The Polaris General, a versatile side-by-side known for its blend of work and recreational capabilities, is a popular choice for off-road enthusiasts. However, like any complex machine, it's not immune to issues, and transmission problems are among the most frequently reported. Understanding these potential problems, their causes, and solutions can save you time, money, and a lot of frustration on the trail.

What's Going on Inside Your Polaris General Transmission?

Before diving into specific problems, let's briefly touch on the basics of how a Polaris General transmission works. Unlike a traditional automotive transmission with gears selected by the driver, the General utilizes a Continuously Variable Transmission (CVT). This system relies on a belt connecting two variable-diameter pulleys: the drive clutch (connected to the engine) and the driven clutch (connected to the transmission).

As engine speed increases, centrifugal force causes the drive clutch to close, effectively increasing its diameter. Simultaneously, the driven clutch opens, decreasing its diameter. This change in pulley ratios provides a smooth and continuous range of "gearing," optimizing engine power for different speeds and loads. The transmission itself handles forward, reverse, and high/low range selections, transferring power to the wheels.

The Dreaded Belt Slip: A Common Culprit

One of the most frequent issues owners face is belt slip. This occurs when the belt loses its grip on the clutch faces, resulting in a loss of power, reduced acceleration, and a burning rubber smell. Several factors can contribute to belt slip:

  • Worn or Damaged Belt: This is the most obvious cause. Over time, the belt wears down, losing its thickness and grip. Cracks, fraying, or missing teeth are clear signs of a belt that needs replacing.
  • Contaminated Clutch Faces: Dirt, mud, water, or oil on the clutch faces can significantly reduce friction, leading to slip.
  • Improper Belt Tension: The belt needs the correct tension to effectively transfer power. Too loose, and it will slip; too tight, and it can cause premature wear on the belt and clutches.
  • Overloading: Exceeding the General's weight capacity puts excessive strain on the belt, increasing the likelihood of slip.
  • Aggressive Driving: Frequent hard acceleration and abrupt stops can generate excessive heat and wear on the belt.
  • Clutch Problems: Worn or damaged clutch components (rollers, weights, springs) can prevent the clutches from engaging properly, leading to belt slip.

Diagnosing Belt Slip: Pay attention to the symptoms. A noticeable loss of power, especially when climbing hills or accelerating, combined with a burning rubber smell, is a strong indicator. Visually inspect the belt for wear and tear. Check the clutch faces for contamination.

Fixing Belt Slip: Start with the basics. Clean the clutch faces with a non-chlorinated brake cleaner. Replace the belt if it's worn or damaged. Ensure the belt tension is correct (refer to your owner's manual for specifications). Avoid overloading the vehicle and try to drive more smoothly. If the problem persists, inspect the clutch components for wear or damage.

Shifting Problems: When Gears Refuse to Cooperate

Another common complaint revolves around difficulty shifting between gears, particularly from park to drive or reverse. This can manifest as a grinding noise, a clunking sound, or simply an inability to engage the desired gear. Possible causes include:

  • Shift Cable Adjustment: The shift cable connects the gear selector to the transmission. If the cable is stretched or misadjusted, it may not fully engage the gears.
  • Worn Shift Linkage: The linkage connecting the shift lever to the transmission can wear over time, leading to sloppy shifting and difficulty engaging gears.
  • Internal Transmission Damage: In more severe cases, the problem may stem from internal damage to the transmission, such as worn gears, damaged shift forks, or a malfunctioning shift actuator.
  • High Idle Speed: If the engine idle speed is too high, it can put pressure on the transmission, making it difficult to shift.
  • Parking Brake Engagement: Ensure the parking brake is fully disengaged. If it's partially engaged, it can make shifting difficult.

Diagnosing Shifting Problems: Pay close attention to the symptoms. Is it difficult to shift into all gears, or just specific ones? Does the problem occur only when the engine is warm or cold? Try adjusting the shift cable (refer to your owner's manual). Inspect the shift linkage for wear and damage. If the problem persists, it may be necessary to consult a qualified mechanic to diagnose potential internal transmission damage.

Fixing Shifting Problems: Start by checking and adjusting the shift cable. Lubricate the shift linkage with a quality grease. If the linkage is worn, replace it. Ensure the engine idle speed is within the specified range. If these steps don't resolve the issue, internal transmission repairs may be necessary.

Overheating: A Silent Killer of Transmissions

Excessive heat is a major enemy of any transmission. It can break down the lubricating oil, damage seals, and warp internal components. In the Polaris General, overheating can often be linked to:

  • Low Transmission Fluid: Insufficient fluid levels can lead to increased friction and heat.
  • Contaminated Transmission Fluid: Old or contaminated fluid loses its lubricating properties and can contribute to overheating.
  • Overloading: As mentioned earlier, overloading puts excessive strain on the transmission, generating more heat.
  • Aggressive Driving: Frequent hard acceleration and prolonged high-speed operation can also lead to overheating.
  • Clogged Transmission Cooler: Some Polaris General models are equipped with a transmission cooler. If this cooler is clogged with dirt or debris, it can't effectively dissipate heat.
  • Airflow Obstruction: Ensure adequate airflow around the transmission. Mud or debris buildup can restrict airflow and contribute to overheating.

Diagnosing Overheating: Watch for signs of overheating, such as a warning light on the dashboard, a burning smell, or a noticeable loss of power. Check the transmission fluid level and condition. Inspect the transmission cooler for clogs.

Fixing Overheating: Regularly check and maintain the transmission fluid level and condition. Replace the fluid according to the manufacturer's recommendations. Avoid overloading the vehicle and try to drive more smoothly. Clean the transmission cooler and ensure adequate airflow around the transmission. Consider installing an aftermarket transmission cooler for added protection, especially if you frequently operate in hot conditions or tow heavy loads.

Clutch Problems: Beyond the Belt

While belt slip is a common symptom, the underlying cause often lies within the clutches themselves. Here are some common clutch-related issues:

  • Worn Clutch Rollers/Weights: The rollers or weights in the drive clutch are responsible for engaging the clutch as engine speed increases. Over time, these components can wear down, preventing the clutch from engaging properly.
  • Damaged Clutch Springs: The clutch springs control the engagement and disengagement of the clutches. Weak or broken springs can lead to inconsistent clutch performance.
  • Sticking Clutch Sheaves: The clutch sheaves (the faces that the belt rides on) can become sticky due to dirt, rust, or corrosion, preventing them from moving freely.
  • One-Way Bearing Failure: Some Polaris General models use a one-way bearing in the drive clutch. If this bearing fails, it can cause jerky acceleration and difficulty braking.

Diagnosing Clutch Problems: Pay attention to symptoms such as jerky acceleration, inconsistent clutch engagement, or unusual noises coming from the clutch area. Inspect the clutch rollers, weights, and springs for wear or damage. Check the clutch sheaves for stickiness.

Fixing Clutch Problems: Replace worn or damaged clutch rollers, weights, and springs. Clean the clutch sheaves with a non-chlorinated brake cleaner and lubricate them with a dry lubricant. If the one-way bearing is faulty, replace it. Consider upgrading to aftermarket clutch components for improved performance and durability.

Electronic Gremlins: When Sensors Go Haywire

The Polaris General's transmission relies on various sensors to monitor its operation and provide feedback to the engine control unit (ECU). A faulty sensor can trigger warning lights, cause erratic shifting, or even prevent the transmission from functioning at all. Common sensor-related issues include:

  • Speed Sensor Failure: The speed sensor provides information about the vehicle's speed to the ECU. A faulty speed sensor can cause shifting problems and trigger a check engine light.
  • Transmission Temperature Sensor Failure: The transmission temperature sensor monitors the temperature of the transmission fluid. A faulty sensor can cause the ECU to misinterpret the transmission's condition and potentially lead to overheating.

Diagnosing Sensor Problems: Use a diagnostic scanner to check for trouble codes. Test the sensors with a multimeter to verify their functionality.

Fixing Sensor Problems: Replace faulty sensors with new ones. Ensure the wiring and connectors are clean and properly connected.

Preventing Problems: A Proactive Approach

The best way to deal with Polaris General transmission problems is to prevent them from happening in the first place. Here are some preventative maintenance tips:

  • Regularly Inspect the Belt: Check the belt for wear, cracks, and fraying. Replace it according to the manufacturer's recommendations.
  • Clean the Clutch Faces: Keep the clutch faces clean and free of contamination.
  • Maintain Proper Belt Tension: Ensure the belt tension is correct.
  • Check and Maintain Transmission Fluid: Regularly check the transmission fluid level and condition. Replace the fluid according to the manufacturer's recommendations.
  • Clean the Transmission Cooler: Keep the transmission cooler clean and free of debris.
  • Avoid Overloading: Don't exceed the General's weight capacity.
  • Drive Smoothly: Avoid aggressive acceleration and abrupt stops.
  • Perform Regular Maintenance: Follow the manufacturer's recommended maintenance schedule.

Frequently Asked Questions

  • Why does my Polaris General belt keep breaking? Several factors can cause belt breakage, including a worn belt, contaminated clutches, overloading, and aggressive driving.
  • How often should I change my Polaris General transmission fluid? Consult your owner's manual for the recommended fluid change interval. Typically, it's every 100 hours of operation or annually.
  • What kind of transmission fluid does my Polaris General use? Use the fluid specified in your owner's manual. Using the wrong fluid can damage the transmission.
  • Is it normal for my Polaris General transmission to be noisy? Some noise is normal, but excessive noise, grinding, or clunking sounds can indicate a problem.
  • Can I upgrade my Polaris General transmission for better performance? Yes, aftermarket clutch kits and other performance upgrades are available to improve transmission performance and durability.

In conclusion, understanding the common transmission problems that can plague a Polaris General, along with their potential causes and solutions, will empower you to diagnose issues early and take proactive steps to prevent them. Regular maintenance and careful driving habits are key to keeping your General's transmission running smoothly for years to come.