris Industries Inc.
  • Page 260 CAUTION The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.34 © Copyright Polaris Industries Inc.

  • Page 261: Troubleshooting - Pvt System

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.35 © Copyright Polaris Industries Inc.
  • Page 262 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 5.36 © Copyright Polaris Industries Inc.
  • Page 263 .............6.40 TROUBLESHOOTING - TRANSMISSION 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 264: General Information - Transmission

    2871698 Rear Output Seal Driver (Part of 2871702 Kit) 2871699 Rear Driveshaft Seal (Part of 2871702 Kit) Guide Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 265: Assembly Views - Transmission

    TRANSMISSION ASSEMBLY VIEWS - TRANSMISSION TRANSMISSION ASSEMBLY VIEW 2016–2018 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 266 101. Planet Gear Bearing, Ball Dog, Engagement 102. Ring Gear, 53T Bearing, Ball Shift Dog, Park 104. Screw, M8 x 1.25 x 25 Bearing, Ball Gear, 46T 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 267: Transmission Assembly View (2019)

    28 ft-lbs (38 Nm) 14 ft-lbs (19 Nm) Bellcrank Nut Sector Cover Fastener (QTY 5) 10 ft-lbs (14 Nm) Park Plate Fastener (QTY 3) 9 ft-lbs (12 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 268: Transmission Vent Line 2017-2018

    The transmission vent line runs up towards the passenger frame rail and through an open section of the frame to a vent line termination fitting. Hose Clamp Vent Line Termination Fitting 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 269: Transmission Vent Line Routing / Retention 2019

    The vent line then routes upward toward the rear of the unit where it enters an open section of the frame where it terminates. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 270: Shift Cable Service

    (H) to the shift lever (D). Disconnect cable end from the lever. 5. Remove the retaining ring (J) and slide the shift lever (D) off the mounting bracket and out from the frame. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 271: Shift Cable Adjustment

    6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut (E) against the mount. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 272: Transmission Service

    ETC (B), fuel injectors (C), rear differential relay and solenoid (D). Remove the five plastic tie straps (E) retaining the harness to the intake plenum. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.10 © Copyright Polaris Industries Inc.
  • Page 273 Place a spacer or support between the vehicle frame and engine to hold the engine up in position while removing the transmission to engine mounting bolts. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.11 © Copyright Polaris Industries Inc.

  • Page 274: Transmission Installation

    4 to properly position the clutch out of the vehicle while using a hoist to prevent center distance. personal injury or damage to vehicle components. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.12 © Copyright Polaris Industries Inc.
  • Page 275 (D) to the engine on the right side. 9. Torque right side mounting bolts to specification using the numbered sequence shown. IMPORTANT DO NOT torque fasteners at this time. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.13 © Copyright Polaris Industries Inc.
  • Page 276 16. Install the fastener securing the bottom of the intake onto the bellcrank. Install the retaining clip (M). plenum to the rear transmission mount. Torque fastener to specification. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.14 © Copyright Polaris Industries Inc.
  • Page 277 Polaris AGL. Refer “Transmission Lubrication”page FLUID CAPACITY Recommended Transmission Lubricant: AGL (PN: 2878068) (Quart) Capacity: 41 oz. (1200 ml) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.15 © Copyright Polaris Industries Inc.

  • Page 278: Transmission Mounting Torque Values

    TRANSMISSION TRANSMISSION MOUNTING TORQUE VALUES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.16 © Copyright Polaris Industries Inc.

  • Page 279: Differential Operation

    This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.17 © Copyright Polaris Industries Inc.
  • Page 280 Female Gear Assembly Differential Cover Assembly Planetary Differential Assembly Fasteners Engagement Dog Bearing Shift Fork Retainer Fastener Torsion Spring Retainer Shift Fork Solenoid Spring Solenoid 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.18 © Copyright Polaris Industries Inc.

  • Page 281: Transmission Disassembly

    6. Remove the compression spring (H). CAUTION Do not pry on case sealing surfaces.Use only the designated pry points on the transmission. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.19 © Copyright Polaris Industries Inc.
  • Page 282 (U) on a clean surface for inspection. If disassembly is required, refer to “Gear Cluster Disassembly”page 6.21. 17. Slide engagement dog (X) off of shift fork guides. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.20 © Copyright Polaris Industries Inc.

  • Page 283: Gear Cluster Disassembly

    4. Tilt the two shafts towards each other and remove the silent chain from the two shafts. 20. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.21 © Copyright Polaris Industries Inc.

  • Page 284: Snorkel Shaft Removal / Disassembly

    CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.22 © Copyright Polaris Industries Inc.
  • Page 285 5. Use an arbor press to remove the snorkel tube from the snorkel shaft. 6. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.23 © Copyright Polaris Industries Inc.

  • Page 286: Planetary Differential Disassembly

    If bushing replacement is required, proceed to Planetary Differential Bushing Replacement”. 2. Remove the six screws retaining the differential cover and remove the cover. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.24 © Copyright Polaris Industries Inc.

  • Page 287: Planetary Differential Bushing Replacement

    7. Press the new bushing into the planet gear until it is flush on each end. Repeat this procedure for the remaining planet gears. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.25 © Copyright Polaris Industries Inc.
  • Page 288 14. Press the new bushing into the side gear until it bottoms out. 11. Install the bushing to the specified depth as shown. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.26 © Copyright Polaris Industries Inc.

  • Page 289: Planetary Differential Assembly

    4. Apply Loctite® 2760 to cover screws. corresponding grade. TORQUE Differential Cover Screws (8.8 Fastener): 18–22 lb-ft (24–30 Nm) TORQUE Differential Cover Screws (10.9 Fastener): 28 ft-lbs (38 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.27 © Copyright Polaris Industries Inc.

  • Page 290: Bevel Differential Disassembly (2019)

    Thrust washer 3. Remove ring gear , thrust washer , and output gear BEVEL DIFFERENTIAL ASSEMBLY (2019) 1. Thoroughly clean the differential components. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.28 © Copyright Polaris Industries Inc.
  • Page 291 Align the hole of the differential pin with the dowel pin When installing the ring gear, align with the mark made hole in the carrier. of the carrier during disassembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.29 © Copyright Polaris Industries Inc.
  • Page 292 TRANSMISSION 6. Install eight fasteners securing ring gear. TORQUE Ring Gear Fasteners: 28 ft-lbs (38 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.30 © Copyright Polaris Industries Inc.

  • Page 293: Gear / Shaft / Bearing Inspection

    TRANSMISSION GEAR / SHAFT / BEARING INSPECTION 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.31 © Copyright Polaris Industries Inc.

  • Page 294: Snorkel Gear Backlash Procedure

    Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.32 © Copyright Polaris Industries Inc.
  • Page 295 If you have a hard time seeing into the hole, insert a small Allen wrench, punch or screwdriver into the hole to feel when the notch is aligned with the hole. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.33 © Copyright Polaris Industries Inc.
  • Page 296 (4th notch). 15. Once the backlash is set, apply Loctite ® 242 to the threads and install the locking screw to secure the snorkel tube. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.34 © Copyright Polaris Industries Inc.

  • Page 297: Transmission Assembly

    Torque specification. TORQUE Shift Fork Screws: 17 lb-ft (23 Nm) 4. Slide engagement dog (U) onto retaining pins of shift fork. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.35 © Copyright Polaris Industries Inc.
  • Page 298 Be sure the shift forks are engaged into the engagement dogs. NOTICE Shift fork pins should be offset towards the input shaft as shown above. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.36 © Copyright Polaris Industries Inc.
  • Page 299 (.070" or 1.8 mm from outer face of bore). 12. Apply a continuous bead of Crankcase 3-Bond Sealant (PN: 2871557) to the left hand transmission mating surface. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.37 © Copyright Polaris Industries Inc.
  • Page 300 Install the shift shaft assembly and sector gear (11T) into the bushing pocket on the left side. Align the timing marks on the gears as shown. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.38 © Copyright Polaris Industries Inc.
  • Page 301 Install the nut and torque to specification. 26. Refer to Transmission Installationpage 6.12 to complete the repair. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.39 © Copyright Polaris Industries Inc.

  • Page 302: Troubleshooting - Transmission

    If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 6.40 © Copyright Polaris Industries Inc.
  • Page 303 ..............7.44 REAR BEARING REPLACEMENT 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 304 ..............7.57 FINAL DRIVE TROUBLESHOOTING 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 305: General Information - Final Drive

    Demand Drive Fluid Front Gearcase Fluid Front Gearcase Fluid 8.5 oz (250 mL) Capcity Front Gearcase Fluid PN 2877922 (Qt) Front Gearcase Fluid PN 2877923 (Qt) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 306: Assembly Views - Final Drive

    PROPSHAFT ASSEMBLY VIEW (2016–2017) Asm, Propshaft Front Asm, Bearing Flex Yoke, Pin Yoke, Slip U-Joint Bolt Yoke, Slip Pin, Spring Fitting U-Joint Asm, Propshaft Rear 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 307 PROPSHAFT ASSEMBLY VIEW - GENERAL 4 (2016–2017) Asm, Propshaft Front Yoke, Slip Asm, Propshaft Center Yoke, Pin Asm, Propshaft Rear Fitting U-Joint Asm, Bearing Flex 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 308: Propshaft Assembly View (2018-2019)

    FINAL DRIVE PROPSHAFT ASSEMBLY VIEW (2018–2019) Grease Fitting Fastener Asm, Prop Shaft, Rear Asm, Prop Shaft, Front Asm, Bearing Pin-Spring 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 309 PROPSHAFT ASSEMBLY VIEW — GENERAL 4 (2018–2019) Grease Fitting U-Joint Asm, Propshaft Rear Asm, Propshaft Center Asm, Bearing Flex Asm, Propshaft Front Fastener Pin, Spring Yoke, Slip 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 310: Drive Shaft Assembly View

    Kit, Boot Plunging Joint Circlip Clamp, Large Circlip REAR DRIVE SHAFT Asm, Rear Drive Shaft Boot Circlip Clamp, Small Kit, Boot Joint, Plunging Clamp, Large Circlip Grease 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 311: Drive Shaft Assembly View (Intl)

    FINAL DRIVE DRIVE SHAFT ASSEMBLY VIEW (INTL) FRONT DRIVE SHAFT (INTL) Outer Race Cage Clamp, Large Ball Kit, Boot ABS Ring Clamp, Small Circlip Shaft 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 312 FINAL DRIVE REAR DRIVE SHAFT (INTL) Outer Race Cage Clamp, Large Ball Kit, Boot ABS Ring Clamp, Small Circlip Shaft 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.10 © Copyright Polaris Industries Inc.

  • Page 313: Front Gearcase Assembly View

    Kit, Cover Fasteners Plug, Drain Complete Seal Repair Plug, Fill Plate, 4WD Armature Asm, Gear Housing and Pinion Gear Bearing Spring, Torsion and Retainer 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.11 © Copyright Polaris Industries Inc.

  • Page 314: Gearcase Vent Line

    GEARCASE VENT LINE The front gearcase vent line routs vertically and into an open section of the frame. Description Hose Clamp Vent Hose Retention Point 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.12 © Copyright Polaris Industries Inc.

  • Page 315: Propshaft Service

    Use care not to damage brake lines when removing propshafts. 8. With the propshafts removed from the vehicle, inspect the shaft for cracks, damage from debris, and straightness. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.13 © Copyright Polaris Industries Inc.
  • Page 316 Not the orientation of the coolant line clip for installation. 8. Slide the rear prop shaft forward to remove it from the transmission output shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.14 © Copyright Polaris Industries Inc.
  • Page 317 NOTICE The rear of the propshaft must be angled and guided backwards to aid in clearing the mount. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.15 © Copyright Polaris Industries Inc.

  • Page 318: Propshaft Removal (2016-2017)

    8. With the propshafts removed from the vehicle, inspect the shaft for cracks, damage from debris, and straightness. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.16 © Copyright Polaris Industries Inc.

  • Page 319: Propshaft Removal - General 4 (2017)

    Use care not to damage brake lines when removing NOTICE propshafts. Note the orientation of the coolant line clip for installation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.17 © Copyright Polaris Industries Inc.
  • Page 320 NOTICE The rear of the propshaft must be angled and guided backwards to aid in clearing the mount. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.18 © Copyright Polaris Industries Inc.

  • Page 321: U-Joint Disassembly

    6. Discard and replace all U-joint parts that were removed from the yoke. 3. Place a remover adapter on other end of U-joint with a smaller OD than the U-joint cap. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.19 © Copyright Polaris Industries Inc.

  • Page 322: U-Joint Assembly

    8. Tighten clamp until both caps are flush with yoke and one cap is past retaining ring groove 4. Place caps into yoke bores and align with U-joint ends by hand. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.20 © Copyright Polaris Industries Inc.
  • Page 323 12. Install second retaining ring with sharp, square edge facing away from U-joint. 13. Verify the U-joint moves freely and does not bind. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.21 © Copyright Polaris Industries Inc.
  • Page 324 Support Bearing Fasteners: 33 lb-ft (45 Nm) 10. Install the skid plates on the vehicle. Refer to “Skid Plate Replacement”page 10.73 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.22 © Copyright Polaris Industries Inc.
  • Page 325 Polaris All Purpose Grease. 3. Lubricate the front, center and rear prop shaft mid joint with Polaris All Purpose Grease. 4. Slide the rear prop shaft forward from the left rear of the machine just below the PVT cover. Install the rear prop shaft on the transmission output shaft.
  • Page 326 TORQUE Support Bearing Fasteners: 33 lb-ft (45 Nm) 11. Install the skid plates on the vehicle. Refer to “Skid Plate Replacement”page 10.73 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.24 © Copyright Polaris Industries Inc.

  • Page 327: Propshaft Installation (2016-2017)

    Reference these marks during installation if still visible. 7. Ensure proper orientation of the support bearing assembly. The shallow ridge of the bearing should be facing upwards. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.25 © Copyright Polaris Industries Inc.

  • Page 328: Propshaft Installation - General 4 (2017)

    3. Lubricate the front, center and rear propshaft mid joint Always use a new roll pin when installing the front with Polaris All Purpose Grease. propshaft onto the gearcase. Do not reuse roll pins. 4. Slide the rear propshaft forward from the left rear of the machine just below the PVT cover.
  • Page 329 7. Mark the front propshaft alignment mark if necessary as shown above. Install the front propshaft in the vehicle, and align with the alignment mark on the center propshaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.27 © Copyright Polaris Industries Inc.
  • Page 330 TORQUE Support Bearing Fasteners: 33 lb-ft (45 Nm) 11. Install the skid plates on the vehicle. Refer to “Skid Plate Replacement”page 10.73 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.28 © Copyright Polaris Industries Inc.

  • Page 331: Drive Shaft Service

    Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.29 © Copyright Polaris Industries Inc.

  • Page 332: Front Drive Shaft Installation

    3. Install drive shaft into the front bearing carrier. NOTICE 2016–2017 models have two cone washers. 4. Install the upper and lower ball joint ends into the front bearing carrier. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.30 © Copyright Polaris Industries Inc.

  • Page 333: Rear Drive Shaft Removal

    Wheel Nuts (Alum): carrier. 120 lb-ft (163 Nm) NOTICE Do not lubricate the stud or the lug nut. 11. Rotate wheel and check for smooth operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.31 © Copyright Polaris Industries Inc.

  • Page 334: Rear Drive Shaft Installation

    2. Align splines of drive shaft with transmission splines and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.32 © Copyright Polaris Industries Inc.
  • Page 335 2016–2017 models have two cone washers. 120 lb-ft (163 Nm) NOTICE Do not lubricate the stud or the lug nut. 9. Rotate wheel and check for smooth operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.33 © Copyright Polaris Industries Inc.

  • Page 336: Drive Shaft / Cv Joint Handling Tips

    Refer to text for grease capacity of CV joints and CV joint boots. 3. Clean the grease from the face of the joint. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.34 © Copyright Polaris Industries Inc.
  • Page 337 If the grease in the joint is obviously contaminated with measured. Use entire contents of package. water and/or dirt, the joint should be replaced. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.35 © Copyright Polaris Industries Inc.
  • Page 338 CV Boot Clamp Pliers: 8700226 18. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.36 © Copyright Polaris Industries Inc.

  • Page 339: Inner Plunging Joint / Boot Replacement

    3. Clean the grease from the face of the joint and place the drive shaft in a soft-jawed vise. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.37 © Copyright Polaris Industries Inc.
  • Page 340 NOTICE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.38 © Copyright Polaris Industries Inc.
  • Page 341 21. Position the boot lip in its groove. Install and tighten the large clamp using the appropriate clamp tool. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.39 © Copyright Polaris Industries Inc.

  • Page 342: Bearing Carrier Service

    10. Remove the bearing carrier from the front drive shaft. NOTICE 2016–2017 models have two cone washers. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.40 © Copyright Polaris Industries Inc.

  • Page 343: Front Bearing Replacement

    3. Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.41 © Copyright Polaris Industries Inc.

  • Page 344: Front Bearing Carrier Installation

    Always use new brake caliper mounting bolts upon assembly. TORQUE Tie Rod End Fastener: 15 lb-ft (20 Nm) 5. Apply Anti-Seize to drive shaft axle splines. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.42 © Copyright Polaris Industries Inc.

  • Page 345: Rear Bearing Carrier Removal / Inspection

    The tire should rotate smoothly without binding or rough spots. 3. Remove the four wheel nuts and rear wheel. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.43 © Copyright Polaris Industries Inc.

  • Page 346: Rear Bearing Replacement

    4. Inspect the bearing carrier housing for scratches, wear or damage. Replace rear bearing carrier if damaged. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.44 © Copyright Polaris Industries Inc.

  • Page 347: Bearing Installation

    4. Wipe the housing clean of any excess compound and install the snap ring NOTICE 2016–2017 models have two cone washers 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.45 © Copyright Polaris Industries Inc.
  • Page 348 Wheel Hub Castle Nut: 180 lb-ft (244 Nm) 7. Install wheel and wheel nuts. Refer to “Wheel Installation”page procedure. 8. Rotate wheel and check for smooth operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.46 © Copyright Polaris Industries Inc.

  • Page 349: Front Gearcase Service

    “over- running” condition for the rollers upon disengagement. 5. Disconnect electrical wires from bus bar. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.47 © Copyright Polaris Industries Inc.
  • Page 350 Drive Shaft plug vent line fitting. Removal”page procedure. 16. Remove the four fasteners securing the front 11. Remove Skid plate. gearcase to the frame. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.48 © Copyright Polaris Industries Inc.

  • Page 351: Front Gearcase Disassembly / Inspection

    3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. IMPORTANT Nylon spacer is non-serviceable and should not be removed. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.49 © Copyright Polaris Industries Inc.
  • Page 352 7. Remove the RH output hub assembly from the 5. Remove the torsion spring retainer and torsion spring gearcase housing. from the top of the ring gear. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.50 © Copyright Polaris Industries Inc.
  • Page 353 Refer to the “Electronic Parts Catalog” for individual part availability. Most parts are to be replaced as an assembly or as a complete kit. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.51 © Copyright Polaris Industries Inc.

  • Page 354: Front Gearcase Assembly

    4. Install the RH output hub into the gearcase housing. 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.52 © Copyright Polaris Industries Inc.
  • Page 355 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.53 © Copyright Polaris Industries Inc.
  • Page 356 11. Install a new O-ring on the cover plate assembly. IMPORTANT Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.54 © Copyright Polaris Industries Inc.

  • Page 357: Front Gearcase Installation

    TORQUE Front Gearcase Mounting Bolts: 33 lb-ft (45 Nm) 4. Install the vent line. TORQUE Propshaft Support Bearing: 33 lb-ft (45 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.55 © Copyright Polaris Industries Inc.
  • Page 358 12. Install winch from passenger side. Shock Fastener: 20 lb-ft (27 Nm) + 90° 15. Reconnect contactor connector. 16. Reconnect electrical wires from bus bar. 17. Reconnect battery. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.56 © Copyright Polaris Industries Inc.

  • Page 359: Troubleshooting - Final Drive

    8. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.57 © Copyright Polaris Industries Inc.
  • Page 360 FINAL DRIVE NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 7.58 © Copyright Polaris Industries Inc.
  • Page 361 ............8.42 SHOCK DISASSEMBLY (WALKER EVANS) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 362 ...........8.59 EPAS TROUBLESHOOTING USING DIGITAL WRENCH 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 363: General Information - Steering / Suspension

    Tool Available Stabilizer Bar Mount 42 lb-ft (57 Nm) Bosch Automotive Service Solutions: Fasteners 1-800-345-2233 or http://polaris.service-solutions.com Stabilizer Bar Link 42 lb-ft (57 Nm) Fasteners 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 364: Service Specifications - Steering / Suspensions

    Steering Wheel Free-play 0.8-1.0 in (20-25 mm) Wheel Toe Out 0-1/8 in (0-3.175 mm) Spring Adjustment Front: 6.625 in (16.828 Rear: 1.625 in (4.128 cm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 365: Assembly Views - Steering / Suspension

    STEERING ASSEMBLY VIEW Steering Wheel EPS Unit Steering Wheel Nut Steering Shaft, Lower Shock, Steering Steering Rack Asm, Tilt Steering Tie Rod End Steering Shaft, Upper 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 366: Front Suspension Assembly View

    Bearing Carrier, Front RH Bushing, Stabilizer Bar Shield, Front Link, Stabilizer Bar Shock, Front RH Control Arm, Lower LH Control Arm, Upper RH Joint, Ball Stabilizer Bar 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 367: Rear Suspension Assembly View

    Bearing Carrier, Rear LH Bracket, Stabilizer Bar Link, Stabilizer Bar Stabilizer Bar Shock, Rear LH Bushing, Stabilizer Bar Control Arm, Upper Rear RH Control Arm, Lower Rear RH 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 368: Steering Assembly Service

    4. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. 2. Remove and discard the pinch bolt retaining the upper steering shaft to the power steering unit. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 369: Steering Wheel Removal

    6. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 370: Steering Shaft Removal - Lower

    5. Lift up on the shaft and remove it through the floor panel. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.10 © Copyright Polaris Industries Inc.

  • Page 371: Steering Shaft Bearing Replacement

    Lower Steering Shaft Pinch Bolt: 48 lb-ft (65 Nm) 3. Install the power steering unit and reassemble the vehicle. Refer “Power Steering Unit Installation”page 8.12 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.11 © Copyright Polaris Industries Inc.

  • Page 372: Power Steering Unit Installation

    Lower Steering Shaft to Power Steering Pinch Bolt: 30 lb-ft (41 Nm) 5. Torque mount bracket fasteners to specification. TORQUE Power Steering Unit Mount Fasteners: 18 lb-ft (24 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.12 © Copyright Polaris Industries Inc.

  • Page 373: Steering Shaft Installation - Upper

    TORQUE Steering Wheel Nut: 65 lb-ft (88 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.13 © Copyright Polaris Industries Inc.
  • Page 374 The upper steering shaft pinch bolt must be replaced with PN 7520943 which has a silver finish and is 10.9 grade. Reference Figure 1. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.14 © Copyright Polaris Industries Inc.

  • Page 375: Tie Rod End / Wheel Hub Inspection

    4. If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). Refer to Final Drive chapter for service procedures. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.15 © Copyright Polaris Industries Inc.

  • Page 376: Steering Rack Installation

    Refer to “Steering Shaft Installation - Lower”page 8.11 procedure. NOTICE It is important the height of both marks be equally positioned to get an accurate measurement. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.16 © Copyright Polaris Industries Inc.

  • Page 377: Wheel Toe Adjustment

    Damage may not be immediately apparent if done incorrectly. 4. After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 15 lb-ft (20 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.17 © Copyright Polaris Industries Inc.

  • Page 378: Steering Wheel Free-Play

    EPAS system is detected, the system will illuminate a fault indicator and transition • Tie Rod Ends to a normal mechanically coupled steering system. The • Steering Shaft U-Joints system is Polaris Digital Wrench® compatible for simplified diagnostics system troubleshooting •...
  • Page 379 Main Power (25A / 30A ORANGE Protected) BROWN Ground 8–PIN CONNECTOR WIRE COLOR FUNCTION Key-On Battery Voltage ORANGE CAN High Signal YELLOW CAN Low Signal GREEN 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.19 © Copyright Polaris Industries Inc.

  • Page 380: Shock Service

    1.230 x 0.082 Top Out 1.250 x .015 1.250 x .015 0.750 x 0.100 Back Up 1.570 x .128 Top Out 1.230 x 0.082 Top Out 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.20 © Copyright Polaris Industries Inc.

  • Page 381: Shock Specifications - General 4

    1.230 x .082 Top Out 1.570 x .128 Top Out .875 x .100 Back UP 1.100 x .012 .875 x .100 Back Up 1.570 x .128 Top Out 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.21 © Copyright Polaris Industries Inc.

  • Page 382: Shock Compression Adjustment

    3. Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle. Discard nuts and replace with new upon installation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.22 © Copyright Polaris Industries Inc.

  • Page 383: Spring Adjustment

    SPRING ADJUSTMENT - FACTORY SETTING FRONT REAR 6.625 in (16.828 cm) 1.625 in (4.128 cm) NOTICE Models with base suspension use softest setting for factory setting. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.23 © Copyright Polaris Industries Inc.

  • Page 384: Spring Adjustment - General 4

    Always return the spring adjuster to the factory setting vehicle. after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.24 © Copyright Polaris Industries Inc.

  • Page 385: Shock Disassembly (Fox)

    2. Discharge nitrogen pressure from reservoir chamber. 5. Place a commercially available bearing cap removal tool around the shock body and install supplied retaining ring. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.25 © Copyright Polaris Industries Inc.
  • Page 386 12. Dump out used oil. 13. Using a 9/16-inch open end wrench and a 1/8-inch Hex Tee handle wrench, remove the bleed screw. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.26 © Copyright Polaris Industries Inc.
  • Page 387 16. Remove the DSC using a DSC removal socket. 19. To assist in breaking the bond with the Loctite® adhesive, apply heat to the body cap. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.27 © Copyright Polaris Industries Inc.
  • Page 388 23. Remove both retaining rings in the body cap using a sharp pick. 24. Press the bearing out of the body cap using a bearing press set or assorted sockets. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.28 © Copyright Polaris Industries Inc.
  • Page 389 32. Remove the piston. Note the orientation of the piston as it comes off the shock shaft - compression side down. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.29 © Copyright Polaris Industries Inc.
  • Page 390 34. Remove the piston bearing if it shows any signs of damage or wear. 38. Place shock shaft in clamp blocks. 35. Remove piston O-ring. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.30 © Copyright Polaris Industries Inc.

  • Page 391: Eyelet-Mounted Rebound Adjuster

    41. Remove Loctite® residue out from threads of the eyelet and shock shaft. EYELET-MOUNTED REBOUND ADJUSTER 1. For shocks with , remove Jet/Check Valve with Hex T- handle wrench. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.31 © Copyright Polaris Industries Inc.

  • Page 392: Dx Bushing And Seal Style Eyelet

    DX BUSHING AND SEAL STYLE EYELET On some models the seal may be in the bearing assembly. NOTICE DX Bushing style eyelets have larger bore diameters than conventional eyelets. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.32 © Copyright Polaris Industries Inc.

  • Page 393: Shock Assembly (Fox)

    3. Install second retaining ring. 6. Remove external O-ring from bearing assembly. NOTICE If internal bearing is damaged, replace with complete bearing assembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.33 © Copyright Polaris Industries Inc.

  • Page 394: Eyelet-Mounted Rebound Adjuster

    Adjust rebound knob to allow metering rod to obtain maximum travel in eyelet. 7. Install a NEW O-ring on needle and apply thin layer of Slick Honey. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.34 © Copyright Polaris Industries Inc.

  • Page 395: Assembly Continued

    Slick Honey to metering rod. Eyelet: 30 lb-ft (41 Nm) 3. Reverse shock shaft in clamp blocks and install air side shaft spacers (if equipped) and jounce bumper. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.35 © Copyright Polaris Industries Inc.
  • Page 396 There are two different sides on the U-Cup seal. When seal is installed, energizing side should be facing internal bearing. 9. Install bearing assembly using the appropriate bullet tool. 6. Install U-Cup seal. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.36 © Copyright Polaris Industries Inc.
  • Page 397 NOTICE 15. Install rebound valve stack with required top out Bearing will be fully seated around piston when done correctly. washer. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.37 © Copyright Polaris Industries Inc.
  • Page 398 20. Install appropriate O-ring and apply a thin layer of shock oil to the O-ring ONLY. NOTICE Ensure retaining ring is fully installed and secure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.38 © Copyright Polaris Industries Inc.
  • Page 399 23. Place body in clamp blocks and install body cap. Torque body cap to specification using body cap socket. TORQUE LSC Knob: 14 lb-in (1.6 Nm) TORQUE Body Cap: 100 lb-ft (136 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.39 © Copyright Polaris Industries Inc.
  • Page 400 34. Fill shock body with oil about 0.750″ from top, or about 1.250″ from top on cup shocks. 35. Quickly pass a propane torch over oil to eliminate any micro air bubbles. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.40 © Copyright Polaris Industries Inc.
  • Page 401 Shock Charge Pressure: 39. Use IFP tool to push down on IFP and fully extend the 100 PSI (690 kPa) shock shaft assembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.41 © Copyright Polaris Industries Inc.

  • Page 402: Shock Disassembly (Walker Evans)

    2. Remove the wiper cap. 10. Remove the piston and valve stack from shaft stem. 11. Remove the seal case and wiper cap from shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.42 © Copyright Polaris Industries Inc.

  • Page 403: Shock Assembly (Walker Evans)

    3. Install the base valve into the can. Then, install the second o-ring into the coupler. 14. Remove the base valve. 15. Remove the IFP from reservoir eyelet cap. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.43 © Copyright Polaris Industries Inc.
  • Page 404 Ensure the seal case is still 1.500” from the top of the main body. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.44 © Copyright Polaris Industries Inc.

  • Page 405: Suspension Service

    10. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.45 © Copyright Polaris Industries Inc.

  • Page 406: Control Arm Installation - Front

    5. Examine control arm bushings and pivot tube. Replace if worn. Discard hardware. 6. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.46 © Copyright Polaris Industries Inc.
  • Page 407 Torque to specification TORQUE Stabilizer Bar Link Fastener:(42 lb-ft (57 Nm)) 8. Install NEW ball joint into control arm. Refer to “Ball Joint Installation”page 8.56 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.47 © Copyright Polaris Industries Inc.
  • Page 408 2016–2018 models have M10 hardware. WARNING Upon control arm installation, test vehicle at low speeds before putting into service. TORQUE Front Control Arm Fasteners: 42 lb-ft (57 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.48 © Copyright Polaris Industries Inc.

  • Page 409: Control Arm Removal - Rear

    5. If not replacing the control arm, thoroughly clean the control arm and pivot tube. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.49 © Copyright Polaris Industries Inc.

  • Page 410: Control Arm Installation - Rear

    7. If not replacing the control arm, thoroughly clean the control arm and pivot tube. TORQUE Rear Inner Control Arm Fasteners: 40 lb-ft (54 Nm) + 90° 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.50 © Copyright Polaris Industries Inc.
  • Page 411 Install NEW fasteners holding control arm to vehicle. Torque fasteners to specification. TORQUE Rear Inner Control Arm Fasteners: 40 lb-ft (54 Nm) + 90° 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.51 © Copyright Polaris Industries Inc.
  • Page 412 Stabilizer Bar Link Fastener:(42 lb-ft (57 Nm)) 7. Install front wheels. Refer “Wheel Installation”page procedure. WARNING Upon control arm installation, test vehicle at low speeds before putting into service. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.52 © Copyright Polaris Industries Inc.

  • Page 413: Stabilizer Bar Removal - Front

    7. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. TORQUE Stabilizer Bar Link Fasteners (Front): 20 ft-lbs (27 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.53 © Copyright Polaris Industries Inc.

  • Page 414: Stabilizer Bar Removal - Rear

    7. Carefully remove the stabilizer bar from the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.54 © Copyright Polaris Industries Inc.

  • Page 415: Stabilizer Bar Installation - Rear

    Torque fasteners to specification. TORQUE Stabilizer Bar Link Fasteners: 42 lb-ft (57 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.55 © Copyright Polaris Industries Inc.

  • Page 416: Ball Joint Service

    2. Place a proper sized driver on the ball joint and place the A-arm in a press. 3. Carefully press the ball joint out of the A-arm and discard the ball joint. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.56 © Copyright Polaris Industries Inc.

  • Page 417: Troubleshooting - Steering / Service

    Verify the EPAS unit has the latest software version and calibration loaded before replacing the EPAS unit. If not, update to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®. POWER STEERING NON-FUNCTIONAL WITH MIL ON 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.57 © Copyright Polaris Industries Inc.

  • Page 418: Power Steering Non-Functional With Mil Off

    STEERING / SUSPENSION POWER STEERING NON-FUNCTIONAL WITH MIL OFF 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.58 © Copyright Polaris Industries Inc.

  • Page 419: Epas Troubleshooting Using Digital Wrench

    STEERING / SUSPENSION EPAS TROUBLESHOOTING USING DIGITAL WRENCH 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.59 © Copyright Polaris Industries Inc.
  • Page 420 STEERING / SUSPENSION NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 8.60 © Copyright Polaris Industries Inc.
  • Page 421 ...............9.38 BRAKE PEDAL INSTALLATION 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 422 ..................9.57 BRAKES LOCK 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 423: General Information - Brake System

    • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 424: Service Specifications - Brake System

    Brake Fluid Type Polaris DOT 4 Brake Fluid PN 2872189 Up to MAX line inside reservoir Brake Fluid Capacity Brake Pedal Free-Play 0.090 in (2.28 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 425: Service Specifications - Brake System (Intl)

    Brake Fluid Type Polaris DOT 4 Brake Fluid PN 2872189 Brake Fluid Capacity Up to MAX line inside reservoir Brake Pedal Free-play 0.090 in (2.28 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 426: Antilock Brake System (Abs) (Intl)

    The ABS feature can be enabled and disabled by the rider. Reference the owners manual for ABS settings. Speed Sensor Tone Ring 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 427: Brake System Assembly View (Intl)

    Rear Brake Caliper Fasteners46 lb-ft (62 Nm) Junction Block Fasteners 35 in-lbs (4 Nm) Brake Pressure Switch Junction Block Master Cylinder Fasteners 22 lb-ft (30 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.

  • Page 428: Brake Line Routing And Retention (Intl)

    BRAKE SYSTEM BRAKE LINE ROUTING AND RETENTION (INTL) MASTER CYLINDER TO ABS MODULE Master Cylinder Routing Clips ABS Module 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 429 BRAKE SYSTEM ABS MODULE TO FRONT BRAKE CALIPERS ABS Module Brake Clip Routing Clip Front Brake Calipers 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual © Copyright Polaris Industries Inc.
  • Page 430 BRAKE SYSTEM ABS MODULE TO JUNCTION BLOCK ABS Module Routing Clip Junction Block 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.10 © Copyright Polaris Industries Inc.
  • Page 431 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Hose Clamp Routing Clip Rear Brake Caliper Clip 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.11 © Copyright Polaris Industries Inc.

  • Page 432: Brake Line Routing And Retention Non-Abs (Intl)

    BRAKE SYSTEM BRAKE LINE ROUTING AND RETENTION NON-ABS (INTL) FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.12 © Copyright Polaris Industries Inc.
  • Page 433 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Master Cylinder 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.13 © Copyright Polaris Industries Inc.
  • Page 434 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Brake Line Retention Points Rear Brake Caliper 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.14 © Copyright Polaris Industries Inc.

  • Page 435: Brake Pedal Removal (Intl)

    TORQUE Brake Pedal Shoulder Bolt:13 lb-ft (18 Nm) 4. Ensure brake pedal freeplay is within specification. Brake Pedal Free-play: 0.090 in (2.28 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.15 © Copyright Polaris Industries Inc.

  • Page 436: Brake Pressure Switch Replacement (Intl)

    The Digital Wrench ABS Brake Bleed Procedure must be performed if the ABS HECU is replaced or air has been ingested into the brake system. This Procedure should only be performed by a trained and certified Polaris Dealership. However repairs such as brake caliper or NOTICE master cylinder replacement only require a standard Pay attention to brake line orientation for reassembly.

  • Page 437: Tone Ring Inspection (Intl)

    Front Drive Shaft Installationpage 7.30 or Rear Drive shaft Installationpage 4. Follow the Electrical connector up to the HECU and unplug it. NOTICE Note the routing of wiring for reinstallation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.17 © Copyright Polaris Industries Inc.

  • Page 438: Wheel Speed Sensor Air Gap Adjustment (Intl)

    2. Insert a feeler gauge of the correct specification between the sensor and the tone ring. Air Gap Specification 0.8–1.0 mm 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.18 © Copyright Polaris Industries Inc.

  • Page 439: Abs Hecu Removal (Intl)

    2. Disconnect the brake lines and allow the brake fluid to drain. NOTICE Note orientation and location of each brake line for reassembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.19 © Copyright Polaris Industries Inc.

  • Page 440: Abs Hecu Installation (Intl)

    1.8 lb-ft (2 Nm)Step 2: Torque all three fasteners to 3 lb-ft (4 Nm)Step 3: Torque all three fasteners to 4 lb-ft (5.4 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.20 © Copyright Polaris Industries Inc.

  • Page 441: Abs Troubleshooting (Intl)

    • Faulty wheel speed sensor wiring • Low brake fluid TORQUE • Air in brake system ABS HECU Flare Fittings (INTL):15 lb-ft (20 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.21 © Copyright Polaris Industries Inc.

  • Page 442: Assembly Views - Brake System

    Rear Caliper Fasteners46 lb-ft (62 Nm) Junction Block Front Caliper Fasteners30 lb-ft (41 Nm) Junction Block Fasteners35 in-lbs (4 Nm) Brake Line Clamp Retention Fasteners 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.22 © Copyright Polaris Industries Inc.

  • Page 443: Brake System Assembly View - General 4

    Rear Caliper Fasteners, 46 lb-ft (62 Nm) Junction Block Front Caliper Fasteners, 30 lb-ft (41 Nm) Junction Block Fasteners, 35 in-lbs (4 Nm) Brake Line Clamp Retention Fasteners 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.23 © Copyright Polaris Industries Inc.

  • Page 444: Line Routing And Retention

    BRAKE SYSTEM LINE ROUTING AND RETENTION FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.24 © Copyright Polaris Industries Inc.
  • Page 445 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Junction Block 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.25 © Copyright Polaris Industries Inc.
  • Page 446 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CLIPERS Junction Block Brake Line Retention Points Rear Brake Calipers 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.26 © Copyright Polaris Industries Inc.

  • Page 447: General 4 Brake Line Routing And Retention

    BRAKE SYSTEM GENERAL 4 BRAKE LINE ROUTING AND RETENTION FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.27 © Copyright Polaris Industries Inc.
  • Page 448 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Junction Block 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.28 © Copyright Polaris Industries Inc.
  • Page 449 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Brake Line Retention Points Rear Brake Calipers 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.29 © Copyright Polaris Industries Inc.

  • Page 450: Brake Line Routing And Retention (2019) General 4

    BRAKE SYSTEM BRAKE LINE ROUTING AND RETENTION (2019) GENERAL 4 FRONT BRAKE CALIPERS TO MASTER CYLINDER Front Brake Calipers Brake Line Retention Points Master Cylinder 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.30 © Copyright Polaris Industries Inc.
  • Page 451 BRAKE SYSTEM MASTER CYLINDER TO JUNCTION BLOCK Master Cylinder Brake Line Retention Points Junction Block 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.31 © Copyright Polaris Industries Inc.
  • Page 452 BRAKE SYSTEM JUNCTION BLOCK TO REAR BRAKE CALIPERS Junction Block Brake Line Retention Points Rear Brake Calipers 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.32 © Copyright Polaris Industries Inc.

  • Page 453: Brake Caliper Assembly View

    FRONT CALIPER Asm, Brake Pad Square Ring Asm, Caliper Mount Caliper, Brake Boot, Pin Seal Bolt Boot, Pin Bushing Bleeder Screw Piston, Brake Cap, Plug 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.33 © Copyright Polaris Industries Inc.

  • Page 454: Rear Caliper

    REAR CALIPER Asm, Brake Pad Square Ring Asm, Caliper Mount Caliper, Brake Boot, Pin Seal Bolt Boot, Pin Bushing Bleeder Screw Piston, Brake Cap, Plug 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.34 © Copyright Polaris Industries Inc.

  • Page 455: Brake System Service

    BRAKE SYSTEM BRAKE SYSTEM SERVICE BRAKE SYSTEM OPERATION OVERVIEW BRAKE BLEEDING / FLUID CHANGE The Polaris brake system consists of the following IMPORTANT components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and When bleeding the brakes or replacing the fluid always brake discs, which are secured to the drive line.

  • Page 456: Brake Burnishing Procedure

    Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.36 © Copyright Polaris Industries Inc.

  • Page 457: Master Cylinder Service

    Brake Pedal Free-play: 0.090 in (2.28 mm) 5. Bleed the brake system. Refer to “Brake Bleeding / Fluid Change”page 9.35 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.37 © Copyright Polaris Industries Inc.

  • Page 458: Brake Pedal Service

    3. Install the clevis pin and clip holding the master cylinder to the brake pedal. 4. Ensure brake pedal freeplay is within specification. Brake Pedal Free-play: 0.090 in (2.28 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.38 © Copyright Polaris Industries Inc.

  • Page 459: Front Pad Service

    WARNING When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.39 © Copyright Polaris Industries Inc.

  • Page 460: Brake Pad Inspection

    4. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2" (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.40 © Copyright Polaris Industries Inc.
  • Page 461 Up to MAX line inside reservoir 7. Install front wheels. Refer “Wheel Installation”page procedure. NOTICE If new pads are installed, refer to “Brake Burnishing Procedure”page 9.36. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.41 © Copyright Polaris Industries Inc.

  • Page 462: Front Caliper Service

    3. Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.42 © Copyright Polaris Industries Inc.

  • Page 463: Brake Caliper Inspection - Front

    Replace if damaged or worn beyond service limit. MEASUREMENT Front Caliper Piston Bore I.D.: Std: 1.373 in (34.874 mm) Service Limit: 1.374 in (34.900 mm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.43 © Copyright Polaris Industries Inc.

  • Page 464: Brake Caliper Assembly - Front

    TORQUE Front Caliper Mount Bolts: 2. Coat pistons with clean Polaris DOT 4 Brake Fluid 30 lb-ft (41 Nm) (PN 2872189). Install pistons with a twisting motion while pushing inward. Piston should slide in and out NOTICE of bore smoothly, with light resistance.
  • Page 465 Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. NOTICE If new pads are installed, refer to “Brake Burnishing Procedure”page 9.36. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.45 © Copyright Polaris Industries Inc.

  • Page 466: Disc Service

    1. Remove the appropriate brake caliper. Refer to “Brake Caliper Removal - Front”page 9.42 or “Brake Caliper Removal Rear”page 9.50 procedure. 2. Remove wheel hub cotter pin , castle nut washers 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.46 © Copyright Polaris Industries Inc.
  • Page 467 Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.47 © Copyright Polaris Industries Inc.

  • Page 468: Rear Pad Service

    7. Remove the inner brake pad. WARNING When removing caliper, be careful not to damage brake line. Support caliper to avoid kinking or bending brake line. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.48 © Copyright Polaris Industries Inc.

  • Page 469: Brake Pad Inspection

    WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.49 © Copyright Polaris Industries Inc.

  • Page 470: Rear Caliper Service

    5. Using a hammer and a small punch, remove the piston from the caliper body . Remove the square O-rings from the caliper body 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.50 © Copyright Polaris Industries Inc.

  • Page 471: Brake Caliper Inspection - Rear

    Rear Caliper Piston Bore I.D.: Std: 1.191 in (30.251 mm) Service Limit: 1.192 in (30.277 mm) 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.

  • Page 472: Brake Caliper Installation - Rear

    If the brake drags, re-check assembly and installation. NOTICE If new pads are installed, refer to “Brake Burnishing Procedure”page 9.36. TORQUE Rear Caliper Mounting Bolts: 46 lb-ft (62 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.52 © Copyright Polaris Industries Inc.

  • Page 473: Parking Brake (Int

    Parking Brake Caliper Fastener, 37 lb-ft (50 Nm) Parking Brake Lever Fastener, 22 lb-ft (30 Nm) Parking Brake Spacer, 2 in (51 mm) Parking Brake Cable Parking Brake Caliper Battery Pad 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.53 © Copyright Polaris Industries Inc.

  • Page 474: Parking Brake Inspection (Intl)

    After 8 full clicks of lever travel, the vehicle should not roll while parked. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.54 © Copyright Polaris Industries Inc.

  • Page 475: Caliper Removal

    2. Using a 1/2” socket and ratchet, remove the brake disc retaining bolt and flat washer. 3. Remove the disc from the transmission shaft. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.55 © Copyright Polaris Industries Inc.
  • Page 476 4. Install the new brake disc. Install the flat washer and mounting bolt . Torque the mounting bolt to specification. TORQUE Parking Brake Disc Mounting Bolt: 20 lb-ft (28 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.56 © Copyright Polaris Industries Inc.

  • Page 477: Troubleshooting - Brake System

    • Residue build up under caliper seals • Operator riding brakes BRAKES LOCK • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.57 © Copyright Polaris Industries Inc.
  • Page 478 BRAKE SYSTEM NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 9.58 © Copyright Polaris Industries Inc.
  • Page 479 ........10.46 INTERIOR BODY COMPONENT INSTALLATION - GENERAL 4 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.1 © Copyright Polaris Industries Inc.
  • Page 480 ............. 10.73 SKID PLATE REPLACEMENT - GENERAL 4 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.2 © Copyright Polaris Industries Inc.

  • Page 481: General Information - Body / Frame

    40 lb-ft (54 Nm) Side ROPS Fasteners 40 lb-ft (54 Nm) Front Cross Fasteners 40 lb-ft (54 Nm) Skid Plate Fasteners 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.3 © Copyright Polaris Industries Inc.

  • Page 482: Assembly Views - Body / Frame

    Panel, Rocker LH Hood Asm, Fender Flare LH Front 1/4 turn latch Fascia, Front Upper Fender, Front LH Fascia, Front Lower Fender, Rear LH 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.4 © Copyright Polaris Industries Inc.

  • Page 483: Exterior Body Component Assembly View - General 4

    Liner, Hood Asm, Fender Flare Front LH Fender, Front LH Fascia, Front Upper Fender, Center Lower LH Fascia, Front Lower Fender, Center Upper LH 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.5 © Copyright Polaris Industries Inc.

  • Page 484: Exterior Body Component Assembly View (Int

    Outer Hood Rocker Assembly, LH Front Upper Floor Panel Rear Fender, LH Front Upper Fascia Rear Fender Flare, LH Front Lower Fascia Front Fender, LH 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.6 © Copyright Polaris Industries Inc.

  • Page 485: Interior Body Component Assembly View

    Floor Main LH Door, Glovebox Console, Center LH Dash, Main Console, Center Cover Panel, Dash Upper Console, Center top Panel, Floor Upper Handle, Grab 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.7 © Copyright Polaris Industries Inc.

  • Page 486: Interior Body Component Assembly View - General 4

    Panel, Close-off Front Dash, Main Floor, Rear LH Door, Glovebox Floor, Rear RH Storage, Dash Center Console, Center Rear Top Panel, Console Controls Console, Center Rear 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.8 © Copyright Polaris Industries Inc.

  • Page 487: Seat Assembly View

    BODY / FRAME SEAT ASSEMBLY VIEW Back, Seat Frame, Seat Bottom, Seat Asm, Seat Base Asm, Seat Slider 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.9 © Copyright Polaris Industries Inc.

  • Page 488: Cargo Box Assembly View

    BODY / FRAME CARGO BOX ASSEMBLY VIEW Asm, Cargo Box Asm, Box Support Asm, Tailgate Latch, Cargo Box 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.10 © Copyright Polaris Industries Inc.

  • Page 489: Door Assembly View

    BODY / FRAME DOOR ASSEMBLY VIEW Panel, Door Outer Panel, Door Inner Frame, Door Trim, Door Inner Door Seal Cover, Door Hinge 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.11 © Copyright Polaris Industries Inc.
  • Page 490 BODY / FRAME Door Latch Door Cable Door Handle Assembly 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.12 © Copyright Polaris Industries Inc.
  • Page 491 BODY / FRAME DOOR ASSEMBLY VIEW 2019 Panel, Door Outer Panel, Door Inner Frame, Door Trim, Door Inner Door Seal Cover, Door Hinge 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.13 © Copyright Polaris Industries Inc.
  • Page 492 BODY / FRAME Door Latch Door Cable Door Handle Assembly 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.14 © Copyright Polaris Industries Inc.

  • Page 493: Door Assembly View - General 4

    DOOR ASSEMBLY VIEW - GENERAL 4 Cover, Bolster Rear Door Seal Panel, Door Outer Panel, Door Inner Bolster, Rear Trim, Door Inner Frame, Door Cover, Door Hinge 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.15 © Copyright Polaris Industries Inc.
  • Page 494 BODY / FRAME Door Cable Door Handle Assembly Door Latch 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.16 © Copyright Polaris Industries Inc.

  • Page 495: Rops Assembly View

    BODY / FRAME ROPS ASSEMBLY VIEW ROPS, Rear ROPS, RH ROPS, LH Panel, Visor Front Cross 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.17 © Copyright Polaris Industries Inc.

  • Page 496: Rops Assembly View - General 4

    ROPS ASSEMBLY VIEW - GENERAL 4 Panel, Visor ROPS,Center ROPS, Front Support ROPS, Rear LH ROPS, Front LH ROPS, Rear RH ROPS, Front RH ROPS, Rear 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.18 © Copyright Polaris Industries Inc.

  • Page 497: Frame Assembly View

    BODY / FRAME FRAME ASSEMBLY VIEW Plate, Skid Rear Frame, Dash Plate, Skid Main Frame, Seat Base Bracket, Suspension Mount Frame, Top Frame, Main 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.19 © Copyright Polaris Industries Inc.

  • Page 498: Frame Assembly View - General 4

    Frame, Main Rear Frame, Seat Base Front Plate, Skid Front Frame, Seat Base Rear Plate, Skid Center Frame, Dash Plate, Skid Rear Bracket, Suspension Mount 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.20 © Copyright Polaris Industries Inc.
  • Page 499 Frame, Top Frame, Main Rear Frame, Seat Base Rear Plate, Skid Front Frame, Seat Base Front Plate, Skid Center Bracket, Suspension Mount Plate, Skid Rear 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.21 © Copyright Polaris Industries Inc.
  • Page 500 Main Frame Outside M10 x 1.25 x 40 40 ft-lbs (54 lbs (14 Nm) Frame, Seat Base Front Fastener M8 x 1.25 x 55 10 ft-lbs (14 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.22 © Copyright Polaris Industries Inc.

  • Page 501: Body Component Removal

    4. Remove Rear View Mirror. Refer to “Rear View Mirror Removalpage 10.24” procedure. 5. Disconnect ROPS audio harness from audio system harness connectors. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.23 © Copyright Polaris Industries Inc.

  • Page 502: Rear View Mirror Removal

    1. Remove the top mounting fastener from the rear view mirror. 2. Remove the rear view mirror from the front support ROPS, taking car not to lose the mounting bracket. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.24 © Copyright Polaris Industries Inc.

  • Page 503: Door Removal - General 4

    1. Open door to expose door hinge. 2. Pull the hood forward and up to remove from the 2. Remove door hinge fasteners. vehicle. 3. Remove door from vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.25 © Copyright Polaris Industries Inc.

  • Page 504: Front Bumper Removal

    3. Remove the front bumper upper mounting fasteners. NOTICE On International models, disconnect the turn indicators in the bumper before removing front bumper. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.26 © Copyright Polaris Industries Inc.
  • Page 505 Pull the rear fender flair from the tabs holding it to the vehicle. NOTICE Remove the gas cap to remove the RH rocker panel. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.27 © Copyright Polaris Industries Inc.
  • Page 506 11. To remove the hood liner, remove the fasteners and clamps securing the terminal block, intake vent, and coolant expansion bottle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.28 © Copyright Polaris Industries Inc.
  • Page 507 Remove the front grill mesh to access the fasteners on the front of the fender. 5. Pull the cargo box handle and lift the cargo box out of the way. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.29 © Copyright Polaris Industries Inc.
  • Page 508 Disconnect the headlights from the electrical harness and remove the front fascia from the vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.30 © Copyright Polaris Industries Inc.

  • Page 509: Exterior Body Component Removal - General 4

    Pull the rear fender flair from the tabs holding it to the vehicle. NOTICE Remove the front grill mesh to access the fasteners on the front of the fender. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.31 © Copyright Polaris Industries Inc.
  • Page 510 13. To remove the hood liner, remove the fasteners and clamps securing the terminal block, intake vent, and coolant expansion bottle. NOTICE Remove the gas cap to remove the RH rocker panel. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.32 © Copyright Polaris Industries Inc.
  • Page 511 Pull the fender tabs up out of the rocker panel. 7. Pull the cargo box handle and lift the cargo box out of the way. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.33 © Copyright Polaris Industries Inc.
  • Page 512 Remove the clutch intake hose from the LH rear fender. 12. To remove the hood liner, remove the fasteners and clamps securing the pulse bar mounting bracket, intake vent, and coolant expansion bottle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.34 © Copyright Polaris Industries Inc.
  • Page 513 14. Remove the fasteners holding the hood liner to the vehicle and remove the hood liner. 3. Remove the fasteners holding the upper floor panel to the main floor panels. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.35 © Copyright Polaris Industries Inc.
  • Page 514 8. Remove the fasteners holding the RH and LH center console panels to the vehicle. NOTICE Remove the gauge cluster, if necessary, to aid in removal. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.36 © Copyright Polaris Industries Inc.
  • Page 515 LH main floors to the vehicle. NOTICE If necessary, loosen/remove the fasteners holding the door latch mounts to the vehicle to aid in panel removal. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.37 © Copyright Polaris Industries Inc.

  • Page 516: Interior Body Component Removal

    3. Remove the fasteners holding the upper floor panel to the main floor panels. NOTICE Remove the gauge cluster, if necessary, to aid in removal. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.38 © Copyright Polaris Industries Inc.
  • Page 517 11. Remove the fasteners holding the rear center console to the vehicle. 12. Disconnect the accessory power outlet and remove the rear center console and top from the vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.39 © Copyright Polaris Industries Inc.
  • Page 518 17. Remove the remaining fasteners holding the rear RH and LH floors to the vehicle. 18. Remove the brake pedal, accelerator pedal, and mounting bracket. Refer “Brake Pedal Removal”page 9.38 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.40 © Copyright Polaris Industries Inc.

  • Page 519: Cargo Box Removal

    4. Remove the fasteners holding the cargo box to the vehicle frame. With the help of an assistant, remove the cargo box from the vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.41 © Copyright Polaris Industries Inc.

  • Page 520: Decal Replacement

    2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.42 © Copyright Polaris Industries Inc.

  • Page 521: Body Component Installation

    Torque fasteners to specification. 4. Lower the cargo box and secure in position. TORQUE Rear Lower Close-off Panel Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.43 © Copyright Polaris Industries Inc.
  • Page 522 8. Install the center console top into the vehicle and over the shift lever. Install the shift boot into the center console top. Connect the 12 V power receptacles to the wiring harness. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.44 © Copyright Polaris Industries Inc.
  • Page 523 14. Install the wiring harness connectors to the controls console panel components. Install the controls console panel into the main dash tabs. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.45 © Copyright Polaris Industries Inc.

  • Page 524: Interior Body Component Installation

    3. Install the rear RH and LH floors in the vehicle and install the fasteners holding the main floors to the vehicle. Torque the fasteners to specification. TORQUE Floor Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.46 © Copyright Polaris Industries Inc.
  • Page 525 3.5 lb-ft (4.7 Nm) TORQUE Rear Upper Close-off Panel Fasteners: 3.5 lb-ft (4.7 Nm) 10. Install the ECU. Refer to “ECU Replacementpage 11.43” procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.47 © Copyright Polaris Industries Inc.
  • Page 526 13. Install the center console top into the vehicle and over the shift lever. Install the shift boot into the center console top. Connect the 12 V power receptacles to the wiring harness. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.48 © Copyright Polaris Industries Inc.
  • Page 527 19. Install the wiring harness connectors to the controls console panel components. Install the controls console panel into the main dash tabs. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.49 © Copyright Polaris Industries Inc.

  • Page 528: Exterior Body Component Installation

    TORQUE Terminal Block Fasteners: 3 lb-ft (4 Nm) Intake Duct Hose Clamp: 3 lb-ft (4 Nm) Coolant Surge Tank Fasteners: 2 lb-ft (2.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.50 © Copyright Polaris Industries Inc.
  • Page 529 Install the fasteners holding the rear fender to the vehicle. the vehicle and rocker panel. Torque the fasteners to specification. TORQUE Rear Fender Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.51 © Copyright Polaris Industries Inc.
  • Page 530 3.5 lb-ft (4.7 Nm) 11. Install the hood onto the vehicle. Refer to “Hood Installation”page 10.56 procedure. TORQUE Front Fender Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.52 © Copyright Polaris Industries Inc.

  • Page 531: Exterior Body Component Installation - General

    TORQUE Terminal Block Fasteners: 3 lb-ft (4 Nm) Intake Duct Hose Clamp: 3 lb-ft (4 Nm) Coolant Surge Tank Fasteners: 2 lb-ft (2.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.53 © Copyright Polaris Industries Inc.
  • Page 532 3.5 lb-ft (4.7 Nm) 10. Install the fasteners holding the center upper fender TORQUE to the vehicle. Rear Fender Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.54 © Copyright Polaris Industries Inc.

  • Page 533: Front Bumper Installation

    3.5 lb-ft (4.7 Nm) TORQUE Front Bumper Fasteners: 13. Install the hood onto the vehicle. Refer to “Hood 30 lb-ft (41 Nm) Installation”page 10.56 procedure. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.55 © Copyright Polaris Industries Inc.

  • Page 534: Hood Installation

    2. Press down on the back of the seat to latch the seat onto the frame. Lift up on the seat to ensure it is fully installed. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.56 © Copyright Polaris Industries Inc.

  • Page 535: Door Installation

    6. Verify the stiker is in a nominal position both vertically and laterally and adjust if needed. 3. With the help of an assistant, align the Driver door hinges with door hinge mounting brackets. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.57 © Copyright Polaris Industries Inc.

  • Page 536: Door Installation - General 4

    If door gap adjustment is needed, make a small adjustment to the striker pin vertical position and redo steps 2, 7, and 8. 10. Verify the door properly open, closes, and locks. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.58 © Copyright Polaris Industries Inc.
  • Page 537 The latch will click twice when fully locked. door hinges using a 13 mm socket and wrench. Torque the nuts to specification. TORQUE Door Hinge Pivot Nut: 8 lb-ft (11 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.59 © Copyright Polaris Industries Inc.
  • Page 538 2,7, and 8. 10. Verify the door properly opens, closes, and locks. 11. Install plastic door panel covers. 4. Ensure the door is fully locked 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.60 © Copyright Polaris Industries Inc.

  • Page 539: Door Cable Adjustment

    1–4. 2. Remove door hinge fastener covers 7. Verify that the door properly opens, closes, and locks. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.61 © Copyright Polaris Industries Inc.
  • Page 540 6. Loosen the door cable lock collar and adjuster until no threads are showing. 4. Push door latch into double lock position. 7. Hold the exterior door handle in the full open position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.62 © Copyright Polaris Industries Inc.
  • Page 541 13. When cable is adjusted properly tighten lock collar. 14. Locate interior door cable adjuster. 15. Push door latch into double lock position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.63 © Copyright Polaris Industries Inc.
  • Page 542 The interior door handle should be about 3/4 of the way through its throw when it releases the latch. Adjust cable if necessary. General 4 Models 1. Remove seven door panel fasteners. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.64 © Copyright Polaris Industries Inc.

  • Page 543: Audio System Installation

    The door handle should be about 3/4 of the way through its throw when it releases the latch. 8. Reinstall the door panel and fasteners. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.65 © Copyright Polaris Industries Inc.
  • Page 544 TORQUE Audio System Fasteners: 3.5 lb-ft (4.7 Nm) 8. Install U-type nuts onto visor panel to audio system mounting points. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.66 © Copyright Polaris Industries Inc.

  • Page 545: Rear View Mirror Installation

    REAR VIEW MIRROR INSTALLATION 1. Install the foam pads on the inside surface of the lower and upper mirror arms to help secure mirror to the tube. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.67 © Copyright Polaris Industries Inc.

  • Page 546: Roof Installation

    1. Ensure the ROPS Visor Trim Panel installed. 2. With the help of an assistant, place the roof onto the top of the ROPS. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.68 © Copyright Polaris Industries Inc.

  • Page 547: Frame Component Installation

    2. Remove the fasteners that hold the front cross to the front RH and LH ROPS. 4. Pull the cargo box handle and lift the cargo box out of the way. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.69 © Copyright Polaris Industries Inc.

  • Page 548: Rops Installation

    ROPS. 7. Remove the fasteners that hold the rear ROPS to the vehicle frame. 3. Close the cargo box and secure in position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.70 © Copyright Polaris Industries Inc.

  • Page 549: Rops Installation - General 4

    40 lb-ft (54 Nm) Front Cross Fasteners: 40 lb-ft (54 Nm) 2. Pull the cargo box handle and lift the cargo box out of the way. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.71 © Copyright Polaris Industries Inc.
  • Page 550 LH ROPS to the vehicle frame and rear ROPS. TORQUE Visor Panel Fasteners: 3.5 lb-ft (4.7 Nm) 8. Close the cargo box and secure in position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.72 © Copyright Polaris Industries Inc.

  • Page 551: Skid Plate Replacement

    4. Reverse removal for installation. Torque fasteners to specification. Skid Plate Fasteners: 3.5 lb-ft (4.7 Nm) TORQUE Skid Plate Fasteners: 3.5 lb-ft (4.7 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.73 © Copyright Polaris Industries Inc.
  • Page 552 BODY / FRAME NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 10.74 © Copyright Polaris Industries Inc.
  • Page 553 ................11.34 DISPLAY UNITS 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.1 © Copyright Polaris Industries Inc.
  • Page 554 ....... 11.67 TEST 2: RESISTANCE VALUE OF EACH STATOR LEG TO GROUND 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.2 © Copyright Polaris Industries Inc.
  • Page 555 ................11.92 ETC LEARN PROCEDURE 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.3 © Copyright Polaris Industries Inc.
  • Page 556 ............11.108 POLARIS MOBILE DIGITAL WRENCH (PMDW) BREAKOUT DIAGRAMS.
  • Page 557 ................11.117 RIDE COMMAND BREAKOUT 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.5 © Copyright Polaris Industries Inc.

  • Page 558: Assembly Views

    If replacing the harness, Noting routing during removal will aid in proper installation. FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.6 © Copyright Polaris Industries Inc.

  • Page 559: Harness Routing / Retention - General 4

    ELECTRICAL REAR HARNESS ROUTING / RETENTION — GENERAL 4 NOTICE If replacing the harness, Noting routing during removal will aid in proper installation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.7 © Copyright Polaris Industries Inc.
  • Page 560 ELECTRICAL FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.8 © Copyright Polaris Industries Inc.
  • Page 561 ELECTRICAL REAR Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.9 © Copyright Polaris Industries Inc.

  • Page 562: Harness Routing / Retention Abs (2018 Intl)

    If replacing the harness, Noting routing during removal will aid in proper installation. FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.10 © Copyright Polaris Industries Inc.
  • Page 563 ELECTRICAL REAR Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.11 © Copyright Polaris Industries Inc.

  • Page 564: Harness Routing / Retention Non-Abs (2018 Intl)

    If replacing the harness, Noting routing during removal will aid in proper installation. FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.12 © Copyright Polaris Industries Inc.
  • Page 565 ELECTRICAL REAR Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.13 © Copyright Polaris Industries Inc.

  • Page 566: Harness Routing / Retention (2019)

    If replacing the harness, Noting routing during removal will aid in proper installation. FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.14 © Copyright Polaris Industries Inc.
  • Page 567 ELECTRICAL REAR 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.15 © Copyright Polaris Industries Inc.

  • Page 568: Harness Routing / Retention 2019 - General 4

    If replacing the harness, Noting routing during removal will aid in proper installation. FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.16 © Copyright Polaris Industries Inc.
  • Page 569 ELECTRICAL REAR Zip Tie Retention Location The white tape on the harness signifies a retention point. Panduit Strap 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.17 © Copyright Polaris Industries Inc.

  • Page 570: Harness Routing / Retention 2019 (Evap)

    If replacing the harness, Noting routing during removal will aid in proper installation. FRONT Zip Tie Retention Location The white tape on the harness signifies a retention point. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.18 © Copyright Polaris Industries Inc.
  • Page 571 ELECTRICAL REAR Zip Tie Retention Location The white tape on the harness signifies a retention point. Edge Clip 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.19 © Copyright Polaris Industries Inc.

  • Page 572: General Information - Electrical System

    • Ignition Key Switch The following components can be accessed with the passenger seat base removed. • Battery* • Battery Cables* • Starter Solenoid* • Relays* 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.20 © Copyright Polaris Industries Inc.

  • Page 573: Special Tools - Electrical System

    12 lb-ft (16 Nm) Timing Light 2870630 3 lb-ft (4 Nm) Terminal Block Fasteners Relay Bypass PU-49466 Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.21 © Copyright Polaris Industries Inc.

  • Page 574: Service Specifications - Electrical System

    1.22 kΩ ± 2% 120 °C) AWD Hub Coil Resistance 24 Ω ± 5% Current Draw - Key Off .01 DCA (10 mA) (Max) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.22 © Copyright Polaris Industries Inc.

  • Page 575: Electrical Diagnostics

    • All associated circuits have no shorts to ground. Testing For A Short To Groundpage 11.25 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) • All associated circuits have no shorts to voltage.

  • Page 576: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris NOTICE machines can be tested using terminal test kit PV–...

  • Page 577: Testing Continuity/Resistance

    9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltagepage 11.26 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.25 © Copyright Polaris Industries Inc.

  • Page 578: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.26 © Copyright Polaris Industries Inc.

  • Page 579: Testing For Intermittent Conditions

    9. If over 10 milliamps, go to the fuse block and start systematically removing one fuse at a time until the value drops, indicating the circuit that requires attention. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.27 © Copyright Polaris Industries Inc.

  • Page 580: Testing Voltage Drop

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.28 © Copyright Polaris Industries Inc.

  • Page 581: Instrument Cluster Service

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.29 © Copyright Polaris Industries Inc.

  • Page 582: Instrument Cluster Overview (Intl)

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.30 © Copyright Polaris Industries Inc.

  • Page 583: Rider Information Display

    11. Neutral Gear Indicator - Illuminates when gear selector is in the neutral (N) position. 1. Vehicle Speed Display - Analog display of vehicle speed in MPH or km/h. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.31 © Copyright Polaris Industries Inc.
  • Page 584 27. Trailer Turn Signal — Flashing illumination at the P = Park same rate as turn signal flashing. – = Gear Signal Error (shifter stuck between gears) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.32 © Copyright Polaris Industries Inc.

  • Page 585: Information Display Area

    A flashing wrench symbol indicates that the preset service Service Hours interval has been reached. AREA 3 MODES MODE DESCRIPTION The clock displays time in a 12-hour or 24-hour format. Clock 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.33 © Copyright Polaris Industries Inc.

  • Page 586: Gauge Settings Menu

    4. Press MODE to save and exit to the settings menu. 1. Press and hold the MODE button to enter the settings menu. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.34 © Copyright Polaris Industries Inc.

  • Page 587: Trip Meter

    1. Press either toggle button to cycle to the trip time option (TT). 2. Press and hold either toggle button until the meter resets to zero. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.35 © Copyright Polaris Industries Inc.

  • Page 588: Instrument Cluster Pinouts (Intl)

    Accy Air Temp Input HIGH BEAM SWITCH INPUT — TRAILER TURN SIGNAL ANALOG FUEL LEVEL INPUT BLACKOUT MODE INPUT — — ACCY AIR TEMP INPUT — 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.36 © Copyright Polaris Industries Inc.

  • Page 589: Instrument Cluster Replacement

    3. Remove the fasteners holding the instrument cluster mounting bracket to the vehicle. 4. Remove the fasteners holding the instrument cluster mounting bracket to the instrument cluster. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.37 © Copyright Polaris Industries Inc.

  • Page 590: Adjustable Speed Limiting Device (Asld) (Intl)

    The setting can be adjusted at any time by the rider in the options menu on the instrument cluster. Refer to the owners manual to access the ALSD. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.38 © Copyright Polaris Industries Inc.

  • Page 591: Ride Command System

    Ride Command Display Mount. 2. Remove seven push pins retaining upper dash panel. 5. Remove three fasteners securing Ride Command Display to its mount. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.39 © Copyright Polaris Industries Inc.
  • Page 592 ELECTRICAL 6. Installation is performed by reversing the removal procedure. TORQUE Ride Command Display Mount Fasteners TORQUE Ride Command Display Fasteners 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.40 © Copyright Polaris Industries Inc.

  • Page 593: Ride Command Troubleshooting

    2. Fix any shorts in the wiring and reinstall new fuse. Go to Step 8 Go to Step 4 Did you find and repair the condition? 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.41 © Copyright Polaris Industries Inc.
  • Page 594 7. If resistance value is out of spec, check for breaks in yellow/green CAN wiring. 8. If all values are within specification, replace GPS antenna with new unit. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.42 © Copyright Polaris Industries Inc.

  • Page 595: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU requirements for the immediate operating conditions. from another Polaris of the same model may be used The ECU then sends output signals to set injector without system or engine component damage.

  • Page 596: Diagnostic Trouble Codes Overview

    (example: 2 means there are 3 codes present). ECU Retaining Screws: 24 lb-in (2.7 Nm) 5. Press MODE to exit to the settings menu. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.44 © Copyright Polaris Industries Inc.

  • Page 597: Diagnostic Trouble Code List

    P0265 Driver Circuit Grounded P1265 Driver Circuit Open / Grounded P1691 Rear Differential Output Driver Circuit Short to B+ P1692 Driver Circuit Grounded P1693 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.45 © Copyright Polaris Industries Inc.
  • Page 598 EPS Off Line (EPS DM1 not seen) 520230 U0131 EPS: Key On, Engine Off, 5 Minute EPS Power Save Condition 520231 C1071 Power Save/Timeout 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.46 © Copyright Polaris Industries Inc.
  • Page 599 ECU Analog to Digital Condition Exists 520307 P1532 Converter Fault - Voltage Accelerator Sensor Synchronicity Fault Sensor Condition Exists 520308 P1533 Difference Exceeds Limit 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.47 © Copyright Polaris Industries Inc.
  • Page 600 ELECTRICAL COMPONENT CONDITION P-CODE ECU Fault - ICO Condition Exists 520309 P1534 ECU Fault - Hardware Condition Exists 520311 P1537 Disruption 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.48 © Copyright Polaris Industries Inc.

  • Page 601: Abs Trouble Codes (Intl)

    C1834 Change Data Drifted High C1934 Data Drifted Low C1A34 Condition Exists C1C34 Wheel Speed Sensor Data Erratic, C103D (Rear Left) Intermittent Or Incorrect 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.49 © Copyright Polaris Industries Inc.
  • Page 602 Acceleration Sensor Not Responding Or Out Of Adjustment Out Of Calibration C1262 Data Drifted High C1162 2584 Brake Pressure Switches Out Of calibration C1263 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.50 © Copyright Polaris Industries Inc.
  • Page 603 Not Responding Or Out Of Adjustment Bad Intelligent Device C101C Or Component 520262 Voltage Above ABS/Brake Controller C1039 Source Voltage Normal, Or Shorted To High Source 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.51 © Copyright Polaris Industries Inc.

  • Page 604: Cylinder Misfire Detection

    If a misfire code has been set and there is no observed misfire, cycle the key and allow 4000 engine revolutions 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.52 © Copyright Polaris Industries Inc.

  • Page 605: Battery Service

    3. Disconnect the red (positive) battery cable. When reinstalling the battery, install the black (negative) cable last. 3. Disconnect the red (positive) battery cable. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.53 © Copyright Polaris Industries Inc.

  • Page 606: Battery Installation

    NOTICE Battery charge can be maintained by using a Polaris battery tender or by charging once a month to make up for self-discharge. Battery tenders can be left connected to automatically charge the battery if voltage drops below a pre-determined level.

  • Page 607: Battery Testing

    Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.55 © Copyright Polaris Industries Inc.
  • Page 608 Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.56 © Copyright Polaris Industries Inc.

  • Page 609: Fuse / Relay Service

    Located in the fuse box under the driver’s seat, the relays assist with component operation like the cooling fan, fuel pump, EFI system, and electronic power assisted steering 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.57 © Copyright Polaris Industries Inc.
  • Page 610 ELECTRICAL 2018 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.58 © Copyright Polaris Industries Inc.
  • Page 611 ELECTRICAL 2019 NOTICE GENERAL 4 models have a 30–amp circuit breaker protects the fan motor circuit. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.59 © Copyright Polaris Industries Inc.

  • Page 612: Fuse / Relay Operation Overview

    Located in the fuse box under the driver’s seat, the relays assist with component operation like the cooling fan, fuel pump, EFI system, and electronic power assisted steering 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.60 © Copyright Polaris Industries Inc.

  • Page 613: Fuse Box Replacement

    High side power from EFI fuse Red / Dark Blue High side output to EFI B+ Splice Dark Green / ECU controlled Yellow ground 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.61 © Copyright Polaris Industries Inc.
  • Page 614 EFI B+, EFI Relay Out Dark Brown Dark EFI Relay Coil LO Green / Yellow Fuel Pump Relay Provides power to the following system: • Fuel Pump 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.62 © Copyright Polaris Industries Inc.
  • Page 615 Orange Key Switch B+, EPS Relay Coil Power Unswitched Fused B+, EPS Fuse Out Orange EPS Relay Power Out Brown Ground, EPS Relay Coil 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.63 © Copyright Polaris Industries Inc.

  • Page 616: Fuse / Circuit Breaker Circuits (2017-2018)

    Switched B+, Drive Fuse RD/DG Chassis Relay, Drive Input TERM 10A WIRE COLOR FUNCTION OG/WH Accessory Terminal, Fuse Accessory Terminal, Fuse RD/DG Accessory 10A 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.64 © Copyright Polaris Industries Inc.

  • Page 617: Fuse / Circuit Breaker Circuits (2019)

    Power to EFI Relay high side Key – 10A Fuse WIRE COLOR FUNCTION Power from EFI Splice Power to B+ Unswitched Red / White Splice #1 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.65 © Copyright Polaris Industries Inc.
  • Page 618 Power to ABS Controller ABS Sensor– 5A Fuse WIRE COLOR FUNCTION Power from ABS splice Red / White Power to ABS Controller Flasher– 10A Fuse 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.66 © Copyright Polaris Industries Inc.

  • Page 619: Charging System Service

    4. Increase engine RPM while observing ammeter and indicate a failed or shorted stator leg. tachometer. Note the RPM at which the battery starts to charge (ammeter indication is positive). 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.67 © Copyright Polaris Industries Inc.

  • Page 620: Test 3: Measure Ac Voltage Output Of Each Stator Leg At Charging Rpm

    The stator cover can be removed with the engine installed in the chassis. Be sure to thoroughly clean the area around the stator cover prior to removal. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.68 © Copyright Polaris Industries Inc.

  • Page 621: Battery Conductance Analyzer

    Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries. Polaris MDX-610P PU-50296 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.69...

  • Page 622: Charging System Testing

    Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.70 © Copyright Polaris Industries Inc.

  • Page 623: Starting System Service

    The (-) negative battery cable is mounted to the engine using the upper starter mounting bolt / stud. 6. Remove the starter from the engine. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.71 © Copyright Polaris Industries Inc.

  • Page 624: Starter Motor Installation

    • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. NOTICE See “Starting System Breakoutpage ” for starter solenoid operation. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.72 © Copyright Polaris Industries Inc.

  • Page 625: Starting System Troubleshooting

    Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.73 © Copyright Polaris Industries Inc.

  • Page 626: Ignition System Service

    4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Retaining Bolt: 8 lb-ft (11 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.74 © Copyright Polaris Industries Inc.

  • Page 627: Spark Plug Service

    Ensure wires are pushed down all the way so they engage onto the spark plugs. 13. Lower the cargo box and secure in position. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.75 © Copyright Polaris Industries Inc.

  • Page 628: Electronic Power-Assisted Steering

    CAN High Signal YELLOW the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system. The CAN Low Signal GREEN system is Polaris Digital Wrench® compatible for simplified diagnostics system troubleshooting through the vehicle’s diagnostic port.

  • Page 629: Lighting System Service

    4. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place. NOTICE Make sure the tab on the bulb locates properly in the housing. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.77 © Copyright Polaris Industries Inc.

  • Page 630: Headlight Removal

    6. Adjust headlight position. Refer to “Headlight Adjustmentpage 11.77” procedure. 3. Carefully lift and remove headlight assembly from the bumper. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.78 © Copyright Polaris Industries Inc.

  • Page 631: Tail Light Replacement

    4. Remove the tail light from the cargo box and disconnect the wire harness. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.79 © Copyright Polaris Industries Inc.

  • Page 632: Winch Service

    30 lb-ft (41 Nm) 2. Install the winch from the passenger side. 6. Remove winch from passenger side. NOTICE If required, Remove winch mounting plate. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.80 © Copyright Polaris Industries Inc.
  • Page 633 4. Reinstall lower fastener on passenger front shock. TORQUE Shock Fastener: 20 lb-ft (27 Nm) + 90° 5. Reconnect contactor connector. 6. Reconnect electrical wires from bus bar. 7. Reconnect battery. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.81 © Copyright Polaris Industries Inc.

  • Page 634: Switch Service

    Fluid Changepage 9.35” procedure. brake line banjo bolt of the master cylinder. The brake switch may be accessed easily through the front LH wheel well. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.82 © Copyright Polaris Industries Inc.

  • Page 635: Headlight Switch

    1 and 2; 4 and 5; 7 and 8. NOTICE Pins 7 and 8 provide power and ground to light the switch lamp. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.83 © Copyright Polaris Industries Inc.

  • Page 636: Ignition (Key) Switch

    C and D. • Turn the ignition key to START. There should be continuity between switch pins A and B; C and D. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.84 © Copyright Polaris Industries Inc.

  • Page 637: Awd / 2Wd Switch

    2 and 3 as well as 3 and 7. • Move the switch to 2WD (NONE / OFF). There should ONLY be continuity between pins 3 and 7. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.85 © Copyright Polaris Industries Inc.

  • Page 638: Awd / 2Wd / Turf Switch

    1. The transmission (gear position) switch is located on the RH side of the transmission and can be accessed through the rear RH wheel well area. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.86 © Copyright Polaris Industries Inc.

  • Page 639: Seat Belt Switch

    If the circuit is open (buckle undone) vehicle speed will be limited to 15 mph. If the circuit is closed (buckle inserted), the vehicle will function normally. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.87 © Copyright Polaris Industries Inc.

  • Page 640: Winch Switch

    3; 1 and 2. • Move the switch to Position 3, ON. There should be continuity (< 1 Ω) between switch pins 1 and 2. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.88 © Copyright Polaris Industries Inc.

  • Page 641: Crankshaft Position Sensor (Cps)

    • Check the sensor mounting, air gap, flywheel encoder ring for damage or runout, and flywheel key. Inspect CPS and flywheel encoder ring for damage. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.89 © Copyright Polaris Industries Inc.

  • Page 642: Cps Replacement

    6. Torque CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 lb-ft (12 Nm) 7. Route CPS wire lead through wire clip and reconnect CPS harness connector. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.90 © Copyright Polaris Industries Inc.

  • Page 643: Electronic Throttle Control (Etc)

    If a problem is encountered, and you 4. Remove the four bolts retaining the ETC housing determine the ETC to be faulty, contact the Polaris to intake plenum. Service Department for specific handling instructions. Do not replace the ETC without factory authorization.

  • Page 644: Etc Learn Procedure

    3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.92 © Copyright Polaris Industries Inc.

  • Page 645: Throttle Position Sensor (Tps)

    The TPS is calibrated to the throttle pedal. If the TPS is 8 lb-ft (11 Nm) faulty, the throttle pedal assembly must be replaced. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.93 © Copyright Polaris Industries Inc.

  • Page 646: Heated Oxygen Sensor (O2)

    O2 sensor (increases the delay). The delay time ensures the oxygen sensor heater has run long enough to provide accurate data. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.94 © Copyright Polaris Industries Inc.

  • Page 647: Temp / Manifold Absolute Pressure Sensor (T-Map)

    Digital Wrench®. If the sensor is faulty, it must be replaced. NOTICE This sensor should only be tested using Digital Wrench® Diagnostic Software (dealer only). 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.95 © Copyright Polaris Industries Inc.

  • Page 648: Engine Coolant Temperature (Ect) Sensor

    29.9 kΩ ± 6% ECT Resistance (248 °F / 120 °C) 1.22 kΩ ± 2% 3. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.96...

  • Page 649: Vehicle Speed Sensor (Vss)

    ECU. The ECU then interprets this switching into the speed the output 4. Connect the harness going to the peed sensor. gear is rotating. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.97 © Copyright Polaris Industries Inc.

  • Page 650: Misc Electrical Service

    See specifications below: TORQUE AWD Hub Coil Resistance: Terminal Block Fasteners: 24 Ω ± 5% 3 lb-ft (4 Nm) 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.98 © Copyright Polaris Industries Inc.

  • Page 651: Pulse Bar

    6. Reinstall the new pulse bar to the pulse bar bracket and secure with fasteners. TORQUE Pulse Bar Fasteners: Torque Until Fastener Is Fully Seated 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.99 © Copyright Polaris Industries Inc.

  • Page 652: Digital Wrench

    Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...

  • Page 653: Digital Wrench® Version And Update Id

    2. Locate the “Service and Warranty” drop-down menu. 3. Click on “Digital Wrench Updates”. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. 4. The Digital Wrench® portal website should appear in a new web browser.
  • Page 654 Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the install. NOTICE Versions and updates are subject to change. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.102 © Copyright Polaris Industries Inc.

  • Page 655: Digital Wrench® Communication Errors

    DIGITAL WRENCH® SERIAL NUMBER LOCATION Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the screen. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.103 © Copyright Polaris Industries Inc.

  • Page 656: Digital Wrench® Feature Map

    ELECTRICAL DIGITAL WRENCH® FEATURE MAP 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.104 © Copyright Polaris Industries Inc.

  • Page 657: Engine Controller Reprogramming (Reflash)

    ECU, an Authorization Key must be obtained by entering a Request Code in the box provided on the Reflash Authorization site. The Request Code is automatically • Proceed to http://polaris.diagsys.com for specific generated by Digital Wrench® during the reprogramming information and FAQs on how to troubleshoot process.
  • Page 658 5. Select the “Special Tests” icon. NOTICE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 6. Select “Engine Controller Reprogramming”. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.106 © Copyright Polaris Industries Inc.
  • Page 659 PC during the process. proceed. 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.107 © Copyright Polaris Industries Inc.

  • Page 660: Polaris Mobile Digital Wrench (Pmdw)

    • PMDW will not work on Microsoft Windows 8™ or Apple IOS™ products (PMDW) • Device must be set to allow the installation of non- Polaris Mobile Digital Wrench (PMDW) is a diagnostic market applications software application (app) designed specifically for Android™ devices. When paired with the Wireless •...

  • Page 661: Breakout Diagrams

    ELECTRICAL BREAKOUT DIAGRAMS COOLING SYSTEM BREAKOUT 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.109 © Copyright Polaris Industries Inc.

  • Page 662: Starting System Breakout

    ELECTRICAL STARTING SYSTEM BREAKOUT Click Here to view Starting system breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.110 © Copyright Polaris Industries Inc.

  • Page 663: Unswitched Chassis Power Breakout

    ELECTRICAL UNSWITCHED CHASSIS POWER BREAKOUT Click Here to view Unswitched chassis power breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.111 © Copyright Polaris Industries Inc.

  • Page 664: Key-On Battery Power Breakout

    ELECTRICAL KEY-ON BATTERY POWER BREAKOUT Click Here to view Key-on battery breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.112 © Copyright Polaris Industries Inc.

  • Page 665: Awd Breakout

    ELECTRICAL AWD BREAKOUT Click Here to view AWD breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.113 © Copyright Polaris Industries Inc.

  • Page 666: Vehicle Speed Sensor Breakout

    ELECTRICAL VEHICLE SPEED SENSOR BREAKOUT Click Here to view VSS breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.114 © Copyright Polaris Industries Inc.

  • Page 667: Lights Breakout

    ELECTRICAL LIGHTS BREAKOUT Click Here to view Lights breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.115 © Copyright Polaris Industries Inc.

  • Page 668: Epas Breakout

    ELECTRICAL EPAS BREAKOUT Click Here to view EPAS breakout for 2019 models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.116 © Copyright Polaris Industries Inc.

  • Page 669: Ride Command Breakout

    ELECTRICAL RIDE COMMAND BREAKOUT Click Here to view Ride Command breakout for 2019 Models. 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.117 © Copyright Polaris Industries Inc.
  • Page 670 ELECTRICAL NOTES 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual 11.118 © Copyright Polaris Industries Inc.
  • Page 671 Wiring Diagrams Topics Covered in this Appendix A.1 Wiring Diagrams To view a wiring diagram, click on the desired model / schematic. 2016: 2016 GENERAL Base (2413267) 2016 GENERAL with Winch (2413243) 2016 GENERAL 4 with Winch (2413412) 2017–2018: 2017–2018 GENERAL Base (2413619) 2017–2018 GENERAL with Winch (2413620) 2017–2018 GENERAL 4 with Winch (2413691) 2018 GENERAL with Ride Command (2413527)
  • Page 672 Audio System Removal ......... 10.23 Service Specifications ..........9.4 Cargo Box Installation ........... 10.43 Special Tools ............9.3 Cargo Box Removal..........10.41 Torque Specifications ..........9.3 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual IX.1 © Copyright Polaris Industries Inc.
  • Page 673 Operation .............. 5.9 Connecting Rod Inspection........3.58 Roller and Pin Inspection .........5.20 Installation ............3.66 Shift Weights ............5.19 Main Bearing Selection..........3.61 Spider Removal .............5.20 Removal / Inspection..........3.51 Spring..............5.17 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual IX.2 © Copyright Polaris Industries Inc.
  • Page 674 Component Overview..........4.7 Camshaft Removal ..........3.35 Purge Valve Ohm Test ..........4.10 Camshaft Sprocket Inspection........3.36 Purge Valve Replacement ........4.10 Connecting Rod Bearing Selection ......3.61 Troubleshooting/Conditions ........4.8 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual IX.3 © Copyright Polaris Industries Inc.
  • Page 675 Assembly View ............4.6 Fuel Sender Test ............4.33 Overview ............11.29 Operation Overview ..........4.33 Pinouts .............. 11.36 Replacement............11.37 Replacement............4.34 Test ..............4.33 Rider Information Display ........11.31 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual IX.4 © Copyright Polaris Industries Inc.
  • Page 676 Ring Groove Clearance ...........3.57 Ring Installation .............3.62 Ring Installed Gap (1000) ........3.57 Ring Removal / Inspection........3.56 Piston to Cylinder Clearance........3.58 Keys Polaris Mobile Digital Wrench (PMDW) .......11.108 Replacement............1.3 Pre-Ride Inspection ............ 2.6 Probe ..............11.24 Probing ..............11.24 Prop Shaft U-Joint Assembly ...........7.20...
  • Page 677 Ignition (Key) Switch ..........11.84 Special Tools Index............. 1.5 Seat Belt Switch........... 11.87 Specifications Winch ..............11.88 Cooling System............3.90 Engine Oil Pressure ..........3.32 Starter 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual IX.6 © Copyright Polaris Industries Inc.
  • Page 678 Wiring Harness Routing / Retention ABS 2018 INTL ......11.10 Routing / Retention EVAP 2019 ....... 11.18 Routing / Retention General 4 2019......11.16 9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual IX.7 © Copyright Polaris Industries Inc.
  • Page 685 [2019 GENERAL] HARNESS-CHASSIS,W/WINCH,DRIVE INSTRUMENT CLUSTER (P/N 3280622) KEY SWITCH TURF SOLENOID DRIVER REAR DIFFERENTIAL SOLENOID (P/N 4012165) (P/N 4012829) WINCH SWITCH HEADLIGHT SWITCH AWD/TURF SWITCH FUNCTION FUNCTION RECEPTACLE RECEPTACLE (P/N 4015688) (P/N 4014069) (P/N 4014611) FILE NAME: 2414379.RSD A B C D E F NOTE: POWERED TO UNLOCK CAN HIGH WIRE COLOR LEGEND...
  • Page 686 [2019 GENERAL] HARNESS-CHASSIS,BASE,DRIVE INSTRUMENT CLUSTER (P/N 3280622) KEY SWITCH TURF SOLENOID DRIVER REAR DIFFERENTIAL SOLENOID HEADLIGHT SWITCH AWD/TURF SWITCH (P/N 4012165) (P/N 4012829) POWER STEERING ASSEMBLY (P/N 2411224) (P/N 4014069) (P/N 4014611) FUNCTION FUNCTION RECEPTACLE RECEPTACLE FILE NAME: 2414380.RSD A B C D E F NOTE: POWERED TO UNLOCK EPS POWER (A) CAN HIGH...
  • Page 687 [2019 GENERAL] HARNESS-CHASSIS,7" DISPLAY 1 2 3 4 5 6 TURF SOLENOID DRIVER RECEPTACLE RECEPTACLE AWD/TURF SWITCH (P/N 4012829) (P/N 4012393) (P/N 4012393) POS 1 (P/N 4014611) FILE NAME: 2414381.RSD (ON) (P/N 2410000) (P/N 2410000) WIRE COLOR LEGEND POS 2 DIODE DIODE BEIGE (TAN)
  • Page 688 2019 GENERAL 4, 7" DISPLAY RIDE COMMAND 1/2 1 2 3 4 5 6 TURF SOLENOID DRIVER RECEPTACLE RECEPTACLE RECEPTACLE (P/N 2410000) (P/N 2410000) AWD/TURF SWITCH (P/N 4012829) (P/N 4012393) (P/N 4012393) (P/N 4012393) POS 1 (P/N 4014611) DIODE DIODE FILE NAME: 2414382.RSD (ON) WIRE COLOR LEGEND...
  • Page 689 2019 GENERAL 4,,7" DISPLAY RIDE COMMAND 2/2 FILE NAME: 2414382.RSD WIRE COLOR LEGEND BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN ORANGE NO = SWITCH NORMALLY OPEN PINK HARNESS: 2414382-01...
  • Page 690 [2019 GENERAL] HARNESS-CHASSIS,WNCH,DRIVE,CRW INSTRUMENT CLUSTER (P/N 3280622) KEY SWITCH TURF SOLENOID DRIVER 1 2 3 4 5 6 REAR DIFFERENTIAL SOLENOID (P/N 4012165) (P/N 4012829) WINCH SWITCH AWD/TURF SWITCH POS 1 FUNCTION FUNCTION RECEPTACLE RECEPTACLE RECEPTACLE (P/N 4015688) (P/N 4014611) FILE NAME: 2414383.RSD (ON) A B C D E F...

This manual is also suitable for:

General 2017General 2018General 2019General 4 2016General 4 2017General 4 2018 ... Show all

Table of Contents