Crankcase Assembly; Cylinder Head Assembly - Polaris Sportsman XP 1000 S 2020 Service Manual

ENGINE / COOLING SYSTEM

CRANKCASE ASSEMBLY

1. Prepare upper and lower crankcase and install all
components as described previously.
2. Inspect crankshaft seals to be sure they are aligned
flush with ends of crankcase.
3. Be sure balance shaft end plugs are installed with
retaining flange fitted in the grooves of crankcase.
4. Be sure oil passage tube is installed with new O-
rings.
5. Clean crankcase mating surfaces to remove all oil
and grease.
6. Apply a thin, continuous film of Polaris Crankcase
Sealant (PN 2871557) to upper and lower crankcase
mating surfaces as shown in "Crankcase Sealant
and Torque Values". Do not allow sealant to dry
before assembly.
7. Apply engine oil to crankshaft main bearings in the
lower crankcase half.
8. Carefully place lower crankcase on upper case,
making sure the oil supply tube and oil pump drive
gear are aligned.
9. Tap with a rubber hammer to seat cases together.
10. Apply a light film of engine oil to flange and threads
of M9 crankcase bolts.
11. Install all crankcase bolts and tighten all lightly by
hand.
12. Inspect mating surfaces to be sure they are joined
properly. Investigate the cause of any gaps.
13. Torque all crankcase bolts in sequence as shown in
"Crankcase Sealant and Torque Values" to final
torque value, then repeat the sequence to verify final
torque.
TORQUE
Crankcase Bolts (M6)
89 in-lbs (10 N·m)
Crankcase Bolts (M9)
Torque in Sequence:
Step 1: 70 in-lbs (8 N·m)
Step 2: 26 ft-lbs (35 N·m)
14. Install cylinder head.
Installation".
15. Rotate the crankshaft by hand several times to verify
there is no interference with the balance shafts. The
crankshaft should rotate smoothly without binding.
3.72
See "Cylinder Head

CYLINDER HEAD ASSEMBLY

NOTICE
Assemble valves one at a time to maintain proper order.
1. Apply engine oil to valve guides and seats.
2. Coat valve stem with Polaris Premium Starter
Grease (PN 2871460).
3. Install valve in guide.
4. Valve seals should be installed after the valves are in
the head to avoid valve seal damage. Install NEW
valve seals on valve guides carefully with a rotating
motion.
5. Dip valve spring and retainer in clean engine oil.
6. Install spring with tight wind facing DOWN (toward
head).
NOTICE
Install valve spring with the orange coil marking towards
7. Place top retainer on spring.
8. Compress spring.
9. Install split keepers with gap even on both sides.
NOTICE
To prevent damage to the valve seals, do not compress
the valve spring more than necessary to install the
keepers. A small magnet can be used to aid installation.
10. Repeat procedure for remaining valves. When all
valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
keepers.
Do not tap on the top retainer or split keepers could
dislodge, causing serious injury. Tap only on the end of
the valve stem.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
the top.
WARNING
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