Polaris General Common Problems

The Polaris General, a versatile side-by-side, blends the utility of a workhorse with the adventurous spirit of a recreational vehicle. It’s a popular choice for tackling tough jobs around the property, exploring trails, and everything in between. However, like any machine pushed to its limits, the General can experience its share of problems. Understanding these common issues and how to address them can save you time, money, and frustration, keeping your General running smoothly for years to come.

Suspension Woes: When the Ride Gets Rough

The suspension system is crucial for a comfortable and capable ride. Unfortunately, it's also a common source of headaches for General owners.

Bushing Breakdown:

What's the issue? Bushings, the small, often rubber or polyurethane components that cushion suspension joints, are notorious for wearing out quickly. This leads to sloppy handling, rattling, and a generally uncomfortable ride.
Why does it happen? Exposure to mud, water, and harsh terrain accelerates bushing wear. The stock bushings, in many cases, are simply not robust enough for the demands placed on them.
The fix: Replacing worn bushings is essential. Consider upgrading to aftermarket polyurethane bushings, which are more durable and resistant to wear and tear. Regular greasing also helps extend their lifespan.

Shock Absorber Struggles:

What's the issue? The shocks, responsible for dampening bumps and controlling the suspension's movement, can leak, lose their effectiveness, or even break.
Why does it happen? Overloading the vehicle, aggressive riding, and the aforementioned harsh conditions contribute to shock failure. Seals can dry out and crack, leading to oil leaks.
The fix: Inspect your shocks regularly for leaks or damage. If they're leaking or performing poorly, replacement or rebuilding (if possible) is necessary. Consider upgrading to heavier-duty shocks if you frequently carry heavy loads or ride aggressively.

A-Arm Anxieties:

What's the issue? Bent or damaged A-arms, the suspension components that connect the wheel hubs to the frame, can result from impacts with rocks, trees, or other obstacles.
Why does it happen? Rough terrain and aggressive driving are the primary culprits.
The fix: Visually inspect your A-arms after any significant impact. Minor bends might be straightened by a professional, but severely damaged A-arms should be replaced. Upgrading to stronger aftermarket A-arms can provide added protection.

Engine and Drivetrain Dilemmas: Keeping the Power Flowing

The engine and drivetrain are the heart and soul of your General. When problems arise here, it can bring your adventures to a screeching halt.

Overheating Issues:

What's the issue? The Polaris General, particularly in hot climates or under heavy load, can be prone to overheating.
Why does it happen? A clogged radiator, low coolant levels, a malfunctioning fan, or even a blown head gasket can cause overheating. Mud and debris easily accumulate in the radiator, restricting airflow.
The fix: Regularly clean your radiator with a pressure washer (be careful not to damage the fins). Check coolant levels and top off as needed. Ensure the cooling fan is operating correctly. If overheating persists, consider a coolant flush or a pressure test to check for leaks. A larger radiator or an auxiliary fan can also improve cooling capacity.

Clutch Conundrums:

What's the issue? The clutch is responsible for transferring power from the engine to the transmission. Problems with the clutch can manifest as slipping, jerky engagement, or a complete loss of power.
Why does it happen? Excessive belt wear, contamination of the clutch components (with water, mud, or oil), and improper clutch tuning can all lead to clutch problems.
The fix: Inspect your clutch belt regularly for wear and tear. Replace it as needed. Keep the clutch housing clean and dry. Consider a clutch kit if you frequently operate in challenging conditions or with oversized tires. A clutch kit can optimize the clutch engagement for your specific riding style and terrain.

Transmission Troubles:

What's the issue? Issues with the transmission can range from difficulty shifting to complete failure.
Why does it happen? Low transmission fluid, contaminated fluid, or worn internal components can cause transmission problems. Aggressive shifting and neglecting maintenance exacerbate the issue.
The fix: Check the transmission fluid level regularly and top off as needed. Change the fluid according to the manufacturer's recommendations. If you experience difficulty shifting or unusual noises, consult a qualified mechanic.

Axle Aches:

What's the issue? Axles are responsible for transferring power from the differential to the wheels. They are vulnerable to damage from impacts and excessive stress.
Why does it happen? Rough terrain, aggressive driving, and oversized tires can strain the axles, leading to bending, breaking, or damage to the CV joints (constant velocity joints).
The fix: Inspect your axles regularly for damage. Replace damaged axles immediately. Consider upgrading to stronger aftermarket axles if you frequently operate in challenging conditions or with oversized tires. Regularly greasing the CV joints also helps extend their lifespan.

Electrical Enigmas: When the Lights Go Out

Electrical problems can be particularly frustrating, as they can be difficult to diagnose and often lead to unexpected breakdowns.

Battery Blues:

What's the issue? The battery is the heart of the electrical system. A weak or dead battery can prevent the engine from starting and can cause other electrical components to malfunction.
Why does it happen? Batteries can lose their charge over time, especially if they are not properly maintained. Leaving the vehicle unused for extended periods, cold weather, and excessive use of accessories can also drain the battery.
The fix: Regularly check the battery voltage and charge it as needed. Use a battery tender to keep the battery charged when the vehicle is not in use. Replace the battery every few years, or sooner if it shows signs of weakness.

Wiring Worries:

What's the issue? Wiring harnesses are exposed to the elements and can be damaged by abrasion, corrosion, or rodent activity.
Why does it happen? Exposure to mud, water, and vibration can cause wires to corrode or break. Rodents can also chew on the wiring, causing shorts and malfunctions.
The fix: Inspect the wiring harness regularly for damage. Repair any damaged wires or connectors. Use dielectric grease to protect electrical connections from corrosion. Consider using wire loom or other protective coverings to protect the wiring harness from abrasion and rodent damage.

Sensor Shenanigans:

What's the issue? The Polaris General relies on various sensors to monitor engine performance and other critical functions. A faulty sensor can cause a variety of problems, from poor engine performance to complete engine shutdown.
Why does it happen? Sensors can fail due to age, exposure to the elements, or physical damage.
The fix: Use a diagnostic scanner to identify faulty sensors. Replace any faulty sensors with new ones. Ensure that the sensor connections are clean and secure.

Other Common Concerns: The Little Things That Add Up

Beyond the major systems, some smaller issues can also plague Polaris General owners.

Brake Bedlam:

What's the issue? Brakes are essential for safety. Worn brake pads, leaky brake lines, or a malfunctioning master cylinder can compromise braking performance.
Why does it happen? Brake pads wear down over time, especially in muddy or sandy conditions. Brake lines can corrode or be damaged by impacts.
The fix: Inspect your brake pads regularly and replace them as needed. Check brake lines for leaks and replace them if necessary. Bleed the brakes to remove any air from the system.

Fuel System Foibles:

What's the issue? Problems with the fuel system can result in poor engine performance, difficulty starting, or complete engine failure.
Why does it happen? A clogged fuel filter, a faulty fuel pump, or contaminated fuel can cause fuel system problems.
The fix: Replace the fuel filter regularly. Use fresh, high-quality fuel. Consider adding a fuel stabilizer if the vehicle will be stored for an extended period.

Plastic Problems:

What's the issue? The plastic body panels of the Polaris General can be prone to cracking, fading, and scratching.
Why does it happen? Exposure to sunlight, impacts with rocks or trees, and general wear and tear can damage the plastic body panels.
The fix: Use plastic polish to protect the plastic from fading and scratching. Repair any cracks or holes with plastic repair products. Consider adding aftermarket body armor to protect the plastic from impacts.

Frequently Asked Questions

Why does my General overheat? Overheating can be caused by a clogged radiator, low coolant, a faulty fan, or a blown head gasket. Regularly clean the radiator and check coolant levels.
My General's clutch is slipping. What should I do? Clutch slipping is often due to a worn belt or contamination. Inspect the belt and clean the clutch housing.
How often should I change the oil in my General? Refer to your owner's manual for the recommended oil change interval, but generally, every 25 hours of use is a good practice.
My General's battery keeps dying. What's the problem? A dying battery could be due to a weak battery, a parasitic draw, or a faulty charging system. Test the battery and charging system and address any parasitic draws.
What are the best tires for my Polaris General? The best tires depend on your typical terrain. Consider mud tires for muddy conditions, all-terrain tires for a balance of performance, and sand tires for sand dunes.

Keeping Your General Going Strong

Addressing these common problems proactively through regular maintenance and careful operation can significantly extend the lifespan of your Polaris General and ensure many more miles of enjoyment. By understanding the potential issues and knowing how to fix them, you can keep your General running smoothly and avoid costly repairs down the road.