Polaris Sportsman XP 1000 S 2021 Manuals

Manuals and User Guides for Polaris Sportsman XP 1000 S 2021. We have 1 Polaris Sportsman XP 1000 S 2021 manual available for free PDF download: Service Manual

Polaris Sportsman XP 1000 S 2021 Service Manual

Polaris Sportsman XP 1000 S 2021 Service Manual (528 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 31.14 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Model Number Designation (2015 +)
  9
- Vehicle Identification
  9
- Vehicle Identification Number (Vin) Designation
  9
- Vehicle and Engine Serial Number Locations
  10
- Reference Information
  11
  - Publication Numbers
    11
  - Special Tools
    12
  - Master Special Tools Table
    13
  - Master Torque Table
    20
- Vehicle Specifications
  24
  - 2021 Sportsman Xp 1000 S (International Models)
    26
- Misc. Specifications and Charts
  28
  - Conversion Table
    28
  - Sae Tap / Drill Sizes
    29
  - Metric Tap / Drill Sizes
    29
  - Decimal Equivalents
    30
- General Diagnostics
  31
- Fluid Inspection
  63
- Fluid Leaks
  63
- Fuel System Diagnostics
  64
  - Fuel System Troubleshooting
    64
- Pvt System Diagnostics
  66
  - Pvt System Troubleshooting
    66
  - Pvt System Overheating / Diagnosis
    68
- Transmission Diagnostics
  69
  - Hard Shifting
    69
  - Transmission Isolation
    69
- Final Drive Diagnostics
  70
  - All Wheel Drive (Awd) Concerns
    70
  - Driveshaft (Half Shaft) Diagnostics
    70
- Brake System Diagnostics
  71
  - Brake Noise Troubleshooting
    71
  - Brake Vibration
    71
  - Caliper Overheats (Brakes Drag)
    72
  - Poor Brake Performance
    72
  - Brakes Lock
    72
- Steering / Suspension Diagnostics
  73
- Electrical Diagnostics
  77
Maintenance Chapter 2 Maintenance 2

85
- Break-In Period
  87
- Chapter 2
  87
- Maintenance
  87
- Periodic Maintenance
  87
- Periodic Maintenance Overview
  87
- Pre-Ride Inspection
  88
- Maintenance Intervals
  89
- Grease Lubrication Points
  99
- Maintenance Quick Reference
  100
- Lubricants / Service Products
  102
  - Polaris Lubricants / Maintenance / Service Products
    102
  - 50/50 Extended-Life Engine Antifreeze
    103
- Fuel System / Air Intake
  104
  - Fuel System
    104
  - Fuel Lines
    104
  - Fuel Filter
    104
  - Vent Lines
    104
  - Air Filter / Pre-Filter Service
    105
- Engine
  106
  - Engine Oil Level
    106
  - Engine Oil and Filter Change
    106
  - Engine Breather Hose
    107
  - Valve Clearance Adjustment
    108
  - Compression and Leakdown Testing
    110
  - Exhaust Silencer Cleaning
    110
  - Engine Mount Isolator Fastener Torque
    111
- Cooling System
  112
  - Cooling System Overview
    112
  - Coolant Level Inspection
    112
  - Cooling System Hoses
    113
  - Coolant Strength / Type
    113
- Pvt / Final Drive / Wheels / Tires
  114
  - Pvt Drying
    114
  - Drive Shaft Boot Inspection
    114
  - Wheel Removal
    114
  - Wheel Installation
    115
  - Tire Pressure
    115
  - Tire Inspection
    115
- Transmission / Gearcase
  116
  - Transmission Lubrication
    116
  - Front Gearcase Lubrication
    117
  - Rear Gearcase Lubrication
    118
- Electrical / Ignition System
  119
- Maintenance
  119
  - Battery Maintenance
    119
    
    Agm Low Maintenance Battery Maintenance
    119
    
    Dry Shipped Agm Battery Maintenance
    119
    
    Lead Acid Conventional Battery Maintenance
    119
    
    Lead Acid Low Maintenance Battery Maintenance
    119
  - Battery off Season Storage
    120
  - Extreme Use 30 Ah Battery
    120
  - Engine / Chassis Ground
    120
  - Spark Plug Service
    121
- Steering
  122
  - Steering Inspection
    122
  - Power Steering Unit (Eps Models)
    122
  - Tie Rod End / Steering Inspection
    122
  - Toe Alignment
    123
  - Toe Alignment Adjustment
    124
- Suspension
  125
- Brake System
  127
  - Brake Fluid Inspection
    127
  - Brake Pad / Disc Inspection
    128
  - Hose / Fitting Inspection
    128
  - Brake Pedal
    129
Chapter 3 Engine / Cooling System

131
- Engine Lubrication Specifications
  134
- General Information - Engine
  134
- Special Tools
  134
- Oil Pressure Test
  135
- Oil Flow Diagram
  136
- Engine Specifications
  137
- General Information - Cooling System
  139
  - Special Tools
    139
  - Cooling System Layout and Testing
    139
  - Cooling System Specifications
    140
  - Cooling System Bleeding Procedure
    140
  - Coolant Drain / Radiator Service
    141
    
    Cooling System Assembly View
    141
    
    Coolant Drain / Fill
    142
    
    Radiator Cleaning
    142
    
    Radiator Installation
    143
    
    Radiator Removal
    143
  - Water Pump Service
    144
    
    Water Pump Impeller Removal
    144
    
    Water Pump Mechanical Seal Replacement
    144
    
    Stator Cover Installation
    146
  - Thermostat
    147
    
    Thermostat Replacement
    147
- Intake / Exhaust System
  148
  - Air Intake Assembly View
    148
  - Exhaust Assembly View
    149
  - Intake Replacement
    151
  - Heat Shields
    153
- Engine Assembly Views
  155
  - Torque Sequence - Main Engine Components
    155
  - Valve Cover Assembly View
    157
  - Camshaft / Camshaft Carrier / Rocker Arm Assembly View
    158
  - Cylinder Head / Valves / Integrated Throttle Body Assembly View
    159
  - Valve and Spring Height Detail
    160
  - Piston / Connecting Rod
    161
  - Crankshaft
    162
  - Crankcase Assembly View
    163
  - Crankcase - Upper
    165
  - Crankcase (Lower) with Oil Pump
    166
  - Balance Shaft / Balance Shaft Timing
    167
  - Drive Coupler / Starter Gear
    168
  - Stator Cover Assembly View
    169
  - Water Pump Cover Assembly View
    170
- Engine Service
  171
  - Accessible Engine Components
    171
  - Top-End Service (Engine in Chassis)
    171
  - Engine Removal
    171
  - Engine Installation Notes
    175
- Engine Disassembly / Inspection
  176
  - Valve Cover Removal / Inspection
    176
  - Rocker Carrier / Camshaft Removal
    176
  - Rocker Arm / Rocker Arm Shaft Inspection
    177
  - Camshaft / Camshaft Bore Inspection
    178
  - Cylinder Head Removal
    178
  - Cylinder Head Cleaning
    178
  - Cylinder Head Warp Inspection
    179
  - Cylinder Head Disassembly
    179
  - Valve Inspection
    180
  - Combustion Chamber
    181
  - Valve Guide Removal / Installation
    181
  - Valve Seat Reconditioning
    181
  - Crankcase Disassembly
    184
  - Crankcase (Lower) / Oil Pump Disassembly
    185
  - Crankcase Disassembly (Upper)
    186
  - Piston / Connecting Rod Removal
    186
  - Counterbalance Shaft Removal / Inspection
    187
  - Crankshaft / Cam Chain Removal
    188
  - Cam Chain / Sprocket Inspection
    188
  - Crankcase Inspection - Lower
    188
  - Crankshaft Inspection
    188
  - Connecting Rod Inspection
    189
  - Connecting Rod Big End Bearing Selection
    190
  - Piston Ring to Groove Clearance Inspection
    192
  - Piston Ring Removal
    192
  - Piston Ring Installed Gap
    192
  - Piston Pin Bore Inspection
    193
  - Cylinder Inspection
    193
  - Piston-To-Cylinder Clearance
    194
- Engine Assembly
  195
  - Crankcase Preparation - Upper
    195
  - Piston Ring Installation
    195
  - Piston / Connecting Rod Assembly
    196
  - Piston / Connecting Rod Installation
    196
  - Crankshaft Installation
    197
  - Oil Passage Tube
    197
  - Balance Shaft Installation
    198
  - Balance Shaft Timing
    199
  - Crankcase Preparation - Lower
    200
- Crankcase Sealant and Torque Values
  201
- Crankcase Assembly
  202
- Cylinder Head Assembly
  202
- Cylinder Head Installation
  203
- Valve Sealing Test
  203
- Camshaft / Camshaft Carrier Assembly
  204
- Camshaft / Camshaft Carrier Installation
  205
- Camshaft Timing
  206
- Camshaft Timing - Quick Reference
  207
- Cam Chain Tensioner Installation
  208
Chapter 4 Engine Electrical

209
- Digital Wrench Diagnostic Connector
  211
- Efi System
  211
  - Operation Overview
    212
  - Initial Priming / Starting Procedure
    212
  - Efi System Layout
    213
    
    Efi System Assembly View
    213
  - Efi Components
    214
    
    Identification / Location
    214
    
    Efi Service Notes
    216
- Fuel Injectors
  217
  - Operation Overview
    217
  - Fuel Injector Service
    217
  - Fuel Injector O-Rings
    218
  - Fuel Injector Test
    218
  - Injector Replacement
    219
- Electronic Control Unit (Ecu)
  220
  - Operation Overview
    220
  - Ecu Service
    220
  - Ecu Removal / Replacement
    221
  - Ecu Pinouts (Domestic Models)
    222
  - Ecu Pinouts (International Models)
    225
- Electronic Throttle Control (Etc)
  228
  - Etc Overview
    228
  - Etc Test
    228
  - Etc Replacement
    228
  - Etc Learn Procedure
    228
- Crankshaft Position Sensor (Cps)
  230
  - Operation Overview
    230
  - Cps Service
    230
- Temperature / Manifold Absolute Pressure (T-Map) Sensor
  231
  - Operation Overview
    231
  - T-Map Test
    231
  - T-Map Replacement
    231
- Engine Coolant Temperature (Ect) Sensor
  232
  - Operation Overview
    232
  - Ect Sensor Test
    232
  - Ect Sensor Replacement
    232
- Throttle Control Sensor (Tcs)
  233
- Igntion Coil
  235
  - Operation Overview
    235
  - Ignition Coil Test
    235
  - Ignition Coil and High Tension Lead Replacement
    236
- Stator / Alternator
  237
  - Stator / Alternator Removal
    237
  - Stator / Alternator Installation
    238
  - Stator / Alternator Test
    238
- Starter Motor
  240
  - Starter / Starter Lockout System Diagram
    240
  - Troubleshooting
    240
  - Starter Motor Removal / Replacement
    240
Chapter 5 Fuel System

243
- Fuel Line / Hose
  244
- Fuel Line Quick Connect Removal
  244
- Fuel Vent Line / Check Valve Testing
  246
- Fuel Vent Line Routing
  247
- Fuel Supply Line Routing
  248
- Fuel Tank
  249
  - Fuel Tank Assembly View
    249
  - Fuel Tank Removal
    251
  - Fuel Tank Installation
    252
- Fuel Pump
  253
  - Operation Overview
    253
  - Fuel Sender Test
    253
  - Fuel Pump Test
    253
  - Fuel Pump Replacement
    255
Chapter 6 Pvt System

259
- Drive Clutch Operation
  260
- Driven Clutch Operation
  260
- General Operation
  260
- Special Tools and Supplies
  260
- Maintenance / Inspection
  261
- Shift Weights
  261
- Pvt System Service
  262
  - Pvt Sealing and Ducting Components
    262
  - Pvt Disassembly
    263
  - Pvt Assembly
    265
- Drive Belt
  267
  - Pvt Break-In (Drive Belt / Clutches)
    267
  - Drive Belt Removal
    267
  - Drive Belt Inspection
    267
  - Drive Belt Installation
    268
  - Belt / Clutch Alignment
    269
- Drive Clutch Service
  271
  - Drive Clutch Assembly View
    271
  - Drive Clutch Disassembly
    272
  - Drive Clutch Spring Inspection
    273
  - Shift Weight Inspection
    273
  - Spider Removal
    274
  - Roller, Pin, and Thrust Washer Inspection
    274
  - Button to Tower Clearance Inspection
    275
  - Bearing Inspection and Service
    275
  - Drive Clutch Inspection
    276
  - Drive Clutch Bushing Service
    277
  - Drive Clutch Assembly
    279
- Driven Clutch Service
  281
  - Driven Clutch Assembly View
    281
  - Driven Clutch Slider Inspection
    282
  - Driven Clutch Disassembly
    282
  - Bushing Service
    284
  - Driven Clutch Assembly
    286
Chapter 7 Transmission

289
- Gear Selector Removal
  290
- Transmission Lubrication Specifications
  290
- Transmission Service
  291
  - Transmission Vent Routing
    291
  - Transmission Removal
    292
  - Transmission Disassembly
    294
  - Transmission Shaft Service
    297
  - Transmission Assembly
    304
  - Transmission Installation
    308
  - Transmission Assembly View
    310
Chapter 8 Final Drive

313
- Wheels
  316
  - Wheel Removal
    316
  - Wheel Installation
    316
- Wheel Studs
  317
  - Wheel Stud Service
    317
- Wheel Hubs
  320
  - Front Hub Assembly View
    320
  - Rear Hub Assembly View
    321
- Front Bearing Carrier
  322
- Front Drive Shaft
  326
  - Removal
    326
  - Installation
    327
- Front Propshaft
  328
  - Removal
    328
  - Installation
    328
- Propshaft U-Joint Service
  329
  - Propshaft U-Joint Disassembly
    329
  - Propshaft U-Joint Assembly
    330
- Front Gearcase Removal / Installation
  332
  - Front Gearcase Removal
    332
  - Front Gearcase Installation
    333
- Front Gearcase (Adc)
  334
- Rear Bearing Carrier
  347
- Rear Drive Shaft
  350
  - Rear Drive Shaft Removal
    350
  - Rear Drive Shaft Installation
    351
- Drive Shaft Service
  352
- Rear Propshaft
  357
  - Removal
    357
  - Installation
    357
- Rear Gearcase
  358
  - Gearcase Removal
    358
  - Gearcase Disassembly / Inspection
    359
  - Gearcase Bearing and Seal Replacement
    360
  - Gearcase Assembly
    362
  - Rear Gearcase Assembly View
    364
  - Gearcase Installation
    365
Chapter 9 Steering / Suspension

367
- Handlebar Removal / Replacement
  369
- Handlebar Installation
  370
- Steering
  371
  - Steering Assembly View
    371
  - Upper Steering Post Removal
    373
  - Upper Steering Post Installation
    374
  - Eps Unit Removal
    375
  - Eps Unit Installation
    376
- Steering Tie Rods
  379
  - Tie Rod / Tie Rod End Replacement
    379
- Front Control Arms
  380
  - Assembly View
    380
  - Front Control Arm Removal
    382
  - Front Control Arm Installation
    383
- Ball Joint Service
  385
  - Service Preparation
    385
  - Ball Joint Removal
    385
  - Ball Joint Installation
    386
- Rear Controls Arms
  388
  - Assembly View
    388
  - Rear Control Arm Removal
    390
  - Rear Control Arm Installation
    391
- Rear Stabilizer Bar
  393
- Shocks / Springs
  396
  - Shock Assembly View (Walker Evans™)
    396
  - Shock Assembly View (Sachs)
    398
  - Shock Removal / Installation
    400
  - Shock / Spring Replacement
    400
- Shock Service
  401
  - Walker Evans™ Shock Assembly View
    401
  - Shock Service Information
    402
  - General Service Information
    404
  - Spring Adjustment (Walker Evans™)
    404
  - Walker Evans™ Shock Rebuild Information
    405
  - Special Tools
    405
  - Valve Shim Arrangement
    405
  - Shock Piston Orientation
    405
Chapter 10 Brake System

415
- General Brake Specifications
  417
- Special Tools / Brake Fluid
  417
- Brake System Operation
  418
- Brake System Service Notes
  418
- Brake System (Domestic Models)
  419
  - Brake System Assembly View
    419
  - Front Caliper Assembly View
    421
  - Rear Caliper Assembly View
    422
  - Front Brake Master Cylinder Assembly View
    423
  - Brake Line Routing
    424
- Brake System (International Models)
  425
  - Brake Fluid Flow
    425
  - Brake System Assembly View
    427
  - Front Caliper Assembly View
    429
  - Rear Caliper Assembly View
    430
  - Front Brake Master Cylinder Assembly View
    431
  - Brake Line Routing
    432
  - Brake Warning System Overview
    433
  - Brake Warning System Inspection
    433
  - Hand Brake Master Cylinder Switch Inspection / Testing
    433
  - Brake Pressure Switch Inspection / Testing
    434
- Brake Fluid Bleeding
  435
- Front Brake Master Cylinder
  440
  - Removal
    440
  - Disassembly
    440
  - Installation
    440
  - Brake Switch Replacement
    441
- Rear Brake Master Cylinder (Domestic Models)
  442
- Rear Brake Master Cylinder (International Models)
  444
- Brake Pads
  446
  - Pad Removal
    446
  - Pad Inspection
    446
  - Pad Installation
    446
  - Brake Burnishing Procedure
    447
- Brake Caliper Service
  448
  - Caliper Removal
    448
  - Caliper Disassembly
    448
  - Caliper Inspection
    449
  - Caliper Assembly
    449
  - Caliper Installation
    450
- Brake Disc Service
  452
  - Disc Inspection
    452
  - Disc Removal / Replacement
    452
Chapter 11 Body / Frame

455
- Decal Replacement
  457
- Multi-Function Pliers
  457
- Plastic Push Rivet Removal
  457
- Body Service
  458
  - Headlight Pod
    458
    
    Headlight Pod Assembly
    458
    
    Headlight Pod Disassembly
    458
  - Seat
    459
    
    Seat Installation
    459
    
    Seat Removal
    459
  - Side Panels
    460
    
    Side Panel Installation
    460
    
    Side Panel Removal
    460
  - Mud Guards
    461
    
    Mud Guard Removal / Installation
    461
  - Front Rack / Storage Box
    462
    
    Front Rack Removal
    462
    
    Front Rack Installation
    463
  - Front Bumper
    464
    
    Front Bumper Installation
    464
    
    Front Bumper Removal
    464
  - Front Bumper Cover
    465
    
    Front Bumper Cover Installation
    465
    
    Front Bumper Cover Removal
    465
  - Front Cab
    466
    
    Front Cab Installation
    466
    
    Front Cab Removal
    466
  - Rear Rack / Storage Box
    469
    
    Rear Rack Installation
    469
    
    Rear Rack Removal
    469
  - Rear Bumper
    471
    
    Rear Bumper Installation
    471
    
    Rear Bumper Removal
    471
  - Rear Bumper Cover
    473
    
    Rear Bumper Cover Installation
    473
    
    Rear Bumper Cover Removal
    473
  - Rear Cab
    474
    
    Rear Cab Removal / Installation
    474
  - License Plate Bracket (International Models)
    474
    
    License Plate Bracket Removal / Installation
    474
- Rear Fog Light Bracket (International Zug Models)
  475
  - Rear Fog Light Bracket Removal / Installation
    475
- Main Frame / Frame Supports
  476
  - Assembly View - Front / Rear
    476
Chapter 12 Body Electrical

479
- Chassis Harness
  483
  - Harness Retention Locations
    483
  - Harness Routing
    484
- Switches / Controls
  485
  - Brake Switch
    485
  - Ignition Key Switch
    485
  - Ignition Key Switch (International Models)
    485
  - Drive Line Switch
    486
  - Off / Run Switch
    486
  - Left-Hand Switch Controls
    487
  - Reverse / Mode Button
    488
  - Headlamp Switch
    488
  - Gear Selector Resistor Module
    489
  - Transmission (Gear Position) Switch
    489
- Battery Service
  490
- Body Electrical
  499
  - Voltage Rectifier / Regulator
    499
    
    Voltage Rectifier / Regulator Overview
    499
    
    Voltage Regulator Removal
    499
    
    Voltage Regulator Installation
    500
  - Current Draw - Key off
    500
  - Battery Charge Test
    501
- Charging System
  499
  - Charging System Overview
    499
- Lights
  502
  - Headlights
    502
    
    Headlight Adjustment, Pod
    502
    
    Headlight Replacement, Pod
    502
    
    Headlight Adjustment, Bumper
    503
    
    Headlight Replacement, Bumper
    503
  - Taillights
    504
    
    Center Brake Light / Work Light Replacement
    504
    
    Taillight / Brake Light Replacement
    504
    
    License Plate Light Replacement (International Models)
    505
- Displays
  506
  - Instrument Cluster
    506
    
    Overview
    506
    
    Instrument Cluster - Key off / no Power
    507
    
    Troubleshooting
    507
    
    Instrument Cluster - Key on / no Power
    508
    
    Instrument Cluster - no High Beam Indicator
    509
    
    Instrument Cluster - no / Incorrect Fuel Level
    510
- Speed Sensor
  511
  - Vehicle Speed Sensor Overview
    511
- All Wheel Drive (Awd) and Adc Coils
  512
  - Operation Overview
    512
  - Diagnosing System Failures
    512
- Fuse / Relays
  514
  - Relay Overview
    514
  - Chassis Relay
    514
  - Fan Relay
    514
  - Efi Relay
    514
  - Bumper Light Relay
    514
  - Start Solenoid Relay
    515
  - Low Beam Light Relay
    515
  - Fuse / Relay Box Layout
    516
- Electronic Power Steering (Eps)
  517
  - Eps Operation
    517
- Winch
  518
  - Winch Assembly View
    518
  - Winch Contactor
    519
- Controller Area Network (Can)
  520

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