IX
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
IX.3
Drive Clutch Assembly View ......................................... 5.6
Drive Shaft........................................................7.29-7.31
Assembly View ....................................................... 7.8
Boot Inspection ......................................................2.31
CV Joint Handling...................................................7.34
Inner Plunging Joint / Boot Replacement .....................7.37
Outer CV Joint / Boot Replacement ............................7.34
Rear Shaft Installation .............................................7.32
Drive Shaft Installation................................................7.30
Driven Clutch
Alignment Procedure ..............................................5.27
Assembly ..................................................... 5.29, 5.33
Assembly View ....................................................... 5.8
Disassembly ................................................. 5.27, 5.31
Operation .............................................................. 5.9
Slider Inspection ....................................................5.31
Dynamic................................................................ 11.23
E
ECU
Diagnostic Trouble Codes Overview ......................... 11.44
ETC Learn Procedure ........................................... 11.92
Operation Overview .............................................. 11.43
Replacement....................................................... 11.43
Service .............................................................. 11.43
Trouble Code List ................................................. 11.45
Electrical .............................................. 11.23, 11.25-11.28
Engine / Chassis Electrical Ground ............................2.43
Throttle Pedal Inspection .........................................2.44
Wiring Diagram
Wiring Schematic .................................................119
Electrical Harness
Harness Routing / Retention 2019............................ 11.14
Routing / Retention 2017–2018
Retention........................................................... 11.6
Routing / Retention ABS 2018 INTL ......................... 11.10
Routing / Retention EVAP 2019 ............................... 11.18
Routing / Retention General 4 ................................... 11.7
Routing / Retention Non-ABS 2018 INTL ................... 11.12
Electrical System
12V Receptacle ................................................... 11.98
AWD Coil............................................................ 11.98
Chassis Ground ................................................... 11.99
Diagnostic Plug.................................................... 11.99
Service Notes ...................................................... 11.20
Service Specifications ........................................... 11.22
Special Tools....................................................... 11.21
Terminal Block ..................................................... 11.98
Torque Specifications ............................................ 11.21
Electronic Throttle Body
Learn Procedure .................................................. 11.92
Electronic Throttle Control (ETC)
Operation Overview .............................................. 11.91
Replacement....................................................... 11.91
Test ................................................................... 11.91
Engine
Assembly View ...............................................3.12-3.15
Balance Shaft Removal / Inspection ...........................3.50
Bearing Selection Identification .................................3.60
Break-In Period......................................................3.32
Breather Hose Inspection................................. 2.18, 3.21
Camshaft Installation / Timing ...................................3.76
Camshaft Removal .................................................3.35
Camshaft Sprocket Inspection...................................3.36
Connecting Rod Bearing Selection .............................3.61
Cooling System Troubleshooting ............................. 3.101
Crankcase Assembly ..............................................3.68
Crankcase Disassembly / Inspection ..........................3.48
Crankshaft Installation .............................................3.66
Crankshaft Main Bearing Selection ............................3.61
Crankshaft Removal / Inspection ...............................3.51
Cylinder / Piston Installation......................................3.65
Cylinder / Piston Removal ........................................3.55
Cylinder Head Assembly..........................................3.74
Cylinder Head Disassmebly......................................3.39
Cylinder Head Installation ........................................3.75
Cylinder Head Removal ...........................................3.38
Cylinder Head Warp................................................3.39
Cylinder Inspection .................................................3.54
Cylinder Leakdown Test................................... 2.18, 3.21
Exhaust Installation ................................................3.88
Exhaust Removal ...................................................3.87
Exhaust Valve Lash - Tappet Selection Matrix...............3.84
Flywheel Installation ...............................................3.72
Flywheel Removal ..................................................3.46
Installation ............................................................3.29
Intake Installation ...................................................3.86
Intake Removal......................................................3.85
Intake Valve Lash - Tappet Selection Matrix .................3.83
Limiting / Misfire ................................................... 11.52
Oil and Filter Change ...................................... 2.17, 3.20
Oil Flow Chart........................................................3.34
Oil Level ....................................................... 2.16, 3.19
Piston / Connecting Rod Assembly.............................3.64
Piston Disassembly / Inspection (1000) .......................3.55
Piston Ring Installation ............................................3.62
Piston Ring Installed Gap (1000) ...............................3.57
Piston Ring Removal / Inspection...............................3.56
Removal...............................................................3.26
Service Notes ......................................................... 3.4
Service Specifications .............................................. 3.6
Special Tools.......................................................... 3.4
Starter Drive Installation...........................................3.72
Stator Cover Installation...........................................3.73
Top End Service.....................................................3.23
Torque Specifications ............................................... 3.5
Troubleshooting ................................................... 3.100
Valve Clearance Inspection .............................. 2.18, 3.21
Valve Cover Removal..............................................3.35
Valve Inspection.....................................................3.40
Valve Sealing Test ..................................................3.42
Valve Seat Reconditioning (1000) ..............................3.42
Engine Coolant Temperature (ECT) Sensor
Operation Overview .............................................. 11.96
Replacement....................................................... 11.96
Engine Serial Number Location ....................................1.14
Engine, Camshaft Timing - Quick Reference ...................3.80
Engine, Valve Cover Installation ...................................3.82
EPAS
System Diagnostics .............................................. 11.76
EPAS System
Operation Overview .......................................8.18, 11.76
Troubleshooting .....................................................8.57
Troubleshooting Using Digital Wrench ........................8.59
ETC Learn Procedure .............................................. 11.92
EVAP System
Carbon Canister Filter Replacement ............................ 4.9
Carbon Canister Replacement ................................... 4.9
Component Overview............................................... 4.7
Purge Valve Ohm Test .............................................4.10
Purge Valve Replacement ........................................4.10
Troubleshooting/Conditions ....................................... 4.8
INDEX
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