Polaris General Issues And Problems

The Polaris General, marketed as a versatile machine bridging the gap between a recreational side-by-side and a work-oriented UTV, has garnered significant popularity. However, like any complex piece of machinery, it's not without its share of reported issues. Understanding these potential problems, their causes, and possible solutions is crucial for both prospective buyers and current owners to ensure a smooth and enjoyable off-road experience.

Common Complaints: What Owners Are Talking About

Let's dive into the frequently discussed problems that seem to plague Polaris General owners. These issues range from relatively minor inconveniences to more serious mechanical failures, so understanding the landscape is vital.

• Clutch Issues: This is arguably the most common complaint. Owners frequently report premature belt wear, slipping clutches, and jerky engagement, especially at lower speeds. This can lead to a loss of power, reduced performance, and the need for frequent belt replacements.
• Heat Management: Many Generals, particularly earlier models, suffer from excessive heat radiating into the cab, especially around the center console and seats. This makes for an uncomfortable riding experience, particularly in warmer climates.
• Electrical Gremlins: Intermittent electrical problems, such as malfunctioning headlights, gauges that flicker, or the engine stalling unexpectedly, are also prevalent. These can be difficult to diagnose and often require specialized tools and expertise.
• Suspension Weaknesses: While the General boasts a decent suspension system, some owners find it lacking, particularly when carrying heavy loads or tackling challenging terrain. This can lead to a rough ride and potential damage to the suspension components.
• A-Arm Bushing Wear: Premature wear of the A-arm bushings is a common gripe. This results in excessive play in the suspension, causing clunking noises and affecting handling.
• Fuel Pump Failures: Some owners have experienced fuel pump failures, resulting in the engine refusing to start or stalling unexpectedly. This can be a frustrating and potentially dangerous issue, especially when off-roading in remote areas.
• Differential Problems: Issues with the differential, including unusual noises, binding, and outright failure, have been reported. These problems can be costly to repair and can severely limit the vehicle's capabilities.

Digging Deeper: Why Are These Problems Happening?

Understanding the why behind these issues can help you prevent them or address them more effectively. Let's break down the likely causes.

• Clutch Issues: Root Causes
  • Belt Design: The factory belt, in some cases, is considered by some owners to be a weak link. Its construction and materials may not be ideal for the demands placed on it, especially with larger tires or increased loads.
  • Clutch Calibration: The factory clutch calibration may not be optimal for all riding conditions. Factors like tire size, altitude, and riding style can significantly impact clutch performance.
  • Riding Habits: Aggressive driving, frequent starts and stops, and prolonged operation at high speeds can accelerate belt wear and clutch damage.
  • Lack of Maintenance: Neglecting to properly maintain the clutch, such as cleaning the sheaves and inspecting the belt regularly, can also contribute to premature failure.
• Heat Management: The Science Behind the Sweat
  • Engine Placement: The engine's placement within the chassis can contribute to heat build-up in the cab.
  • Insufficient Insulation: Lack of adequate insulation around the engine and exhaust system allows heat to radiate into the cabin.
  • Airflow Restrictions: Poor airflow around the engine can trap heat and exacerbate the problem.
• Electrical Gremlins: Tracing the Circuitry
  • Wiring Harness Issues: Poorly routed or insufficiently protected wiring harnesses can be susceptible to damage from vibration, moisture, and abrasion.
  • Loose Connections: Loose or corroded electrical connections can cause intermittent problems and be difficult to track down.
  • Faulty Sensors: Malfunctioning sensors can send incorrect signals to the engine control unit (ECU), leading to performance issues.
• Suspension Weaknesses: Under Pressure
  • Spring Rates: The factory spring rates may not be adequate for heavier loads or aggressive riding.
  • Shock Absorber Performance: The shock absorbers may not provide sufficient damping, leading to a harsh ride and reduced control.
  • Component Quality: The quality of the suspension components, such as the shocks and springs, can impact their durability and performance.
• A-Arm Bushing Wear: The Friction Factor
  • Material Choice: The material used for the A-arm bushings may not be durable enough to withstand the constant stress and friction.
  • Lack of Lubrication: Insufficient lubrication can accelerate bushing wear.
  • Contamination: Dirt and debris can infiltrate the bushings, causing them to wear more quickly.
• Fuel Pump Failures: Empty Tank Blues
  • Fuel Quality: Poor fuel quality can damage the fuel pump.
  • Overheating: Overheating can cause the fuel pump to fail.
  • Manufacturing Defects: In some cases, fuel pump failures may be due to manufacturing defects.
• Differential Problems: Gear Grinding Grief
  • Lack of Maintenance: Neglecting to change the differential fluid regularly can lead to premature wear and failure.
  • Abuse: Abusive driving, such as excessive wheel spin or hard landings, can damage the differential.
  • Water Intrusion: Water intrusion can contaminate the differential fluid and cause corrosion.

Solutions and Workarounds: Getting Back on the Trail

Now for the good news: many of these issues can be addressed with some preventative maintenance, aftermarket upgrades, or simple workarounds.

• Clutch Solutions:
  • Belt Replacement: Opt for a high-quality aftermarket belt designed for higher horsepower and more demanding applications. Brands like Gates and EPI Performance offer robust options.
  • Clutch Kit Installation: Consider installing a clutch kit that's specifically designed for your riding style and tire size. These kits often include new springs, weights, and helixes to optimize clutch performance.
  • Clutch Maintenance: Regularly clean the clutch sheaves with a Scotch-Brite pad and compressed air. Inspect the belt for wear and replace it as needed.
  • Proper Engagement: Avoid jerky starts and stops. Use low range when towing or climbing steep hills.
• Heat Management Solutions:
  • Heat Shielding: Install heat shields around the engine and exhaust system to reduce heat radiation into the cab.
  • Insulation: Add insulation to the center console and other areas where heat is a problem.
  • Fan Upgrades: Consider upgrading to a higher-flow fan to improve airflow around the engine.
  • Reflective Window Film: Apply reflective window film to reduce solar heat gain.
• Electrical Solutions:
  • Wiring Inspection: Regularly inspect the wiring harness for damage and repair any frayed or broken wires.
  • Connection Cleaning: Clean and tighten all electrical connections. Use dielectric grease to prevent corrosion.
  • Battery Maintenance: Ensure the battery is properly charged and maintained.
  • Fuse Replacement: Replace any blown fuses with the correct amperage rating.
• Suspension Solutions:
  • Spring Upgrades: Install heavier-duty springs to improve load-carrying capacity and ride quality.
  • Shock Absorber Upgrades: Upgrade to aftermarket shock absorbers with adjustable damping to fine-tune the suspension performance.
  • Sway Bar Upgrades: Install heavier-duty sway bars to reduce body roll and improve handling.
• A-Arm Bushing Solutions:
  • Bushing Replacement: Replace worn A-arm bushings with high-quality aftermarket bushings made from durable materials like polyurethane.
  • Regular Lubrication: Regularly lubricate the A-arm bushings with a high-quality grease.
  • Grease Fittings: Install grease fittings on the A-arms to make lubrication easier.
• Fuel Pump Solutions:
  • Fuel Filter Maintenance: Regularly replace the fuel filter to prevent contaminants from damaging the fuel pump.
  • Fuel Additives: Use fuel additives to clean the fuel system and prevent fuel pump corrosion.
  • Fuel Pump Replacement: Replace the fuel pump with a high-quality aftermarket pump if it fails.
• Differential Solutions:
  • Fluid Changes: Change the differential fluid regularly according to the manufacturer's recommendations.
  • Inspection: Inspect the differential for leaks or damage.
  • Proper Lubrication: Use the correct type of differential fluid.

Preventative Maintenance: The Key to Longevity

The best way to avoid many of these problems is to follow a strict preventative maintenance schedule. This includes:

• Regularly checking and changing fluids (engine oil, transmission fluid, differential fluid).
• Inspecting and lubricating all moving parts.
• Cleaning and inspecting the air filter.
• Checking and adjusting the tire pressure.
• Inspecting the brakes.
• Keeping the machine clean.
• Following the manufacturer's recommended maintenance schedule.

Frequently Asked Questions

• Why is my Polaris General clutch belt wearing out so quickly? Several factors contribute, including aggressive riding, improper clutch calibration, and a potentially weak factory belt. Upgrading to an aftermarket belt and clutch kit can often resolve this.
• My General gets really hot in the cab, what can I do? Install heat shielding around the engine and exhaust, add insulation, and consider a fan upgrade to improve airflow.
• My General's headlights are flickering. What's going on? Check the wiring harness for damage, clean and tighten all electrical connections, and ensure the battery is properly charged.
• How often should I change the fluids in my Polaris General? Consult your owner's manual for the recommended fluid change intervals. Generally, engine oil should be changed every 50 hours, and other fluids should be changed at least annually.
• What type of fuel should I use in my Polaris General? Use the fuel grade recommended in your owner's manual. Typically, this is regular unleaded gasoline with an octane rating of 87 or higher.

Conclusion

The Polaris General is a capable and versatile machine, but it’s crucial to be aware of its potential issues. By understanding the common problems, their causes, and the available solutions, you can proactively maintain your General and ensure many years of enjoyable off-road adventures. Regular maintenance and well-chosen upgrades can significantly improve reliability and performance.