Polaris Sportsman XP 1000 S 2020 Service Manual
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Polaris Sportsman XP 1000 S 2020 Service Manual

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Table of Contents

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2020-2021 Sportsman XP 1000 S
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2020 (PN 9931493 R03)
© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris Sportsman XP 1000 S 2020

  • Page 1 Publication Printed September 2020 (PN 9931493 R03) © Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 2 SAFETY WARNINGS The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 4 • Updated pins 3 and 4 in the “Instrument Cluster Pinouts” topic. FEEDBACK FORM A feedback form has been created for the technician or consumer to provide Polaris with an overall satisfaction rating for this service manual, provide comments on your experience or upload pictures/video.
  • Page 5 2020-2021 Sportsman XP 1000 S Service Manual Chapter Summary CHAPTER 1 : GENERAL INFORMATION CHAPTER 2 : MAINTENANCE CHAPTER 3 : ENGINE / COOLING SYSTEM CHAPTER 4 : ENGINE ELECTRICAL CHAPTER 5 : FUEL SYSTEM CHAPTER 6 : PVT SYSTEM CHAPTER 7 : TRANSMISSION CHAPTER 8 :...

  • Page 7: Table Of Contents

    ..........1.42 POLARIS MOBILE DIGITAL WRENCH® (PMDW) .
  • Page 8 ................1.76 TESTING VOLTAGE DROP 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 9: Vehicle Identification

    * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J = 2018; K = 2019, L = 2020, M = 2021 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 10: Vehicle And Engine Serial Number Locations

    . International Models: The VIN is stamped on the lower frame rail on the front LH side of the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 11: Reference Information

    Sportsman XP 1000 S EU (Intl.) A21SLE95FG 9931152 2021 A21SLS95CG Sportsman XP 1000 S Tractor (Intl.) 9931153 A21SLS95EG Sportsman XP 1000 S ZUG (Intl.) A21SLS95FG 9931152 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 12: Special Tools

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.

  • Page 13: Master Special Tools Table

    (Use With 2.375” Bore Stand) Nut Puller PU-50625 PW-47054 PA-49316-A Stator Cover Removal Handles Valve Spring Compressor Water Pump Seal Installation Tool PA-49317 PV-1253 or PV-43513-A PU-50869 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 14 Oil Filter Wrench Oil Pressure Gauge Tool Kit PU-50105 PV-43531 PU-50784 Oil Pressure Gauge Adapter Valve Spring Compressor Adapter Cylinder Leakdown Tester PU-52492 PV-43513-A PV-35667-A Hydrometer PU-50338 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 15 (Includes: PU-47470, PU-47469, PU- 47468) Fluke 77 Digital Multi-Meter or Fluke Fuel Pressure Gauge Adapter Fuel Pump Service Tool PS-48762 115 DMM PU-50326 (PV-43568) or (PV-43546) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 16 Primary Clutch Puller Drive Clutch Spider Removal and Installation Tool 9314177-A PU-52907 2870341 Piston Pin Puller Roller Pin Tool Universal Clutch Compressor 2870386 2870910-A PU-50518-A 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.10 © Copyright Polaris Inc.
  • Page 17 FINAL DRIVE 1 3/4” Straight Wrench ADC Gearcase Piston Installation CV Boot Clamp Pliers 2870772 Tool 8700226 or PU-48951 PA-48542 Roller Pin Removal Tool 2872608 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.11 © Copyright Polaris Inc.
  • Page 18 Strut Compression Tools Shock Absorber Spring Compression PU-50506 2871573, 2871574, 2870623 Tool 2870623 BRAKES Mity Vac® Pressure Test Tool 2870975 BODY / FRAME Multi-Function Pliers 2876389 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.12 © Copyright Polaris Inc.
  • Page 19 Fluke® 77 Digital Multimeter PU-50296 2870836 PV-43568 Hall Sensor Probe Harness Static Timing Light Harness Timing Light 2460761 2871745 2870630 Relay Bypass Connector Test Kit PU-49466 PV-43526 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.13 © Copyright Polaris Inc.

  • Page 20: Master Torque Table

    Crankcase Bolts (M6) 89 in-lbs (10 N·m) 35 ft-lbs (47 N·m) Lambda Sensor Crankcase Bolts (M9) Torque in Sequence: Silencer End Cap Bolts 10 ft-lbs (14 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.14 © Copyright Polaris Inc.
  • Page 21 T-MAP Sensor Retaining 30 in-lbs (3 N·m) Bolt Throttle Control Sensor 9 in-lbs (1 N·m) Lever Screw Upper Fuel Fill Hose 24 in-lbs (3 N·m) Clamp 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.15 © Copyright Polaris Inc.
  • Page 22 Lock Nut 7 in-lbs (1 N·m) Reservoir Cover Screws LH Steering Idler 20 ft-lbs (27 N·m) Fasteners Rear Stabilizer End Rod 30 ft-lbs (40 N·m) Fasteners 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.16 © Copyright Polaris Inc.
  • Page 23 Rear Extender Screws Rear Fog Light Bracket 53 in-lbs (6 N·m) Fasteners 18 in-lbs (2 N·m) Rear Rack Screws Rear Storage 7 ft-lbs (9 N·m) Compartment Screws 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.17 © Copyright Polaris Inc.

  • Page 24: Vehicle Specifications

    1200 ± 50 RPM Engine Max RPM 7600 RPM Limit Overheat Warning Instrument Cluster Indicator Lubrication System Pressurized Wet Sump Polaris PS-4 Synthetic 4-Cycle Engine Oil Capacity / Engine Oil Requirement 2 qt (1.9 L) Polaris 50/50 Extended Life Coolant Capacity / Antifreeze Requirement 2.7 qt (2.6 L)
  • Page 25 Disc, Rear Wheel Unswitched: 10 A EPS: 30 A Brake - Parking Hydraulic Lock, All Wheel Fuel Pump: 10 A Brake Fluid Polaris DOT 4 Brake Fluid Capacity / DRIVETRAIN 0.37 qt (35 L) Requirement Transmission Type Automatic PVT Shift Type...

  • Page 26: 2021 Sportsman Xp 1000 S (International Models)

    7600 RPM Limit Overheat Warning Instrument Cluster Indicator Lubrication System Pressurized Wet Sump 2 qt (1.9 L) Engine Oil Capacity / Polaris PS-4 Synthetic 4-Cycle Requirement Engine Oil 2.7 qt (2.6 L) Coolant Capacity / Polaris 50/50 Extended Life Requirement Antifreeze...
  • Page 27 EPS: 30 A Brake - Parking Hydraulic Lock, All Wheel Fuel Pump: 10 A Brake Fluid 0.37 qt (35 L) DRIVETRAIN Capacity / Polaris DOT 4 Brake Fluid Requirement Transmission Type Automatic PVT Shift Type In-Line H-L-N-R-P CLUTCH SETTINGS Transmission...

  • Page 28: Misc. Specifications And Charts

    π (3.14) x Radius² x Height = °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.22 © Copyright Polaris Inc.

  • Page 29: Sae Tap / Drill Sizes

    5/16–18 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 3–4 7/16–14 2 3/4 7/16–20 25/64 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.23 © Copyright Polaris Inc.

  • Page 30: Decimal Equivalents

    17/32 0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 0.5938″ 19/32 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.24 © Copyright Polaris Inc.

  • Page 31: General Diagnostics

    Return the vehicle to the Has concern been repaired Are there any codes present? consumer at this time. after Guided Diagnostic? ↓ ↙ 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.25 © Copyright Polaris Inc.

  • Page 32: Guided Symptom References

    Refer to the Symptom Checklist for various conditions. – If the concern has been verified and all of the information has already been collected, please start an Ask Polaris case at this time. If this information has not yet been gathered, gather this information first.

  • Page 33: Engine And Drivability Diagnostic Procedures

    Functional with MIL ON) page 1.67 • Connect to Digital Wrench®. Check codes and continue with Digital Wrench® Guided diagnosis. • If no codes are present, proceed to step 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.27 © Copyright Polaris Inc.
  • Page 34 • After checking for air supply and fuel pressure, perform leakdown test. • Refer to Engine Cranks but does Not Start page 1.30 for more information. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.28 © Copyright Polaris Inc.
  • Page 35 These concerns may also be caused by a mechanical failure. • If the concern can not be diagnosed or repaired using normal diagnostic means, please contact Polaris Technical Service Team. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.29...

  • Page 36: Engine Cranks But Does Not Start

    10. Listen for unusual noises while cranking. • If filled with fuel, vehicle starts, and gauge still is not reading test the fuel sending unit. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.30 © Copyright Polaris Inc.
  • Page 37 – Bent valve or stuck valve – Valve spring broken or weak – Valve not seating properly (bent or carbon accumulated on sealing surface) – Rocker arm sticking 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.31 © Copyright Polaris Inc.

  • Page 38: No Crank No Start Or Slow Crank

    (starter / starter solenoid / wiring). Acceptable voltage drop during cranking is 0.1 V per connection. 5. Check Brake Switch operation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.32 © Copyright Polaris Inc.

  • Page 39: Over Heating

    • Check level and correct as necessary. Check maintenance history to determine if oil need to be changed. 7. Check Cooling Fan operation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.33 © Copyright Polaris Inc.

  • Page 40: Warning Lights

    Guided Diagnostic for further diagnosis. 5. BRAKE WARNING • Detects brake system failure. • Inspect brake system for leaks, damage, etc. Refer to Brake System chapter for more information. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.34 © Copyright Polaris Inc.

  • Page 41: Engine Troubleshooting

    • Broken throttle cable • Restricted exhaust system • Incorrect ignition timing • Obstruction in air intake • Low fuel pressure • Throttle Body 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.35 © Copyright Polaris Inc.
  • Page 42 • Low fuel pressure electrical concern / failed) faulty • Poor fuel quality – Poor connections in ignition system – Ignition timing incorrect – Sheared flywheel key 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.36 © Copyright Polaris Inc.

  • Page 43: Cooling Troubleshooting

    • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) TEMPERATURE TOO LOW • Thermostat stuck open • Contaminated coolant • Thermostat opening too soon 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.37 © Copyright Polaris Inc.

  • Page 44: Digital Wrench

    GENERAL INFORMATION DIGITAL WRENCH DIGITAL WRENCH® SOFTWARE OVERVIEW The Polaris Digital Wrench® software allows a technician to perform the following tasks: • Analyze real-time engine data • Create customer service account records • Generate / upload service reports • Perform guided diagnostic procedures •...

  • Page 45: Digital Wrench® Software Installation And Updates

    To check if a Digital Wrench® software update is following: available, do the following: 1. Open a web browser and log on to your Polaris dealer 1. Open a web browser and log on to the Polaris dealer website (www.polarisdealers.com).

  • Page 46: Digital Wrench® Diagnostic Connector

    DIGITAL WRENCH® COMMUNICATION ERRORS If you experience problems connecting to a vehicle, or any other Digital Wrench® software-related problem, visit the Digital Wrench® home page (www.polaris.diagsys. com) and locate the following information under Knowledge Base: • Errors and Troubleshooting • Frequently Asked Questions (FAQs) •...

  • Page 47: Digital Wrench® Feature Map

    Perform specialized testing Access the Digital Wrench® and adjustment functions System Help. service reports. Print the current screen as a Open the ASSERT ASK formatted printout. form. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.41 © Copyright Polaris Inc.

  • Page 48: Engine Controller Reprogramming (Reflash)

    – Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®. progress. 10. Open a web browser and log on to your Polaris dealer • Understand the Process website (www.polarisdealers.com). Review the Digital Wrench® System Help before you 11.
  • Page 49 GENERAL INFORMATION You can download the PMDW app on your Android device from the Polaris dealer website. From the Service and Warranty drop-down, select Digital Wrench, and then click Mobile Digital Wrench App Download. MINIMUM SPECIFICATIONS FOR ANDROID DEVICES • Minimum operating system: Android 3.1 “Honeycomb”...

  • Page 50: Engine Electrical Diagnostics

    0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present). 5. Press MODE to exit to the settings menu. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.44 © Copyright Polaris Inc.

  • Page 51: Master Trouble Code List

    Voltage Above Normal, Or Shorted To High Source P0108 Manifold Absolute Pressure Sensor Voltage Too Low P0107 Mechanical System Not Responding Or Out Of Adjustment P1106 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.45 © Copyright Polaris Inc.
  • Page 52 P1568 Data Valid But Above Normal Operating Range - Moderately Severe P1571 Level Data Valid But Below Normal Operating Range - Moderately Severe P1573 Level 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.46 © Copyright Polaris Inc.
  • Page 53 Mechanical System Not Responding Or Out Of Adjustment P0016 Camshaft Position Sensor Abnormal Frequency Or Pulse Width Or Period P0340 Voltage Above Normal, Or Shorted To High Source P1739 Tachometer Driver Circuit 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.47 © Copyright Polaris Inc.
  • Page 54 Wheel Speed Sensor (Rear or Voltage Above Normal, Or Shorted To High Source C113D Rear Left) Voltage Below Normal, Or Shorted To Low Source C123D 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.48 © Copyright Polaris Inc.
  • Page 55 1485 Current Below Normal Or Open Circuit P0685 Voltage Above Normal P0694 1557 Fan Driver 2 Voltage Below Normal, Or Shorted To Low Source P0693 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.49 © Copyright Polaris Inc.
  • Page 56 P17AE ECU Output Supply Voltage 3 3599 Voltage Above Normal, Or Shorted To High Source P17AA Voltage Below Normal, Or Shorted To Low Source P17AB 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.50 © Copyright Polaris Inc.
  • Page 57 Data Valid But Below Normal Operating Range - Least Severe Level P0174 Data Erratic, Intermittent Or Incorrect P1684 520206 Reverse Alarm Voltage Above Normal, Or Shorted To High Source P1682 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.51 © Copyright Polaris Inc.
  • Page 58 Current Below Normal Or Open Circuit C1029 ABS Solenoid (Front Right Out) 520257 Condition Exists C1329 Voltage Above Normal, Or Shorted To High Source C1020 520260 ABS Motor 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.52 © Copyright Polaris Inc.
  • Page 59 520287 Condition Exists P1542 ECU Monitoring of Injection Cut Off 520288 (Level 1) ECU Monitoring of Injection Cut Off Condition Exists P1543 520289 (Level 2) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.53 © Copyright Polaris Inc.
  • Page 60 Drive Mode Select Switch Voltage Below Normal, Or Shorted To Low Source P153B Operator Presence Switch Voltage Above Normal, Or Shorted To High Source P251C 524070 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.54 © Copyright Polaris Inc.
  • Page 61 EPS Fault Lamp Driver Circuit 524085 Voltage Above Normal, Or Shorted To High Source C106D EPS SEPIC Voltage Error 524086 Voltage Below Normal, Or Shorted To Low Source C106E 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.55 © Copyright Polaris Inc.

  • Page 62: Cylinder Misfire Detection

    Once this condition is met, the check engine light will turn off and the code(s) will show as historic. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.56 © Copyright Polaris Inc.

  • Page 63: Fluid Leaks

    • If a fluid is contaminated with metal or debris, suspect that there is a mechanical failure causing the fluid contamination. Refer to the Service Manual information related to the system in question. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.57 © Copyright Polaris Inc.

  • Page 64: Fuel System Diagnostics

    • Intake air leak (throttle shaft, intake ducts, air box cover) • Spark plug erosion / fouling • Faulty oxygen sensor • Engine runs hot • Surging • High / Erratic idle 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.58 © Copyright Polaris Inc.
  • Page 65 • High percentage of cylinder leakdown (worn engine) • Low compression (worn engine) • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.59 © Copyright Polaris Inc.

  • Page 66: Pvt System Diagnostics

    Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.60 © Copyright Polaris Inc.
  • Page 67 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.61 © Copyright Polaris Inc.

  • Page 68: Pvt System Overheating / Diagnosis

    PVT system. than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel Poor engine performance.

  • Page 69: Transmission Diagnostics

    • If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle. If it functions properly then there is likely still an outside concern causing the issue. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.63 © Copyright Polaris Inc.

  • Page 70: Final Drive Diagnostics

    Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.64 © Copyright Polaris Inc.

  • Page 71: Brake System Diagnostics

    • Brake Disc damaged VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING) • Worn Suspension components • Alignment issues 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.65 © Copyright Polaris Inc.

  • Page 72: Caliper Overheats (Brakes Drag)

    • Failed brake hose / line • Caliper pistons sticking • Improper assembly of brake system components • Failed master cylinder • Faulty distribution block (INTL models only ) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.66 © Copyright Polaris Inc.

  • Page 73: Steering / Suspension Diagnostics

    Check wiring from Connector to Ignition Switch 12 VDC on Pin 3 of the 8 pin EPS Connector? Circuit ↓ Begin Digital Wrench EPS Troubleshooting Procedure 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.67 © Copyright Polaris Inc.

  • Page 74: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)

    Instrument during MIL lamp Functional Trouble- Cluster Instrument and MIL shooting Power Up Cluster ON” Procedure Self Test? Power Up. ↑ ← ← ↓ ← 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.68 © Copyright Polaris Inc.

  • Page 75: Eps Troubleshooting (Using Digital Wrench®)

    If inverter temperature error code is present, replace Power Steering Module. If error is not present, Module is OK. EPS inverter temperature can be checked using Digital Wrench. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.69 © Copyright Polaris Inc.

  • Page 76: Shock Analysis

    (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal and what could be identified as a bad shock. MISTING OR WEEPAGE LEAKAGE 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.70 © Copyright Polaris Inc.

  • Page 77: Electrical Diagnostics

    • All associated circuits have no shorts to voltage. DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Voltage page 1.74 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) DYNAMIC TESTING for electrical testing.

  • Page 78: Connector Probing Guidelines

    To avoid causing damage, use of the appropriate Back probing is typically not advisable on sealed adapters is required. Most terminals used on Polaris connectors, as it can easily cause damage to the wire, machines can be tested using terminal test kit PV–...

  • Page 79: Testing Continuity / Resistance

    9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 1.74 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.73 © Copyright Polaris Inc.

  • Page 80: Testing For A Short To Voltage

    For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.74 © Copyright Polaris Inc.

  • Page 81: Testing For Intermittent Conditions

    Failure to do so can lead to serious injury and/or damage to the machine. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.75 © Copyright Polaris Inc.

  • Page 82: Current Draw - Key Off

    IMPORTANT Charging system damage will occur if incompatible components are installed. Always reference the Polaris TESTING VOLTAGE DROP Electronic Parts Catalog for the proper part numbers. NOTICE If you disconnect the connector at the load, and...
  • Page 83 GENERAL INFORMATION For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.77 © Copyright Polaris Inc.
  • Page 84 GENERAL INFORMATION NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 1.78 © Copyright Polaris Inc.
  • Page 85 ........2.18 POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS .
  • Page 86 ................... .2.45 BRAKE PEDAL 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 87: Maintenance

    Inspection, adjustment, and lubrication of important components are explained in the maintenance interval charts. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. IMPORTANT Service and adjustments are critical.

  • Page 88: Pre-Ride Inspection

    • Ensure rim is not cracked / bent Wheels / Lug Nuts • Verify proper lug nut torque • Inspect cable / line and switch Winch (if equipped) • Ensure operation 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 89: Maintenance Intervals

    The following symbols denote potential items to be aware of during maintenance: • XU Perform these procedures more often for vehicles subjected to severe use. • D Have an authorized Polaris dealer perform these services. • E Emission Control System Service (California)
  • Page 90 Steering Lubricate Throttle Body Intake Duct Inspect ducts for proper sealing / air leaks Inspect; adjust; lubricate; replace if necessary Throttle Cable Transmission Fluid Check level 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 91 175 HOUR / 1750 MILE (2800 KM) SERVICE ITEM REMARKS Inspect XU / D Brake Pad Wear Engine Oil Check level Front / Rear Gearcase Fluid Check level 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 92 Inspect; adjust as needed Valve Clearance Wheel Bearings Inspect; replace as needed Inspect for wear, routing, security; apply dielectric grease to Wiring connectors subjected to water, mud, etc. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 93 Front / Rear Gearcase Fluid Check level Inspect; cycle key to pressurize fuel pump; check lines and fittings for Fuel System Check leaks and abrasion. Transmission Fluid Check level 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 94 325 HOUR / 3250 MILE (5200 KM) SERVICE ITEM REMARKS Inspect XU / D Brake Pad Wear Engine Oil Check level Front / Rear Gearcase Fluid Check level 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.10 © Copyright Polaris Inc.
  • Page 95 Inspect; replace as needed Battery Check terminals; clean; test; replace as needed Change every two years Brake Fluid Inspect XU / D Brake Pad Wear 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.11 © Copyright Polaris Inc.
  • Page 96 Front / Rear Gearcase Fluid Check level Inspect; cycle key to pressurize fuel pump; check lines and fittings for Fuel System Check leaks and abrasion. Transmission Fluid Check level 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.12 © Copyright Polaris Inc.
  • Page 97 Clutches (Drive/Driven) Inspect; clean; replace worn parts Cooling Hoses Inspect for leaks Cooling System Replace coolant with Polaris 50/50 Extended-Life Antifreeze. Inspect; replace as needed Drive Belt 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.13 © Copyright Polaris Inc.
  • Page 98 Transmission Fluid Check level Wheel Bearings Inspect; replace as needed Inspect for wear, routing, security; apply dielectric grease to Wiring connectors subjected to water, mud, etc. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.14 © Copyright Polaris Inc.

  • Page 99: Grease Lubrication Points

    Grease before long periods of Grease fittings every 500 Polaris Premium U-Joint storage and after thoroughly Front Propshaft Yoke miles (800 km). Lubricant washing or submerging the ATV. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.15 © Copyright Polaris Inc.

  • Page 100: Maintenance Quick Reference

    FREQUENCY Perform a break-in oil and filter change at 25 hours / 250 miles (whichever Add engine oil as indicated Polaris PS-4 Synthetic 4- comes first); change every Engine Oil Cycle Engine Oil by the level on the dipstick. 100 hours thereafter.
  • Page 101 Fluid hours / 2000 miles thereafter. Change brake fluid every Maintain fluid level in both two years or 200 hours / Polaris DOT 4 Brake Fluid master cylinder reservoirs Brake Fluid 2000 miles (whichever to indicated levels. comes first). 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.17...

  • Page 102: Lubricants / Service Products

    MAINTENANCE LUBRICANTS / SERVICE PRODUCTS POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS LUBRICANTS, MAINTENANCE, AND SERVICE NOTICE PRODUCTS Each item can be purchased separately at your local (1 gal.) (6 count) Polaris dealer. Polaris 50/50 Extended Life Antifreeze 2880512 The number count indicated by each part number in the (55 gal.) (1 count)

  • Page 103: 50/50 Extended-Life Engine Antifreeze

    MAINTENANCE 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE All liquid-cooled Polaris vehicles use 50/50 Extended Life antifreeze, which has a 5-year service life. It’s important to note that conventional, 60/40 antifreeze can be mixed with 50/50 Extended Life antifreeze. However, mixing the two will affect the service interval. To receive the full 5-year service interval benefit, the cooling system must be fully drained and replenished with the Extended Life antifreeze.

  • Page 104: Fuel System / Air Intake

    Replace if necessary. 2. Make sure the fuel lines are routed properly and secured where applicable. IMPORTANT Make sure the fuel lines are not kinked or pinched. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.20 © Copyright Polaris Inc.

  • Page 105: Air Filter / Pre-Filter Service

    INSTALLATION 1. Inspect airbox cover seal for damage. It should adhere tightly to the cover and seal all the way around. Replace seal as needed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.21 © Copyright Polaris Inc.

  • Page 106: Engine

    ENGINE OIL LEVEL 5. Remove the dipstick again and check the oil level. Polaris recommends the use of Polaris PS-4 Synthetic 4- Cycle Engine Oil. Oil may need to be changed more frequently if Polaris engine oil is not used.

  • Page 107: Engine Breather Hose

    The sealing surfaces on the drain plug and crankcase Recommended Oil Type: should be clean and free of burrs, nicks or scratches. Polaris PS-4 Synthetic 4-Cycle Engine Oil Capacity: 9. Reinstall drain plug and torque to specification. Approximately 2 US quarts (1.9 L) TORQUE 16.

  • Page 108: Valve Clearance Adjustment

    15. Remove the (6) valve cover bolts and remove the valve cover from the engine. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.24 © Copyright Polaris Inc.
  • Page 109 (see step 18). Ensure you do not rely on the play up and down of the rocker after adjusting one exhaust valve. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.25 © Copyright Polaris Inc.

  • Page 110: Compression And Leakdown Testing

    1. Remove the four silencer end cap bolts. Plenum to Throttle Body Fasteners 89 in-lbs (10 N·m) 30. Start the engine to ensure proper valve adjustment was performed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.26 © Copyright Polaris Inc.

  • Page 111: Engine Mount Isolator Fastener Torque

    10. Reinstall the four silencer end cap bolts and torque to TORQUE specification. Engine Mount Isolator Fasteners 27 ft-lbs (37 N·m) TORQUE Silencer End Cap Bolts 10 ft-lbs (14 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.27 © Copyright Polaris Inc.

  • Page 112: Cooling System

    Overheating of engine could occur if air is not fully purged from system. Polaris recommends the use of Polaris 50/50 Extended Life Antifreeze or a 50/50 mixture of high quality 3. If the coolant level is below the MIN line on the bottle, aluminum compatible antifreeze and distilled water.

  • Page 113: Cooling System Hoses

    MAINTENANCE COOLANT STRENGTH / TYPE 7. Fill recovery bottle to MAX level with Polaris 50/50 Extended Life Coolant or a 50/50 mixture of Test the strength of the coolant using an antifreeze antifreeze/coolant and distilled water as required for hydrometer.

  • Page 114: Pvt / Final Drive / Wheels / Tires

    7. Allow the engine RPM to return to idle, then shift into low gear. 8. Test the PVT system for belt slippage. If the belt slips, repeat the process. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.30 © Copyright Polaris Inc.

  • Page 115: Wheel Installation

    TIRE PRESSURE TIRE PRESSURE INSPECTION (PSI - COLD) FRONT REAR 10 psi (69 kPa) 10 psi (69 kPa) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.31 © Copyright Polaris Inc.

  • Page 116: Transmission / Gearcase

    Do not overfill. FLUID CAPACITY Recommended Transmission Lubricant: Polaris AGL Gearcase Lubricant Capacity: 37 oz. (1100 ml) 7. Reinstall fill plug with a new O-ring and torque to 3. If lubricant level is not even with the bottom threads, specification.

  • Page 117: Front Gearcase Lubrication

    Maintain the fluid level even with the bottom threads of the fill plug hole. FLUID CAPACITY Recommended Front Gearcase Fluid: Polaris Demand Drive Fluid Capacity: 9.3 oz. (275 ml) 8. Inspect the fill plug and O-ring for signs of damage or 3.

  • Page 118: Rear Gearcase Lubrication

    FLUID CAPACITY 3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill. Recommended Rear Gearcase Lubricant: Polaris ATV Angle Drive Fluid 4. Reinstall fill plug and torque to specification. Capacity: TORQUE 7.1 oz (210 ml)

  • Page 119: Electrical / Ignition System

    BatteryMINDer® 2012 AGM - 2 AMP charger. Batteries will self discharge more rapidly when stored in extreme temperatures. BatteryMINDer® 2012 AGM - 2 AMP battery charger 2830438 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.35 © Copyright Polaris Inc.

  • Page 120: Battery Off Season Storage

    EXTREME USE 30 AH BATTERY connection allows the engine to provide a ground path. Polaris offers a 30 AH battery (P/N 4014609) for use in extreme conditions where the factory installed battery can not maintain a charge because of multiple electrical accessories.

  • Page 121: Spark Plug Service

    Adjust gap if necessary by carefully bending the side electrode. 12. Reinstall the shift linkage, upper RH side panel and seat. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.37 © Copyright Polaris Inc.

  • Page 122: Steering

    Whenever steering components are replaced, check front right wheel well by removing the mud guard. front end alignment. Use only genuine Polaris parts. To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

  • Page 123: Toe Alignment

    The frog should MEASUREMENT always point straight back from the steering post. Wheel Toe-Out Alignment: 1/4 to 1/2” (6.4 to 12.7 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.39 © Copyright Polaris Inc.

  • Page 124: Toe Alignment Adjustment

    Damage may not be immediately apparent if done incorrectly. See illustration. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.40 © Copyright Polaris Inc.

  • Page 125: Suspension

    (-) to decrease ride height. IMPORTANT DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.41 © Copyright Polaris Inc.

  • Page 126: Spring Adjustment (Sachs)

    8 clicks from full clockwise position Firmest Full clockwise position Shock Spanner Wrench: 2877408 NOTICE Models with base suspension use softest setting for factory setting. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.42 © Copyright Polaris Inc.

  • Page 127: Brake System

    • If the fluid level is low, add .25” - .30” (6 - 8 mm) from indicated fill line or specification. the top of the reservoir. Only use DOT 4 Brake Fluid approved by Polaris. Mixing fluids can cause system degradation. Always use a new sealed container of brake fluid. After opening a new bottle, properly dispose of the unused portion of brake fluid.

  • Page 128: Brake Pad / Disc Inspection

    HOSE / FITTING INSPECTION Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.44 © Copyright Polaris Inc.

  • Page 129: Brake Pedal

    • If brake pedal requires an excessive amount of travel to operate, inspect brake pads, pedal, linkage springs, master cylinder and hoses for wear, damage or leakage. Replace components as needed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.45 © Copyright Polaris Inc.
  • Page 130 MAINTENANCE NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 2.46 © Copyright Polaris Inc.
  • Page 131 ..............3.38 DRIVE COUPLER / STARTER GEAR 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 132 ..............3.70 CRANKCASE PREPARATION - LOWER 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 133 ..............3.78 CAM CHAIN TENSIONER INSTALLATION 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 134: General Information - Engine

    Valve Spring Compressor Adapter PV-43513-A Water Pump Bearing / Seal Installer PA-49378 Water Pump Mechanical Seal Installer PA-44995-A Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com ENGINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Capacity: Approximately 2 US quarts (1.9 L) Recommended Oil Type:...

  • Page 135: Oil Pressure Test

    This could also be due to a stuck oil pressure regulator. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 136: Oil Flow Diagram

    ENGINE / COOLING SYSTEM OIL FLOW DIAGRAM 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 137: Engine Specifications

    4.5488" ± .012" (115.54 ± 0.30 mm) Valve Spring Free Length 1.904" (48.35 mm) Valve Spring Intake - 1.650" (41.91 mm) Valve Spring Installed Height Exhaust - 1.650" (41.91 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 138 MAG End Crankshaft Main Journal Diameter (Standard) 2.1642” - 2.1649” (54.97 - 54.99 mm) Connecting Rod Journal Diameter 1.7718” - 1.7726” (45.005 - 45.025 mm) (Standard) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 139: General Information - Cooling System

    Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris 50/50 Extended Life Antifreeze is recommended for use in all cooling systems, and comes pre-mixed and ready to use.

  • Page 140: Cooling System Specifications

    6. Squeeze coolant lines to help purge the system of air. 7. With engine still idling, top off the radiator with Polaris Premium Antifreeze. If no air bubbles are seen at the radiator filler neck, the system should be purged of air.

  • Page 141: Coolant Drain / Radiator Service

    36 in-lbs (4 N·m) Coolant Hose, Engine Out Coolant Bottle Torque Until Fully Seated Coolant Bottle Screws Spring Band Clamp Radiator Support Fasteners 6 ft-lbs (8 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.11 © Copyright Polaris Inc.

  • Page 142: Coolant Drain / Fill

    5. Drain coolant from radiator by removing the coolant hose from the lower right-hand portion of the radiator. 6. Completely drain coolant and properly dispose of it. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.12 © Copyright Polaris Inc.

  • Page 143: Radiator Removal

    Then lift 3.10 to complete the bleeding procedure. up on the bottle and remove it from the radiator fan shroud. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.13 © Copyright Polaris Inc.

  • Page 144: Water Pump Service

    DO NOT place fingers between cover and crankcase at any time during the removal process or injury could result. 4. Remove CPS, stator wire guide, and stator from the cover. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.14 © Copyright Polaris Inc.
  • Page 145 6. Press shaft down until flush with end of mechanical seal or until the seal spring starts to compress. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.15 © Copyright Polaris Inc.

  • Page 146: Stator Cover Installation

    If pump shaft assembly (shaft, drive coupler hub, and bearing) is in good condition, proceed to the next 4. Refer to the following pages for stator cover step. assembly and torque information. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.16 © Copyright Polaris Inc.

  • Page 147: Thermostat

    7. Remove the fasteners securing the thermostat housing, and then the housing 8. Replace the thermostat and seal. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.17 © Copyright Polaris Inc.

  • Page 148: Intake / Exhaust System

    Air Hood Intake Air Intake Box Hose Clamp Breather Hose Spring Band Clamp Air Temp Sensor Airbox Mounting Fasteners 8 ft-lbs (11 N·m) Airbox Mount Washer 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.18 © Copyright Polaris Inc.

  • Page 149: Exhaust Assembly View

    Models) Silencer End Cap Exhaust Sealing Gasket Silencer Exhaust Isolator Exhaust Spring Front Exhaust Bracket Front Exhaust Bracket Bolts Exhaust Seal 10 ft-lbs (14 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.19 © Copyright Polaris Inc.
  • Page 150 Silencer End Cap 35 ft-lbs (47 N·m) Silencer Exhaust Isolator Exhaust Spring Front Exhaust Bracket Front Exhaust Bracket Bolts Exhaust Seal 10 ft-lbs (14 N·m) Exhaust Pipe 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.20 © Copyright Polaris Inc.

  • Page 151: Intake Replacement

    2. Remove the breather hose from the side of the airbox. 5. Disconnect the spark plug wires. 6. Remove the bolts retaining the ECU to the ECU bracket mount 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.21 © Copyright Polaris Inc.
  • Page 152 TORQUE Airbox Mounting Fasteners 8 ft-lbs (11 N·m) ECU Bracket Mount Fasteners Torque Until Fully Seated ETC Housing Retaining Bolts 89 in-lbs (10 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.22 © Copyright Polaris Inc.

  • Page 153: Heat Shields

    Inspect the heat shields. Ensure they are not damaged, and are properly secured. If any heat shields are found to be damaged or missing, they must be replaced. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.23 © Copyright Polaris Inc.
  • Page 154 Drip Tray Heat Shield Silencer Heat Shield Bottom Rear Cab Shield (International Models Only) Silencer Shield Inlets (Upper / Lower) Trailer Connector Shield (International Models Only) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.24 © Copyright Polaris Inc.

  • Page 155: Engine Assembly Views

    TORQUE SEQUENCE - MAIN ENGINE COMPONENTS See the Master Torque Table for torque specifications. VALVE COVER CYLINDER HEAD CAMSHAFT CARRIER OIL PUMP COVER WATER PUMP COVER STATOR COVER 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.25 © Copyright Polaris Inc.
  • Page 156 ENGINE / COOLING SYSTEM DRIVE COUPLER / STARTER GEAR CRANKCASE COVER 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.26 © Copyright Polaris Inc.

  • Page 157: Valve Cover Assembly View

    VALVE COVER ASSEMBLY VIEW REF. DESCRIPTION NOTES Apply sealant to both inside corners of cover gasket. Valve Cover Seal Recommended Lubricant: Polaris Crankcase Sealant, 3-Bond 1215 2871557 Labyrinth Cover Screws Labyrinth Cover Valve Cover O-Ring Apply all purpose grease. Head Isolator Covers 89 in-lbs (10 N·m)

  • Page 158: Camshaft / Camshaft Carrier / Rocker Arm Assembly View

    Camshaft Carrier Bolts (M8) See “Torque Specification and Torque Sequence - Main Engine Components” for torque sequence. Apply Moly Lube Grease or the Polaris recommended lubricant to the camshaft lobes. Camshaft Recommended Lubricant: Polaris Premium Starter Grease...

  • Page 159: Cylinder Head / Valves / Integrated Throttle Body Assembly View

    Valve Seal assembly. 8 in-lbs (0.9 N·m) Thermostat Cover Bleed Screw Washer Thermostat Cover Thermostat Housing Fasteners 89 in-lbs (10 N·m) Thermostat Seal Stant Thermostat 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.29 © Copyright Polaris Inc.

  • Page 160: Valve And Spring Height Detail

    ENGINE / COOLING SYSTEM VALVE AND SPRING HEIGHT DETAIL 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.30 © Copyright Polaris Inc.

  • Page 161: Piston / Connecting Rod

    ENGINE / COOLING SYSTEM PISTON / CONNECTING ROD 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.31 © Copyright Polaris Inc.

  • Page 162: Crankshaft

    ENGINE / COOLING SYSTEM CRANKSHAFT 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.32 © Copyright Polaris Inc.

  • Page 163: Crankcase Assembly View

    ENGINE / COOLING SYSTEM CRANKCASE ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.33 © Copyright Polaris Inc.
  • Page 164 Torque in Sequence: Step 1: 71 in-lbs (8 N·m) Step 2: 26 ft-lbs (35 N·m) Crankcase Bolts (M9 x 160) Apply a light film of engine oil. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.34 © Copyright Polaris Inc.

  • Page 165: Crankcase - Upper

    ENGINE / COOLING SYSTEM CRANKCASE - UPPER 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.35 © Copyright Polaris Inc.

  • Page 166: Crankcase (Lower) With Oil Pump

    ENGINE / COOLING SYSTEM CRANKCASE (LOWER) WITH OIL PUMP 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.36 © Copyright Polaris Inc.

  • Page 167: Balance Shaft / Balance Shaft Timing

    ENGINE / COOLING SYSTEM BALANCE SHAFT / BALANCE SHAFT TIMING 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.37 © Copyright Polaris Inc.

  • Page 168: Drive Coupler / Starter Gear

    ENGINE / COOLING SYSTEM DRIVE COUPLER / STARTER GEAR 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.38 © Copyright Polaris Inc.

  • Page 169: Stator Cover Assembly View

    Stator Screws Stator O-Ring All coupler spline teeth must be coated with Water Pump Drive Coupler Polaris Premium Starter Grease (PN 2871460) before assembly. Water Pump Bearing Crankshaft Position Sensor (CPS) Fastener 89 in-lbs (10 N·m) Crankshaft Position Sensor (CPS)

  • Page 170: Water Pump Cover Assembly View

    Water Pump Impeller Washer Water Pump Impeller Bolt 10 ft-lbs (14 N·m) Water Pump Cover 89 in-lbs (10 N·m) Water Pump Cover Fasteners Torque in sequence shown. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.40 © Copyright Polaris Inc.

  • Page 171: Engine Service

    Upon engine removal, use a mechanical lift or have an assistant help remove the engine from the vehicle to prevent personal injury or damage to vehicle components. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.41 © Copyright Polaris Inc.
  • Page 172 (see Fuel System chapter). 20. Remove the four screws retaining the engine skid plate and remove the plate from the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.42 © Copyright Polaris Inc.
  • Page 173 27. Remove the upper radiator hose from the thermostat housing. Insert a clean shop towel into the outlet. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.43 © Copyright Polaris Inc.
  • Page 174 30. Remove the spade wire (white/red) and battery cable from starter motor solenoid. 31. Remove engine ground cable from crankcase. 32. Disconnect harness from ECT sensor. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.44 © Copyright Polaris Inc.

  • Page 175: Engine Installation Notes

    ENGINE / COOLING SYSTEM ENGINE INSTALLATION NOTES 1. Use only the Polaris recommended lubricant. Never substitute or mix oil brands. Serious engine damage After the engine is installed in the frame, review the can result. following checklist and perform all steps that apply.

  • Page 176: Engine Disassembly / Inspection

    / rocker arm assembly from cylinder head. 5. Lift camshaft from cylinder head. IMPORTANT DO NOT rotate the engine using the camshaft sprocket retaining bolt. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.46 © Copyright Polaris Inc.

  • Page 177: Rocker Arm / Rocker Arm Shaft Inspection

    Roller should turn smoothly without binding. Replace rocker arm if roller surface is damaged, or if roller does not turn smoothly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.47 © Copyright Polaris Inc.

  • Page 178: Camshaft / Camshaft Bore Inspection

    Clean sealing surfaces with rubbing alcohol, electrical contact cleaner or a brake cleaner that does not leave a solvent residue. Do not touch sealing surfaces of the new head gasket. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.48 © Copyright Polaris Inc.

  • Page 179: Cylinder Head Warp Inspection

    Mark parts or place them in a rack as you remove them. MEASUREMENT Valve Spring Free Length: Std: 1.861" (47.26 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.49 © Copyright Polaris Inc.

  • Page 180: Valve Inspection

    NOTICE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.50 © Copyright Polaris Inc.

  • Page 181: Combustion Chamber

    If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked the cylinder head must be replaced. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.51 © Copyright Polaris Inc.
  • Page 182 NOTICE Remove only the amount of material necessary to repair the seat surface. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.52 © Copyright Polaris Inc.
  • Page 183 MEASUREMENT Valve Seat Width: Intake Std: 0.028″ (0.7 mm) Limit: 0.055″ (1.4 mm) Exhaust Std: 0.039″ (1.0 mm) Limit: 0.071″ (1.8 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.53 © Copyright Polaris Inc.

  • Page 184: Crankcase Disassembly

    Water pump cover removal is not required in the following step unless water pump or cover gasket service will be performed. Water pump service is described in the Engine / Cooling System chapter. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.54 © Copyright Polaris Inc.

  • Page 185: Crankcase (Lower) / Oil Pump Disassembly

    NOTICE Replace oil pump as an assembly and pressure relief valve if debris has entered pump or if pump damage is evident. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.55 © Copyright Polaris Inc.

  • Page 186: Crankcase Disassembly (Upper)

    8. Inspect inner rotor drive pin for wear or damage. NOTICE Piston assemblies / replacement pistons can be installed in either orientation as each piston is symmetric. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.56 © Copyright Polaris Inc.

  • Page 187: Counterbalance Shaft Removal / Inspection

    . Split gear should rotate and oil pipe side). return freely and completely without binding. 3. Lift both balance shafts from upper crankcase and remove end plugs. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.57 © Copyright Polaris Inc.

  • Page 188: Crankshaft / Cam Chain Removal

    (D) and replace if runout exceeds specification above. CRANKSHAFT INSPECTION 1. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.58 © Copyright Polaris Inc.

  • Page 189: Connecting Rod Inspection

    0.7873 ± .0001" (19.9975 ± .0025 mm) 5. Inspect small end and big end of connecting rod (and matching rod cap) for damage, galling of surface or pitting. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.59 © Copyright Polaris Inc.

  • Page 190: Connecting Rod Big End Bearing Selection

    2. If re-installing the original connecting rod, select the appropriate bearing from the table below based on connecting rod big end I.D. measurements. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.60 © Copyright Polaris Inc.
  • Page 191 Bore Diameter 47.993mm) 47.999mm) 48.005mm) 48.011mm) Target Oil 0.0009- 0.0022″ Clearance (Con (0.023 mm - 0.057 mm) Rod Bearing) Bearing color to White Blue Yellow install 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.61 © Copyright Polaris Inc.

  • Page 192: Piston Ring To Groove Clearance Inspection

    A difference between top and bottom end gap measurements is a general indication of cylinder taper (wear). The cylinder should be measured for taper and out of round. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.62 © Copyright Polaris Inc.

  • Page 193: Piston Pin Bore Inspection

    5. Inspect taper and out of round with a dial bore MEASUREMENT gauge. Piston Pin Bore: 0.7877 ± .0002" (20.007 ± .004 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.63 © Copyright Polaris Inc.

  • Page 194: Piston-To-Cylinder Clearance

    .001" (.025 mm) Maximum Cylinder Out of Round: Limit: .001" (.025 mm) Maximum MEASUREMENT Standard Bore Size 3.4252" ± .0005 (87 mm ± .01 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.64 © Copyright Polaris Inc.

  • Page 195: Engine Assembly

    Ends must butt squarely together and must not overlap. 3. Install bottom rail first, then top rail with end gap located as shown at right. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.65 © Copyright Polaris Inc.

  • Page 196: Piston / Connecting Rod Assembly

    DO NOT apply heat directly to piston rings or a loss of radial tension could result. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.66 © Copyright Polaris Inc.

  • Page 197: Crankshaft Installation

    Step 1: 9 ft-lbs (12 N·m) Step 2: 20 ft-lbs (27 N·m) Step 3: Tighten an additional 90° 3. Apply Polaris Premium Starter Grease (PN 2871460) to each main and rod bearing journal of crankshaft. OIL PASSAGE TUBE 4. Loop cam chain over crankshaft sprocket.

  • Page 198: Balance Shaft Installation

    10. Place balance shaft end plugs in upper crankcase. 4. Install balance shaft, placing the tooth with the single dot between the two dots on the crankshaft gear. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.68 © Copyright Polaris Inc.

  • Page 199: Balance Shaft Timing

    ENGINE / COOLING SYSTEM BALANCE SHAFT TIMING 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.69 © Copyright Polaris Inc.

  • Page 200: Crankcase Preparation - Lower

    Flush all passages with solvent and then warm soapy water. Rinse with clear warm water and dry with compressed air. Be sure passages are clean and dry before assembling the lower crankcase. Assemble parts in order A-J. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.70 © Copyright Polaris Inc.

  • Page 201: Crankcase Sealant And Torque Values

    ENGINE / COOLING SYSTEM CRANKCASE SEALANT AND TORQUE VALUES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.71 © Copyright Polaris Inc.

  • Page 202: Crankcase Assembly

    Install NEW and grease. valve seals on valve guides carefully with a rotating 6. Apply a thin, continuous film of Polaris Crankcase motion. Sealant (PN 2871557) to upper and lower crankcase 5. Dip valve spring and retainer in clean engine oil.

  • Page 203: Valve Sealing Test

    The valve seats should hold fluid with no seepage. 3. Repeat for exhaust valves by pouring fluid into each exhaust port 4. Lift cam chain and install chain guide. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.73 © Copyright Polaris Inc.

  • Page 204: Camshaft / Camshaft Carrier Assembly

    5. Ensure tabs are engaged in slots. Secure cam chain with a wire so it will not fall into crankcase. ASSEMBLY 1. Apply moly lube grease or the Polaris recommended lubricant to the camshaft lobes. Recommended Lubricant: Polaris Premium Starter Grease 2871460 2.

  • Page 205: Camshaft / Camshaft Carrier Installation

    . This is TDC for MAG side cylinder. TORQUE Camshaft Carrier Bolts (M8) 12 ft-lb (17 Nm) 4. Rotate camshaft until pin is at 10:00 position 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.75 © Copyright Polaris Inc.

  • Page 206: Camshaft Timing

    4. Place the sprocket (with marks facing out) on the chain and engage all teeth. 5. Align two sprocket marks with valve cover gasket surface. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.76 © Copyright Polaris Inc.

  • Page 207: Camshaft Timing - Quick Reference

    ENGINE / COOLING SYSTEM CAMSHAFT TIMING - QUICK REFERENCE 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.77 © Copyright Polaris Inc.

  • Page 208: Cam Chain Tensioner Installation

    5. Torque bolts to specification. TORQUE Cam Chain Tensioner Cap Bolts 7 ft-lbs (9 N·m) 6. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 3.78 © Copyright Polaris Inc.
  • Page 209 ............. . .4.25 THROTTLE CONTROL SENSOR TEST 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 210 ............4.32 STARTER MOTOR REMOVAL / REPLACEMENT 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 211: Digital Wrench Diagnostic Connector

    • Wire Harness Assembly ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench®. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 212: Operation Overview

    During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 213: Efi System Layout

    Lubricate O-ring with White Lithium Grease Crankshaft Position Sensor (CPS) (8570044) or Engine Oil. Fuel Injectors Fuel Rail Fuel Line Fuel Pump Engine Coolant Temperature (ECT) Sensor 17 ft-lbs (23 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 214: Efi Components

    Fuel Line (Quick Connect) Mounted on the top portion of the magneto cover on the Located between the injector fuel rail and the fuel tank. front of the engine. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 215 Located in the fuel tank as an assembly. Engine Coolant Temperature (ECT) Sensor Ignition Coil Mounted on the cylinder head, below the throttle body. Mounted to the RH side of the airbox. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 216: Efi Service Notes

    6. If the sensor and wiring passes inspection, and reconnecting the ECU does not resolve the issue, use a known-good ECU (from another Polaris 850) to test for problem resolution. • Never attempt to service any fuel system component while engine is running or ignition switch "on".

  • Page 217: Fuel Injectors

    “injection duration” or “pulse width”. It may vary in length depending on the speed and load requirements of the engine. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 218: Fuel Injector O-Rings

    Always install NEW o-rings when removing the fuel rail or injectors. IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.10 © Copyright Polaris Inc.

  • Page 219: Injector Replacement

    4. Remove the two fasteners retaining the fuel rail to the throttle body. 5. Gently pry / pull up to disengage the injector from the port. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.11 © Copyright Polaris Inc.

  • Page 220: Electronic Control Unit (Ecu)

    Polaris Technical Service. For the purpose of troubleshooting, a known-good ECU from another Polaris vehicle of the same model and year may be used, but ensure that you do not put an ECU from a machine equipped with EPS into a non-EPS model.

  • Page 221: Ecu Removal / Replacement

    NOTICE If replacing the ECU, you must reflash the new ECU with the correct calibration upon installation and prior to attempting to start the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.13 © Copyright Polaris Inc.

  • Page 222: Ecu Pinouts (Domestic Models)

    ENGINE ELECTRICAL ECU PINOUTS (DOMESTIC MODELS) NOTICE Last two digits of pin number equals cavity number. I.E. 210 = pin 10. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.14 © Copyright Polaris Inc.
  • Page 223 GROUND, ECU BROWN SPLICE, GROUND B GROUND, ECU BROWN SPLICE, EFI RELAY EFI B+, ECM1 RED/DARK BLUE SPLICE, EFI RELAY EFI B+, ECM2 RED/DARK BLUE 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.15 © Copyright Polaris Inc.
  • Page 224 GREEN/BLACK ETC THROTTLE BODY ETC MOTOR (-) BLACK/GREEN ETC THROTTLE BODY IGNITION DRIVER 1 (PTO) WHITE IGNITION COIL IGNITION DRIVER 2 (MAG) BLACK IGNITION COIL 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.16 © Copyright Polaris Inc.

  • Page 225: Ecu Pinouts (International Models)

    ENGINE ELECTRICAL ECU PINOUTS (INTERNATIONAL MODELS) NOTICE Last two digits of pin number equals cavity number. I.E. 210 = pin 10. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.17 © Copyright Polaris Inc.
  • Page 226 GROUND, ECU BROWN SPLICE, GROUND B GROUND, ECU BROWN SPLICE, EFI RELAY EFI RELAY, B+ RED/DARK BLUE SPLICE, EFI RELAY EFI RELAY, B+ RED/DARK BLUE 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.18 © Copyright Polaris Inc.
  • Page 227 GREEN/BLACK ETC THROTTLE BODY ETC MOTOR (-) BLACK/GREEN ETC THROTTLE BODY IGNITION DRIVER 2 (MAG) WHITE IGNITION COIL IGNITION DRIVER 1 (PTO) BLACK IGNITION COIL 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.19 © Copyright Polaris Inc.

  • Page 228: Electronic Throttle Control (Etc)

    No internal servicing or adjustments may be TORQUE performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris ETC Housing Retaining Bolts Service Department for specific handling instructions. Do 89 in-lbs (10 N·m) not replace the ETC under warranty without factory authorization.
  • Page 229 3. Turn key back on and start the vehicle. The vehicle should operate normally. 4. If the procedure was interrupted at any time, start back at step 1. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.21 © Copyright Polaris Inc.

  • Page 230: Crankshaft Position Sensor (Cps)

    This sensor must be properly connected at all times. If the sensor fails or becomes disconnected for any reason, the engine will stop running. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.22 © Copyright Polaris Inc.

  • Page 231: Temperature / Manifold Absolute Pressure (T-Map) Sensor

    O-ring to aid installation. 6. Torque retaining bolt to specification. TORQUE T-MAP Sensor Retaining Bolt 30 in-lbs (3 N·m) 7. Reverse the previous steps to assemble the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.23 © Copyright Polaris Inc.

  • Page 232: Engine Coolant Temperature (Ect) Sensor

    After a few seconds, the fan should turn on and the “Check Engine” indicator should display on the instrument cluster. This indicates all other components are working properly. Polaris dealers can test the sensor by using the Digital Wrench® Diagnostic Software (dealer only). TEMPERATURE °F (°C) RESISTANCE 5.

  • Page 233: Throttle Control Sensor (Tcs)

    9. Assemble the headlight pod and re-fasten the wiring with panduit straps as required. 10. Connect the negative (-) battery cable. 1. Disconnect the negative (-) battery cable. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.25 © Copyright Polaris Inc.

  • Page 234: Throttle Control Sensor Lever Replacement

    4. Remove the five-lobe tamper resistant T15 , and remove the old lever. TORQUE Throttle Control Sensor Lever Screw 9 in-lbs (1 N·m) 8. Press new plug into the lever until flush. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.26 © Copyright Polaris Inc.

  • Page 235: Igntion Coil

    Between High MAG: 975Ω ± Tension Lead Ends PTO: 1188Ω ± PRIMARY TEST Measure Between Connector Pins 1 & 2, 2 & 3 0.4 W Ω 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.27 © Copyright Polaris Inc.

  • Page 236: Ignition Coil And High Tension Lead Replacement

    11. Reinstall shift linkage, upper RH side panel, and seat. 6. Remove the coil assembly and disconnect the high tension leads by pulling on the coil side end caps. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.28 © Copyright Polaris Inc.

  • Page 237: Stator / Alternator

    6. Disconnect the stator wire harness and remove the CPS from the stator cover. 7. Remove the coolant by-pass hose from the water pump cover fitting. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.29 © Copyright Polaris Inc.

  • Page 238: Stator / Alternator Installation

    TEST 2: Resistance Value of Each Stator Leg to Ground 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.30 © Copyright Polaris Inc.
  • Page 239 AC VOLTAGE READING READING 115 Vac ± 10 % (Nominal) 6000 171 Vac ± 10 % (Peak) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.31 © Copyright Polaris Inc.

  • Page 240: Starter Motor

    Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.32 © Copyright Polaris Inc.
  • Page 241 10. Install the two bolts securing the starter motor to the crankcase housing and torque to specification. TORQUE Starter Mounting Bolts 20 ft-lbs (27 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.33 © Copyright Polaris Inc.
  • Page 242 ENGINE ELECTRICAL NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 4.34 © Copyright Polaris Inc.
  • Page 243 ............... .5.13 FUEL PUMP REPLACEMENT 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 244: Fuel Line / Hose

    2. Gently pry the retaining clip upwards into the open position. IMPORTANT Do not over-pry or excessively bend the retaining tabs. This can damage the retaining clip, and require replacement of the fuel line assembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 245 1. The retaining clip can be closed without the insertion of a hard line end. The retaining clip is designed to lock only when a hard line end has been fully inserted. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 246: Fuel Vent Line / Check Valve Testing

    In-Line Check Valve (If Equipped) The fuel vent line and check valve(s) can be tested using the following special tool: Mity Vac® Pressure Test Tool 2870975 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 247: Fuel Vent Line Routing

    Y-fitting. The vent splits to the upper line that runs into the headlight pod, and the lower line that runs down along the frame rail. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 248: Fuel Supply Line Routing

    FUEL SYSTEM FUEL SUPPLY LINE ROUTING The line routes under the frame rail. There are no anchor/retention fasteners related to this line. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 249: Fuel Tank

    Gas Tank Cap Fuel Inlet Band Clamp Fuel Fill Hose Constant Tension Clamp PFA Nut 70 ft-lbs (95 N·m) Fuel Pump PFA Gasket Replace if removed. Fuel Tank 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 250 FUEL SYSTEM FUEL FLOW ASSEMBLY 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 251: Fuel Tank Removal

    8. Disconnect the fuel pump electrical harness. 13. Carefully pull fuel tank out the right side of the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 252: Fuel Tank Installation

    13. Reinstall the upper side panels and seat. 14. Test the fuel pump by turning on the key and listening for the pump to activate. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.10 © Copyright Polaris Inc.

  • Page 253: Fuel Pump

    • If the engine fails to start. • If the engine is stopped with the key switch "ON" (as in the case of an accident). 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.11 © Copyright Polaris Inc.
  • Page 254 “3” and “4” in the plug on the pump to check for continuity within the fuel pump. NOTICE If there was no continuity between the pump terminals, replace the fuel pump assembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.12 © Copyright Polaris Inc.

  • Page 255: Fuel Pump Replacement

    Carefully disconnect the main harness from the fuel pump electrical connector and pull the main harness connector through the “+” shaped pass- through in the cover. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.13 © Copyright Polaris Inc.
  • Page 256 8. Remove new fuel pump assembly, gasket and PFA nut from packaging. Use care not to bend float arm during unpacking. Do not lift or carry fuel pump assembly by the float arm. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.14 © Copyright Polaris Inc.
  • Page 257 (tank upright) and full (tank upside down) positions. b. Fully seat the rubber cover’s lip until it engages fully around the bottom of the PFA nut. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.15 © Copyright Polaris Inc.
  • Page 258 18. Carefully slide the fuel tank back into position. Ensure vent line has not been pinched during installation of fuel tank. 19. Refer to “Fuel Tank Installation” to complete the repair. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 5.16 © Copyright Polaris Inc.
  • Page 259 ............... .6.28 DRIVEN CLUTCH ASSEMBLY 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 260: General Information

    PART NUMBER TOOL DESCRIPTION clutch upshift and backshift. During the development of a Clutch Alignment Tool PA-49011-A Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions Clutch Bushing Replacement Tool 2871025 and the vehicle’s intended usage.

  • Page 261: Shift Weights

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water fording. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 262: Pvt System Service

    Inner PVT Cover Fasteners 5 ft-lbs (7 N·m) Clutch Cover Seal Outer PVT Cover Outer PVT Cover Fasteners 30 in-lbs (3.4 N·m) Outer PVT Cover Drain Plug O-Ring 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 263: Pvt Disassembly

    2. Remove the fasteners securing the rear rack and storage assembly to the chassis. 5. Loosen the clamp securing the outlet duct to the inner PVT cover. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 264 9. Remove the (11) fasteners securing the outer PVT cover to the inner PVT cover. Then remove the drive belt. See Drive Belt Removal page 6.9. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 265: Pvt Assembly

    The mating surface must be clean to IMPORTANT ensure adhesion of new silicone sealant. Polaris recommends using a socket wrench to insert the Primary Clutch Puller. Use of an impact driver is not 2. Be sure to “flame treat” the inner PVT cover prior to recommended as it could damage the Primary Clutch applying silicone to ensure good adhesion.
  • Page 266 13. Replace the clutch cover seal. 14. Reinstall outer PVT cover and secure with fasteners. Torque fasteners to specification. TORQUE Outer PVT Cover Fasteners 30 in-lbs (3.4 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 267: Drive Belt

    3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. 6. Using care, pull the outer PVT cover out the LH wheel well. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 268: Drive Belt Installation

    8. Start the engine and test the operation of the PVT Torque fasteners to specification. system. TORQUE Outer PVT Cover Fasteners 30 in-lbs (3.4 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.10 © Copyright Polaris Inc.

  • Page 269: Belt / Clutch Alignment

    Replace if necessary. MEASUREMENT Maximum Drive Belt Width: 1.219” (30.96 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.11 © Copyright Polaris Inc.
  • Page 270 12. Retest for PVT creeping and/or harsh gear selector engagement. If symptoms persist, proceed to step 13. Inspect and verify the engine and transmission mounts and isolators are not loose or damaged. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.12 © Copyright Polaris Inc.

  • Page 271: Drive Clutch Service

    20 in-lbs (2 N·m) Clutch Button Roller Pin Limiter Spacer Clutch Spring Drive Clutch Bearing Drive Clutch Cover 8 ft-lbs (11 N·m) Drive Clutch Cover Bolts 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.13 © Copyright Polaris Inc.

  • Page 272: Drive Clutch Disassembly

    DO NOT reassemble the drive clutch without the limiter spacer. Belt life will be greatly reduced. 3. Remove the drive clutch cover bolts evenly in a cross pattern and remove cover. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.14 © Copyright Polaris Inc.

  • Page 273: Drive Clutch Spring Inspection

    A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin, and Thrust Washer Inspection” for more information. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.15 © Copyright Polaris Inc.

  • Page 274: Spider Removal

    ITEM DESCRIPTION washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of 2870910-A these washers. Roller Pin Tool 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.16 © Copyright Polaris Inc.

  • Page 275: Button To Tower Clearance Inspection

    9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.17 © Copyright Polaris Inc.

  • Page 276: Drive Clutch Inspection

    Measure the thickness and compare to specification. Replace if worn or damaged. MEASUREMENT PTFE Washer Thickness: Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.18 © Copyright Polaris Inc.

  • Page 277: Drive Clutch Bushing Service

    CLUTCH BUSHING REPLACEMENT TOOL KIT (PN 2871226) QTY. ITEM PART DESCRIPTION PART # P-90 Drive/Driven Clutch Bushing Install 5020628 Tool Drive Clutch Cover Bushing Removal/ 5020629 Installation Tool (all clutches) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.19 © Copyright Polaris Inc.
  • Page 278 10. Remove nut from puller rod and set aside. 7. Remove nut from puller rod and set aside. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.20 © Copyright Polaris Inc.

  • Page 279: Drive Clutch Assembly

    1. Install the shift weights, bolts and nuts onto the Moveable Sheave movable sheave. Torque nuts to specification. Spider TORQUE Shift Weight Nuts Alignment Marks 20 in-lbs (2 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.21 © Copyright Polaris Inc.
  • Page 280 , aligning “X” mark with other marks. IMPORTANT If the aligning marks are not in alignment, the clutch will not be in balance. The drive clutch assembly must be replaced. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.22 © Copyright Polaris Inc.

  • Page 281: Driven Clutch Service

    Washer E-Clip Shim Slider Pin Thrust Washer Square Slider Clutch Roller Stationary Sheave Driven Clutch Helix (Cam) Spring Pin Driven Clutch Helix Fasteners Moveable Sheave 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.23 © Copyright Polaris Inc.

  • Page 282: Driven Clutch Slider Inspection

    3. Place the driven clutch (helix side up) into the Universal Clutch Compressor. Slider to Sheave Clearance Service Limit: 0.175″ (4.5 mm) Slider Width Service Limit: 0.975″ (24.8 mm) Universal Clutch Compressor PU-50518-A 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.24 © Copyright Polaris Inc.
  • Page 283 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTICE Spring is compression only and has no torsional wind. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.25 © Copyright Polaris Inc.

  • Page 284: Bushing Service

    CLUTCH BUSHING TOOL KIT (PN 2201379-A) QTY. ITEM PART DESCRIPTION PART # Puller Tool 5132027 Puller Nut 5132501 Main Adapter 5132029 Bushing Removal Tool 5132028 – Bushing Tool PA-47336 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.26 © Copyright Polaris Inc.
  • Page 285 11. Remove nut (left hand thread) from puller rod and set aside. 12. Remove adapters from puller. 13. Remove bushing and removal tool from adapters. Discard bushing. 5. Install Adapter Reducer 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.27 © Copyright Polaris Inc.

  • Page 286: Driven Clutch Assembly

    2. Install the square sliders and slider pins 6. Install left hand thread nut onto puller rod and hand tighten against installation tool. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.28 © Copyright Polaris Inc.
  • Page 287 47 in-lbs (5 N·m) 9. Once back together, verify the grease / tape marks made during disassembly are properly aligned. 10. Install the drive clutch on the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.29 © Copyright Polaris Inc.
  • Page 288 PVT SYSTEM NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 6.30 © Copyright Polaris Inc.
  • Page 289 ..............7.22 TRANSMISSION ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 290: General Information

    3. Remove the retaining screw from the back side and pull the gear selector out from the frame support as an assembly. 4. Remove RH frame support to ease removal. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 291: Transmission Service

    If there is oil present in the bell housing vent, either the engine or transmission seals are leaking, and service is required. NOTICE Clutch intake removed for visibility of vents. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 292: Transmission Removal

    15. Remove the exhaust springs retaining the exhaust pipe to the silencer and remove the pipe from the 12. Disconnect the gear selector switch from the top of vehicle. the transmission. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 293 19. Remove the (4) bolts securing the RH frame support transmission assembly out the right side the of and remove the support from the vehicle. vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 294: Transmission Disassembly

    NOTICE Take note of any shims that may have fallen into the case during cover removal. Be sure to reinstall during “Transmission Assembly”. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 295 13. Repeat the previous step to remove the lower shift 10. Remove the (2) screws retaining the oil deflector fork. plate. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 296 Lightly tap on each shaft to ease assemblies. removal. 16. Inspect all bearings, gear teeth, engagement dogs and silent chain. 17. Remove the detent plug, snap ring, washer and gear selector switch. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 297: Transmission Shaft Service

    Shaft bearings can be serviced using an arbor press. CLUTCH INPUT SHAFT Bearing Gear Needle Bearing Thrust Washer Engagement Dog “High” Input Shaft Retaining Ring Silent Chain Bearing Thrust Washer 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 298 TRANSMISSION PRIMARY SHAFT Retaining Ring Primary Shaft Bearing Shim Bearing 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.10 © Copyright Polaris Inc.
  • Page 299 TRANSMISSION REAR OUTPUT SHAFT Bearing Retaining Ring Rear Output Shaft Bearing Sprocket 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.11 © Copyright Polaris Inc.
  • Page 300 Silent Chain Engagement Dog “Rev / Low” Shim Sprocket Sprocket Needle Bearing Reverse Shaft Gear Shim Needle Bearing Retaining Ring Bearing Thrust Washer Retaining Ring 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.12 © Copyright Polaris Inc.
  • Page 301 TRANSMISSION COUPLER INPUT SHAFT Bearing Bearing Cover Coupler Input Shaft Shim Torx Screws Retaining Ring Replace if removed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.13 © Copyright Polaris Inc.
  • Page 302 TRANSMISSION CAM SHIFT SHAFT Snap Ring Thrust Washer Thrust Washer O-Ring Switch Cam Assembly Retaining Ring 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.14 © Copyright Polaris Inc.
  • Page 303 TRANSMISSION BELLCRANK SHIFT SHAFT O-Ring Bellcrank Gear Sector Ribbed Washer Bellcrank Shift Shaft Thrust Washer 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.15 © Copyright Polaris Inc.

  • Page 304: Transmission Assembly

    TRANSMISSION TRANSMISSION ASSEMBLY 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.16 © Copyright Polaris Inc.
  • Page 305 O-rings. Forcing the shift shafts straight into the transmission housing may cut the O-rings. 5. Install new O-rings on both shift shafts and lubricate prior to installation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.17 © Copyright Polaris Inc.
  • Page 306 11. Install the transmission switch, washer and snap ring. 12. Install the detent plug and torque to specification. TORQUE Shift Detent Plug Fasteners 20 ft-lbs (27 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.18 © Copyright Polaris Inc.
  • Page 307 21. Install the rear output shaft assembly and silent chain. 22. Lift up slightly on the rear output shaft and install the front output shaft assembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.19 © Copyright Polaris Inc.

  • Page 308: Transmission Installation

    34. Install the drive clutch, driven clutch, and drive belt. TORQUE See the PVT System chapter for more information. Transmission to Engine Bolts 19 ft-lbs (26 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.20 © Copyright Polaris Inc.
  • Page 309 9. Install the screw retaining the isolator mount to the chassis on the lower RH side and torque to Recommended Transmission Lubricant: specification. Polaris AGL Gearcase Lubricant Capacity: 37 oz. (1100 ml) 16. Reinstall fill plug with a new O-ring and torque to specification.

  • Page 310: Transmission Assembly View

    TRANSMISSION TRANSMISSION ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.22 © Copyright Polaris Inc.
  • Page 311 Compression Spring O-Ring Wave Spring O-Ring Torsion Spring, Park Pawl O-Ring Compression Spring Seal Seal, Triple Lip Gearcase, Cover Bell Housing Speed Sensor Gearcase, Main 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.23 © Copyright Polaris Inc.
  • Page 312 TRANSMISSION NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 7.24 © Copyright Polaris Inc.
  • Page 313 ..............8.39 REAR DRIVE SHAFT INSTALLATION 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 314 ................8.53 GEARCASE INSTALLATION 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 315: General Information

    PART NUMBER TOOL DESCRIPTION 2872608 Roll Pin Removal Tool Axle Boot Clamp Tool PU-48951 CV Boot Clamp Pliers (Ear) 8700226 Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 316: Wheels

    On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel. Be sure to properly torque and install all wheel nuts. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 317: Wheel Studs

    Wear eye protection when removing and installing bearings and seals. 3. Remove the wheel nuts , wheel , and tire from the hub 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 318 Rear Hub: Insert the stud in the rotor and hub. 9. Install the lug nut for the corresponding new stud(s). TORQUE Wheel Lug Nuts 120 ft-lbs (162 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 319 TORQUE 2nd Torque Application: 120 ft-lbs (162 Nm) 12. Properly lower vehicle and verify proper operation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 320: Wheel Hubs

    Brake Disc Fasteners Snap (Retaining) Ring Install with sharp edge out. Add Loctite® 603 retaining compound to Bearing bearing bore prior to bearing installation. Bearing Carrier 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 321: Rear Hub Assembly View

    Brake Disc Fasteners Snap (Retaining) Ring Install with sharp edge out. Add Loctite® 603 retaining compound to Bearing bearing bore prior to bearing installation. Bearing Carrier 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 322: Front Bearing Carrier

    11. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper and lower ball joint ends. 12. Remove the bearing carrier from the front drive shaft. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.10 © Copyright Polaris Inc.

  • Page 323: Front Bearing Carrier Replacement

    4. Wipe the housing clean of any excess compound and remove the bearing by pressing it out from the back install the snap ring. side. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.11 © Copyright Polaris Inc.

  • Page 324: Front Bearing Carrier Installation

    . Torque nut to specification. NOTICE Refer to the Polaris Electronic Parts Catalog for fastener replacements. 4. Apply grease to drive shaft axle splines. 5. Install the front wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side facing out toward the castle nut.
  • Page 325 120 ft-lbs (162 N·m) 10. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.13 © Copyright Polaris Inc.

  • Page 326: Front Drive Shaft

    10. Refer to Drive Shaft Service (Drive Shaft / CV Joint Handling Tips page 8.40) if repairing the drive shaft. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.14 © Copyright Polaris Inc.

  • Page 327: Installation

    3. Install the drive shaft into the front bearing carrier. 4. Refer to Front Bearing Carrier Installation page 8.12 to properly reassemble the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.15 © Copyright Polaris Inc.

  • Page 328: Front Propshaft

    4. Pull shaft back towards the transmission to remove it from the front gearcase input shaft, then pull it forward to remove it from the transmission output shaft. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.16 © Copyright Polaris Inc.

  • Page 329: Propshaft U-Joint Service

    ID than the U-joint cap OD on one end. 5. Tighten clamp with hand tools to force U-joint cups out of yoke. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.17 © Copyright Polaris Inc.

  • Page 330: Propshaft U-Joint Assembly

    8. Tighten clamp until both caps are flush with yoke and one cap is past retaining ring groove 4. Place caps into yoke bores and align with U-joint ends by hand. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.18 © Copyright Polaris Inc.
  • Page 331 11. Tighten clamp until other cap is below retaining ring groove. 12. Install second retaining ring with sharp, square edge facing away from U-joint. 13. Verify the U-joint moves freely and does not bind. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.19 © Copyright Polaris Inc.

  • Page 332: Front Gearcase Removal / Installation

    8. Remove the gearcase from the front RH wheel well area and carefully slide it between the upper and lower A-arms. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.20 © Copyright Polaris Inc.

  • Page 333: Front Gearcase Installation

    8. Add the recommended amount of fluid. Maintain fluid level even with the bottom threads of the fill plug hole. FLUID CAPACITY Recommended Front Gearcase Fluid: Polaris Demand Drive Fluid Capacity: 9.3 oz. (275 ml) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.21...

  • Page 334: Front Gearcase (Adc)

    FINAL DRIVE FRONT GEARCASE (ADC) FRONT GEARCASE ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.22 © Copyright Polaris Inc.
  • Page 335 Clutch Housing (Ring Gear) Encapsulated Coil Gearcase Housing Encapsulated Coil BD Roll Cage Weld Stud Hub Assembly Fill Plug Hub Machining Drain Plug, Magnetic Rollers 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.23 © Copyright Polaris Inc.

  • Page 336: Operation, Front Gearcase (4Wdc)

    During engine braking the front drive can also speed differentiate across the axle when turning. Also, if the outer wheel slips or loses traction the inner wheel will then begin to slow the vehicle as well. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.24 © Copyright Polaris Inc.

  • Page 337: Disassembly / Inspection, Front Gearcase (Adc)

    Troubleshooting for detailed inspection process. NOTICE Press on the output hub assembly while lifting up on the outer cover plate to prevent removing more than the cover plate. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.25 © Copyright Polaris Inc.
  • Page 338 Inspect the roll cage for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.26 © Copyright Polaris Inc.
  • Page 339 Inspect the input shaft bearing for signs of wear. Replace the input shaft cover O-ring prior to reassembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.27 © Copyright Polaris Inc.

  • Page 340: Reassembly, Front Gearcase (Adc)

    8. Install the rollers and roll cage into the ring gear. 4. Install input shaft, bearing, and snap ring Insert the rollers as the roll cage is installed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.28 © Copyright Polaris Inc.
  • Page 341 14. Install the cover plate assembly with a new O-ring onto the gearcase. NOTICE Verify the square O-ring is placed flat on the cover surface. If the O-ring is twisted, fluid leaks may occur. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.29 © Copyright Polaris Inc.
  • Page 342 9 ft-lbs (12 N·m) 16. Add the recommended fluid to front gearcase. FLUID CAPACITY Recommended Front Gearcase Fluid: Polaris Demand Drive Fluid Capacity: 7.6 oz. (225 ml) Add fluid until it is visible at the bottom of the fill plug hole threads.

  • Page 343: Troubleshooting, Front Gearcase (Adc)

    If it locks vehicle. to the drive train in only one direction, ADC is not indexing cage in both directions 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.31 © Copyright Polaris Inc.
  • Page 344 If pole faces are severely problem has been fixed. If worn and damaged, not, continue onto replace output cover. additional problems listed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.32 © Copyright Polaris Inc.
  • Page 345 If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.33 © Copyright Polaris Inc.
  • Page 346 5. Inspect the rollers for nicks, scratches, and flat spots. Also inspect the roll cage for cracks and ensure the rollers are able to slide up and down and in and out freely within the roll cage sliding surfaces. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.34 © Copyright Polaris Inc.

  • Page 347: Rear Bearing Carrier

    4. Remove the cotter pin , castle nut and washers 8. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.35 © Copyright Polaris Inc.

  • Page 348: Rear Bearing Carrier Bearing Replacement

    Use care to not allow any of the Loctite ® compound to get in the bearing. 8. Wipe the housing clean of any excess compound and install the snap ring. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.36 © Copyright Polaris Inc.

  • Page 349: Rear Bearing Carrier Installation

    40 ft-lbs (54 N·m) 8. Install the wheel, washers and wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Lug Nuts 120 ft-lbs (162 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.37 © Copyright Polaris Inc.

  • Page 350: Rear Drive Shaft

    6. Remove the upper A-arm fastener. 10. Refer to Drive Shaft / CV Joint Handling Tips page 8.40 if repairing the drive shaft. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.38 © Copyright Polaris Inc.

  • Page 351: Rear Drive Shaft Installation

    3. Rotate the bearing carrier onto the drive axle and rotate into upper A-arm. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.39 © Copyright Polaris Inc.

  • Page 352: Drive Shaft Service

    Refer to text for grease capacity of CV joints and CV joint boots. 3. Clean the grease from the face of the joint. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.40 © Copyright Polaris Inc.
  • Page 353 The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.41 © Copyright Polaris Inc.

  • Page 354: Inner Plunging Joint / Boot Replacement

    INNER PLUNGING JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.42 © Copyright Polaris Inc.
  • Page 355 NOTICE The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.43 © Copyright Polaris Inc.
  • Page 356 Slide a straight O-ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.44 © Copyright Polaris Inc.

  • Page 357: Rear Propshaft

    3. Slide the shaft towards the transmission and pivot the propshaft down. Slide the propshaft off the transmission output shaft and out from the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.45 © Copyright Polaris Inc.

  • Page 358: Rear Gearcase

    6. Remove both rear drive shafts from the gearcase. IMPORTANT Before you remove the rear propshaft from the vehicle, add a mark on the rear propshaft flange. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.46 © Copyright Polaris Inc.

  • Page 359: Gearcase Disassembly / Inspection

    11. Disconnect the gearcase breather hose from the gearcase. 3. Lift the gearcase cover off the main gearcase half and note the shim between the cover and the ring gear. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.47 © Copyright Polaris Inc.

  • Page 360: Gearcase Bearing And Seal Replacement

    Disassembly and Inspection” procedure. 1. Remove the nut and lock washer from the pinion shaft (if necessary, hold the coupler in a vise to remove the nut). 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.48 © Copyright Polaris Inc.
  • Page 361 5. Support the pinion shaft and press the bearing off the shaft (see Figure 8-27). 6. Thoroughly clean the pinion shaft. WARNING Wear appropriate safety equipment while installing bearings to reduce the risk of injury. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.49 © Copyright Polaris Inc.

  • Page 362: Gearcase Assembly

    13. Install pinion shaft and a new retaining ring. Install the retaining ring with the straight edge facing the GEARCASE ASSEMBLY bearing. 1. Grease all seals with Polaris Premium All Season Grease upon assembly to prevent from damaging seals. 2. Install the ring gear into the main gearcase.
  • Page 363 8. Proceed to “Rear Gearcase Installation” before installing the coupler, lock washer and retaining nut. Doing so will allow you to properly torque the coupler retaining nut. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.51 © Copyright Polaris Inc.

  • Page 364: Rear Gearcase Assembly View

    Pinion Shaft Lock Washer Ring Gear Dowel Pin Vent Tube Retaining Ring Coupler Shim O-Ring Ball Bearing Triple Lip Seal Ball Bearing Triple Lip Seal 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.52 © Copyright Polaris Inc.

  • Page 365: Gearcase Installation

    3. Install the (4) rear gearcase mounting fasteners. Torque to specification. 7. Install the weld mount and weld mount fasteners. TORQUE Rear Gearcase Mounting Fasteners 37 ft-lbs (50 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.53 © Copyright Polaris Inc.
  • Page 366 9. On the RH side of the vehicle, install the (2) springs 11. Install the rear bumper. See Rear Bumper Installation page 11.17. to the exhaust and slide the exhaust into the rear of the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 8.54 © Copyright Polaris Inc.
  • Page 367 ..............9.39 SHOCK PISTON ORIENTATION 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 368 ..............9.42 WALKER EVANS™ SHOCK ASSEMBLY 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 369: General Information

    Remove the handlebar grips. b. Remove the LH and RH controls. c. Pry open the upper and lower handlebar blocks and remove them from the handlebar. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 370: Handlebar Installation

    5. Tighten the rear bolts. Torque the (2) rear bolts to specification. TORQUE Handlebar Block Fasteners 14 ft-lbs (19 N·m) NOTICE There will be a slight gap on the backside of the handlebar blocks after installation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 371: Steering

    STEERING / SUSPENSION STEERING STEERING ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.
  • Page 372 RH Steering Idler Fasteners 40 ft-lbs (54 N·m) Steering Post Fasteners (Lower) 20 ft-lbs (27 N·m) LH Steering Idler LH Steering Idler Fasteners 20 ft-lbs (27 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 373: Upper Steering Post Removal

    EPS unit. 8. Carefully lift the upper steering post up from the EPS unit and remove the upper steering post from the chassis. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 374: Upper Steering Post Installation

    Striking the steering post can permanently damage the Ensure all vent line, wiring harness, and throttle cable EPS unit and cause a power steering fault. routings are correct. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 375: Eps Unit Removal

    6. Disconnect the (2) electrical harnesses from the EPS unit. 8. Carefully lift the upper steering post up from the EPS unit. 9. Remove the lower steering post pinch bolt and nut. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual © Copyright Polaris Inc.

  • Page 376: Eps Unit Installation

    1. Install the (4) screws that retain the EPS mount to the EPS unit and torque to specification. TORQUE EPS Mount Fasteners 30 ft-lbs (41 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.10 © Copyright Polaris Inc.
  • Page 377 EPS unit and cause a power steering fault. 7. Install the (2) pinch bolts and nuts into the upper steering post and loosely tighten by hand. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.11 © Copyright Polaris Inc.
  • Page 378 20 ft-lbs (27 N·m) 12. Tighten the (2) pinch bolts in the upper steering post and torque to specification. TORQUE Steering Post Fasteners (Upper) 14 ft-lbs (19 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.12 © Copyright Polaris Inc.

  • Page 379: Steering Tie Rods

    Install new tie rod end and torque jam nuts to specification. TORQUE Tie Rod Jam Nuts 13 ft-lbs (18 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.13 © Copyright Polaris Inc.

  • Page 380: Front Control Arms

    STEERING / SUSPENSION FRONT CONTROL ARMS ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.14 © Copyright Polaris Inc.
  • Page 381 Flange Nut 40 ft-lbs (54 N·m) Washer Bolt Torque fastener from nut side. Flange Nut Torque fastener from bolt side. Washer Bolt 40 ft-lbs (54 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.15 © Copyright Polaris Inc.

  • Page 382: Front Control Arm Removal

    1. Elevate and safely support the front of the vehicle and remove the front wheel. 2. Remove the lower taper nut from the lower ball joint. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.16 © Copyright Polaris Inc.

  • Page 383: Front Control Arm Installation

    Torque new fasteners to specification. TORQUE A-Arm Fasteners 40 ft-lbs (54 N·m) 2. Install new ball joint into upper A-Arm. See Ball Joint Installation page 9.20. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.17 © Copyright Polaris Inc.
  • Page 384 40 ft-lbs (54 N·m) TORQUE Wheel Lug Nuts 120 ft-lbs (162 N·m) IMPORTANT Upon A-arm installation completion, test vehicle at low speeds before putting into service. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.18 © Copyright Polaris Inc.

  • Page 385: Ball Joint Service

    5. If necessary, remove the lower front shock fastener from the A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.19 © Copyright Polaris Inc.

  • Page 386: Ball Joint Installation

    A-arm to engage the Installation Adapter and Spacer 5. Tighten the Press Asm. screw and fully install the ball joint into the arm. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.20 © Copyright Polaris Inc.
  • Page 387 Rear Caliper Mounting Fasteners 40 ft-lbs (54 N·m) 10. Install wheel and (4) wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Lug Nuts 120 ft-lbs (162 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.21 © Copyright Polaris Inc.

  • Page 388: Rear Controls Arms

    STEERING / SUSPENSION REAR CONTROLS ARMS ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.22 © Copyright Polaris Inc.
  • Page 389 Torque fastener from nut side. Washer 40 ft-lbs (54 N·m) Rear Control Arm (Lower) Control Bushing Bushing Carrier Washer Bolt 70 ft-lbs (95 N·m) Shock Shield Push Rivet 2& 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.23 © Copyright Polaris Inc.

  • Page 390: Rear Control Arm Removal

    5. If not replacing the A-arm, thoroughly clean the A-arm and pivot shafts. REAR LOWER A-ARM REMOVAL 1. Elevate and safely support the rear of the vehicle and remove the rear wheel and hub. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.24 © Copyright Polaris Inc.

  • Page 391: Rear Control Arm Installation

    Torque new fasteners to specification. A-Arm Fasteners TORQUE 40 ft-lbs (54 N·m) Rear Lower A-Arm to Bearing Carrier Fasteners 70 ft-lbs (95 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.25 © Copyright Polaris Inc.
  • Page 392 120 ft-lbs (162 N·m) IMPORTANT Upon A-arm installation completion, test vehicle at low speeds before putting into service. TORQUE Shock Mount Fasteners (Front/Rear, Upper/Lower) 40 ft-lbs (54 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.26 © Copyright Polaris Inc.

  • Page 393: Rear Stabilizer Bar

    Rear Stabilizer to Linkage Fastener Bolt 35 ft-lbs (47 N·m) Bushing Strap Bracket Fasteners 20 ft-lbs (27 N·m) Bushing Strap Bracket Apply Polaris Premium All Season Grease Bushing (8570063) prior to assembly. Screw 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.27...

  • Page 394: Stabilizer Linkage Removal / Installation

    4. Reverse this procedure to reinstall the stabilizer linkage. Torque fasteners to specification. TORQUE Rear Stabilizer to Linkage Fastener 35 ft-lbs (47 N·m) Rear Stabilizer End Rod Fasteners 30 ft-lbs (40 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.28 © Copyright Polaris Inc.
  • Page 395 6. Reverse this procedure to reinstall the stabilizer bar. Torque fasteners to specification. TORQUE Rear Stabilizer End Rod Fasteners 30 ft-lbs (40 N·m) Bushing Strap Bracket Fasteners 20 ft-lbs (27 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.29 © Copyright Polaris Inc.

  • Page 396: Shocks / Springs

    SHOCK ASSEMBLY VIEW (WALKER EVANS™) FRONT SHOCK Spring Spacer 40 ft-lbs (54 N·m) Washer Front Shock O-Ring Spring Retainer Bushing Reducer Tender Spring Spring Bolt 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.30 © Copyright Polaris Inc.
  • Page 397 Torque from the nut side. Spring Retainer Washer Shock Sleeve Rear Shock Bolt 40 ft-lbs (54 N·m) Bolt Torque from the bolt side. Tender Spring Washer Spring Spacer 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.31 © Copyright Polaris Inc.

  • Page 398: Shock Assembly View (Sachs)

    SHOCK ASSEMBLY VIEW (SACHS) FRONT SHOCK Bushing Reducer 40 ft-lbs (54 N·m) Washer Bolt Spring Retainer Spring Spherical Bearing Front Shock Retaining Ring Cam Adjuster O-Ring 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.32 © Copyright Polaris Inc.
  • Page 399 40 ft-lbs (54 N·m) Cam Adjuster Torque from the nut side. Spring Tender Spring Washer Bolt 40 ft-lbs (54 N·m) Rear Shock Torque from the bolt side. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.33 © Copyright Polaris Inc.

  • Page 400: Shock Removal / Installation

    1. 6. Reinstall the shock onto the vehicle and torque new fasteners to specification. TORQUE Shock Mount Fasteners (Front/Rear, Upper/Lower) 40 ft-lbs (54 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.34 © Copyright Polaris Inc.

  • Page 401: Shock Service

    Front Piston Asm. Shaft Jam Nut Clicker Knob Retaining Ring Detent Spring Spring Adjuster Detent Ball Seal Head Asm. Clicker Stud Wiper Cap Piston, Clicker 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.35 © Copyright Polaris Inc.

  • Page 402: Shock Service Information

    1.00 x .025 1.45 x .008 .700 x .010 .625 x .065 1.00 x .008 .750 x .065 1.50 x .008 1.55 x .010 1.55 x .010 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.36 © Copyright Polaris Inc.
  • Page 403 1.50 x .008 .700 x .010 .625 x .065 1.50 x .008 1.00 x .095 1.55 x .008 1.00 x .010 1.55 x .008 1.55 x .008 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.37 © Copyright Polaris Inc.

  • Page 404: General Service Information

    Always adjust both the left and right springs equally. IMPORTANT DO NOT increase the spring adjustment by more than one inch (25.4 mm) over the factory setting. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.38 © Copyright Polaris Inc.

  • Page 405: Walker Evans™ Shock Rebuild Information

    It is strongly recommended you wear safety glasses and ear protection during these procedures. 1. Clean and carefully remove shock from the vehicle. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.39 © Copyright Polaris Inc.
  • Page 406 5. Carefully depressurize the shock. 8. Using a 1" open-end wrench or adjustable wrench, loosen and remove the bearing cap from the shock body. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.40 © Copyright Polaris Inc.
  • Page 407 Rear Shock Rod Holding Tool: PU-50931 NOTICE Insert the IFP Tool (PS-45908) and cycle the Internal Floating Piston (IFP) a few times to purge the shock oil from the reservoir. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.41 © Copyright Polaris Inc.
  • Page 408 Front Shock Seal Protector Sleeve: PU-50939 Rear Shock Body Holding Tool: PU-50938 Rear Shock Seal Protector Sleeve: PU-50952 4. Install seal head assembly onto the shock shaft. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.42 © Copyright Polaris Inc.
  • Page 409 9. Front Shocks Only: Assemble the clicker valve stack on top of the fastener and install the assembly into the reservoir body. Tighten the valve stack fastener securely. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.43 © Copyright Polaris Inc.
  • Page 410 15. Screw IFP Tool (PS-45908) onto the floating piston. Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans™ Shocks 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.44 © Copyright Polaris Inc.
  • Page 411 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.45 © Copyright Polaris Inc.
  • Page 412 35. Reinstall the valve cap. 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.46 © Copyright Polaris Inc.
  • Page 413 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTICE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.47 © Copyright Polaris Inc.
  • Page 414 STEERING / SUSPENSION NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 9.48 © Copyright Polaris Inc.
  • Page 415 BRAKE PADS..................10.32 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.1 © Copyright Polaris Inc.
  • Page 416 ..............10.38 DISC REMOVAL / REPLACEMENT 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.2 © Copyright Polaris Inc.

  • Page 417: General Information

    SPECIAL TOOLS / BRAKE FLUID PART NUMBER TOOL DESCRIPTION Mity Vac® Pressure Test Tool 2870975 2872189 Polaris DOT 4 Brake Fluid Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.3 © Copyright Polaris Inc.

  • Page 418: Brake System Service Notes

    Do NOT fill the reservoir beyond the MAX LEVEL line. • DO NOT allow brake cleaning products to contact When servicing Polaris brake systems, only use Polaris painted surfaces. Paint damage will occur as a result. DOT 4 Brake Fluid.

  • Page 419: Brake System (Domestic Models)

    BRAKE SYSTEM BRAKE SYSTEM (DOMESTIC MODELS) BRAKE SYSTEM ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.5 © Copyright Polaris Inc.
  • Page 420 Brake Switch (Front Front LH Brake Caliper Rear Brake Line Cylinder Brake Line Brake Master Cylinder) Front Brake Master Brake Pedal Reservoir Front LH Brake Line Cylinder 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.6 © Copyright Polaris Inc.

  • Page 421: Front Caliper Assembly View

    Any time caliper mount is removed or Caliper Mount serviced, clean slide pins and re-apply silicone grease. Piston When replacing, apply Polaris DOT 4 Brake Caliper Seal (Outer) Fluid to component. Caliper Seal (Inner) Boot, Pin Seal Boot, Pin Bushing Caliper Asm.

  • Page 422: Rear Caliper Assembly View

    Any time caliper mount is removed, or caliper Caliper Mount is serviced, clean slide pins and re-apply silicone grease. When replacing, apply Polaris DOT 4 Brake Pistons Fluid to component. Boot, Pin Bushing Square O-Rings (Thin) When replacing, apply Polaris DOT 4 Brake Fluid to component.

  • Page 423: Front Brake Master Cylinder Assembly View

    Piston Pivot Pin Front Brake Master Locking Lever Cylinder Clamp Screws O-Ring Dust Boot 70 in-lbs (8 N·m) Lever Return Spring Reservoir Cover Brake Switch 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.9 © Copyright Polaris Inc.

  • Page 424: Brake Line Routing

    BRAKE LINE ROUTING The first image displays the front brake line routing. The second image displays the rear brake line routing. All retainers are indicated with a 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.10 © Copyright Polaris Inc.

  • Page 425: Brake System (International Models)

    Hand Brake Master Cylinder with Reservoir Rear Left Caliper AUX Port Brake Pressure Switch Front Right Caliper Distribution Block Front Left Caliper Plug Piston Rear Right Caliper AUX Port 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.11 © Copyright Polaris Inc.
  • Page 426 Foot Brake Master Cylinder Front Left Caliper Brake Pressure Switch Rear Right Caliper SERV Port Distribution Block Rear Left Caliper SERV Port Plug Reducing Valve Piston 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.12 © Copyright Polaris Inc.

  • Page 427: Brake System Assembly View

    BRAKE SYSTEM BRAKE SYSTEM ASSEMBLY VIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.13 © Copyright Polaris Inc.
  • Page 428 Banjo Bolt with Bleeder Brake Reservoir Hose Front LH Brake Line Rear Master Cylinder Rear (SERV) Brake Reducing Valve Front LH Brake Caliper Brake Line Line 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.14 © Copyright Polaris Inc.

  • Page 429: Front Caliper Assembly View

    Any time caliper mount is removed or Caliper Mount serviced, clean slide pins and re-apply silicone grease. Piston When replacing, apply Polaris DOT 4 Brake Caliper Seal (Outer) Fluid to component. Caliper Seal (Inner) Boot, Pin Seal Boot, Pin Bushing Caliper Asm.

  • Page 430: Rear Caliper Assembly View

    Any time caliper mount is removed, or caliper Caliper Mount is serviced, clean slide pins and re-apply silicone grease. Piston Caliper Seal (Outer) When replacing, apply Polaris DOT 4 Brake Fluid to component. Caliper Seal (Inner) Square O-Ring Boot, Pin Bushing Boot, Pin Seal Caliper Asm.

  • Page 431: Front Brake Master Cylinder Assembly View

    Piston Pivot Pin Front Brake Master Locking Lever Cylinder Clamp Screws O-Ring Dust Boot 70 in-lbs (8 N·m) Lever Return Spring Reservoir Cover Brake Switch 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.17 © Copyright Polaris Inc.

  • Page 432: Brake Line Routing

    BRAKE LINE ROUTING The first image displays the front brake line routing. The second image displays the rear brake line routing. All retainers are indicated with a 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.18 © Copyright Polaris Inc.

  • Page 433: Brake Warning System Overview

    Hand Brake Master Cylinder Switch. 4. If the Hand Brake Master Cylinder Switch test fails, resistance is not within specification and the switch should be replaced. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.19 © Copyright Polaris Inc.

  • Page 434: Brake Pressure Switch Inspection / Testing

    4. Refer to “Rear Brake System Bleeding (International Models)” if replacing the Brake Pressure Switch as the brake bleeding procedure will need to be performed. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.20 © Copyright Polaris Inc.

  • Page 435: Brake Fluid Bleeding

    .25” - .30” (6 - 8 mm) from the top of the reservoir. 11. Tighten bleeder screw securely and remove bleeder Polaris DOT 4 Brake Fluid hose. Torque bleeder screw to specification. 2872189 TORQUE 4. Loosely install the brake fluid reservoir diaphragm,...

  • Page 436: Rear Brake System Bleeding

    MAX level mark TORQUE on the reservoir. Reservoir Cover Screws Polaris DOT 4 Brake Fluid 7 in-lbs (1 N·m) 2872189 15. Field test machine at low speed before putting into 5. Remove old brake fluid from the reservoir with a Mity service.

  • Page 437: Rear Brake System Bleeding (International Models)

    MAX level mark. 4. If changing fluid, remove old fluid from reservoir with Polaris DOT 4 Brake Fluid a Mity Vac Pressure Test Tool (PN 2870975) or 2872189 similar tool.
  • Page 438 25. Repeat procedure on the remaining rear caliper. 26. Using a funnel, add brake fluid to the MAX level mark on the reservoir. Polaris DOT 4 Brake Fluid 2872189 27. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve.

  • Page 439: Distribution Block Bleeder Screw (International Models)

    6. Remove the battery and battery bracket from the vehicle. The distribution block bleeder screw is located underneath the battery bracket as shown. 4. Remove the two battery terminal fasteners. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.25 © Copyright Polaris Inc.

  • Page 440: Front Brake Master Cylinder

    1. Clean the master cylinder and reservoir assembly. component. Polaris offers a number of service kits to Make sure you have a clean work area to rebuild this style of master cylinder. Refer to the Polaris disassemble brake components. Electronic Parts Catalog.

  • Page 441: Brake Switch Replacement

    Speed up brake bleeding by purging air before brake mounting holes and lock the switch in place. line is attached. Fill with Polaris DOT 4 Brake Fluid (PN 2872189) and pump lever slowly 2 to 3 times with finger over the outlet end to purge master cylinder of air.

  • Page 442: Rear Brake Master Cylinder (Domestic Models)

    5. Reinstall the front and rear brake lines back onto the master cylinder. 6. Proceed to Rear Brake System Bleeding page 10.22 to complete the bleeding procedure. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.28 © Copyright Polaris Inc.

  • Page 443: Brake Switch Replacement

    TORQUE Brake Switch (Rear Brake Master Cylinder) 180 in-lbs (20 N·m) 4. Proceed to Rear Brake System Bleeding page 10.22 to complete the bleeding procedure. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.29 © Copyright Polaris Inc.

  • Page 444: Rear Brake Master Cylinder (International Models)

    Brake fluid will leak out of the distribution block when the brake pressure switch is replaced. Place a suitable catch container / rags below the distribution block prior to brake pressure switch removal. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.30 © Copyright Polaris Inc.
  • Page 445 TORQUE Brake Pressure Switch 180 in-lbs (20 N·m) 4. Proceed to Rear Brake System Bleeding (International Models) page 10.23 to complete the bleeding procedure. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.31 © Copyright Polaris Inc.

  • Page 446: Brake Pads

    WARNING If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean brake pads. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.32 © Copyright Polaris Inc.

  • Page 447: Brake Burnishing Procedure

    After making contact, back off set screw 1/2 turn (counterclockwise). 6. Verify fluid level in reservoir is at specified level inside reservoir and install reservoir cap. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.33 © Copyright Polaris Inc.

  • Page 448: Brake Caliper Service

    3. Apply force to the back of the piston through the open brake fluid supply port. This will remove the piston from the caliper body. Also remove the O-rings at this time. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.34 © Copyright Polaris Inc.

  • Page 449: Caliper Inspection

    Rear Caliper(s): Caliper Bore I.D. See “General Brake Specifications”. 2. Coat piston with Polaris DOT 4 Brake Fluid. Install piston with a twisting motion while pushing inward. Piston should slide in and out of the bore smoothly, with light resistance.

  • Page 450: Caliper Installation

    IMPORTANT If pads are contaminated with oils or grease, they MUST be replaced. TORQUE Brake Line Banjo Fasteners 15 ft-lbs (20 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.36 © Copyright Polaris Inc.
  • Page 451 “Brake Fluid Bleeding”. 4. Install the wheel and (4) wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Lug Nuts 120 ft-lbs (162 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.37 © Copyright Polaris Inc.

  • Page 452: Brake Disc Service

    Always use new wheel studs if removed from the wheel New: 0.02” / 0.51 mm (International Models) hub assembly. Service Limit: .010” / .254 mm 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.38 © Copyright Polaris Inc.
  • Page 453 11. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TORQUE Wheel Hub Castle Nut 80 ft-lbs (108 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.39 © Copyright Polaris Inc.
  • Page 454 BRAKE SYSTEM NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 10.40 © Copyright Polaris Inc.
  • Page 455 ........11.20 LICENSE PLATE BRACKET REMOVAL / INSTALLATION 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.1 © Copyright Polaris Inc.
  • Page 456 ..............11.22 ASSEMBLY VIEW – FRONT / REAR 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.2 © Copyright Polaris Inc.

  • Page 457: General Information

    BODY / FRAME GENERAL INFORMATION DECAL REPLACEMENT PLASTIC PUSH RIVET REMOVAL Polaris ATVs use plastic push rivets to fasten most body WARNING components. Use the multi-function pliers to ease removal and prevent damage. The following procedure involves the use of an open flame.

  • Page 458: Body Service

    4. Disconnect the wiring harness from the electrical components fastened to the pod. NOTICE Take note of all vent line, wiring harness, and throttle cable routings for reassembly purposes. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.4 © Copyright Polaris Inc.

  • Page 459: Seat

    2. Lift the rear of the seat and slide the seat rearward. 3. Press the rear of the seat down firmly to seat the pin in the latch 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.5 © Copyright Polaris Inc.

  • Page 460: Side Panels

    3. Lift the rear of the side panel assembly and pull to the rear of the vehicle. 3. Install the push rivets that retain the side panels. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.6 © Copyright Polaris Inc.

  • Page 461: Mud Guards

    2. Remove the mud guard. 3. Reverse this procedure to reinstall the front mud guard. Torque screws to specification. TORQUE Front Mud Guard Screws 18 in-lbs (2 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.7 © Copyright Polaris Inc.

  • Page 462: Front Rack / Storage Box

    5. Remove the front storage compartment 2. Remove the front rack pins 3. Remove the screws securing the travel limiter cables. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.8 © Copyright Polaris Inc.

  • Page 463: Front Rack Installation

    5. Close the front rack and latch the front rack latches 2. Align the quarter turn latches and turn them to the lock position. 3. Install the screws securing the travel limiter cables. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.9 © Copyright Polaris Inc.

  • Page 464: Front Bumper

    2. Remove the front bumper from the radiator weld support. TORQUE Bumper Mounting Bolts (Upper / Lower) 18 ft-lbs (24 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.10 © Copyright Polaris Inc.

  • Page 465: Front Bumper Cover

    Torque Until Fully Seated 4. Install the headlights. 5. Connect the headlights to the main wiring harness. 6. Install the front bumper. See Front Bumper Installation page 11.10. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.11 © Copyright Polaris Inc.

  • Page 466: Front Cab

    NOTICE LH side shown. 5. Remove the gas cap and cover opening with tape to prevent debris from entering the fuel tank. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.12 © Copyright Polaris Inc.
  • Page 467 Repeat on other side. TORQUE NOTICE LH side shown. Front Cover Screws 30 in-lbs (3 N·m) TORQUE Front Cab to Front Bumper Cover Screws 18 in-lbs (2 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.13 © Copyright Polaris Inc.
  • Page 468 9. Remove the tape from the gas tank inlet. 10. Reinstall the gas cap. 11. Reinstall the front rack / storage box, side panels, and seat. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.14 © Copyright Polaris Inc.

  • Page 469: Rear Rack / Storage Box

    Torque screws to specification. 3. Remove the rack. TORQUE Rear Extender Screws 7 ft-lbs (9 N·m) Rear Storage Compartment Screws 7 ft-lbs (9 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.15 © Copyright Polaris Inc.
  • Page 470 BODY / FRAME 4. Install the (4) screws retaining the rear rack and torque to specification. TORQUE Rear Rack Screws 18 in-lbs (2 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.16 © Copyright Polaris Inc.

  • Page 471: Rear Bumper

    TORQUE Hitch Mounting Bolts (Upper / Lower) 3. Remove the rear bumper from the rear rack support / rear hitch weld. 18 ft-lbs (24 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.17 © Copyright Polaris Inc.
  • Page 472 3. Ensure each upper mount is fully seated. Then, torque upper mounting bolts to specification. TORQUE Bumper Mounting Bolts (Upper / Lower) 18 ft-lbs (24 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.18 © Copyright Polaris Inc.

  • Page 473: Rear Bumper Cover

    3. Install the tail lights. 4. Connect the tail lights to the main wiring harness. 5. Install the rear rack. See Rear Rack Installation page 11.15. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.19 © Copyright Polaris Inc.

  • Page 474: Rear Cab

    4. Remove the rear cab with the rear rack and rear specification. fender flares attached. TORQUE 5. Reverse this procedure to reinstall the rear cab. License Plate Bracket Fasteners 8 ft-lbs (11 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.20 © Copyright Polaris Inc.

  • Page 475: Rear Fog Light Bracket (International Zug Models)

    Torque fasteners to specification. TORQUE Rear Fog Light Bracket Fasteners 53 in-lbs (6 N·m) TORQUE Rear Fog Light Screws Torque Until Fully Seated 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.21 © Copyright Polaris Inc.

  • Page 476: Main Frame / Frame Supports

    BODY / FRAME MAIN FRAME / FRAME SUPPORTS ASSEMBLY VIEW – FRONT / REAR 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.22 © Copyright Polaris Inc.
  • Page 477 Oil Filter Plate Screws 7 ft-lbs (9 N·m) Lower LH Frame Support Screws 45 ft-lbs (60 N·m) Hitch Mounting Bolts (Upper / Lower) 18 ft-lbs (24 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.23 © Copyright Polaris Inc.
  • Page 478 BODY / FRAME NOTES 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 11.24 © Copyright Polaris Inc.
  • Page 479 ..............12.21 CHARGING SYSTEM OVERVIEW 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.1 © Copyright Polaris Inc.
  • Page 480 CONTROLLER AREA NETWORK (CAN) ..............12.42 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.2 © Copyright Polaris Inc.
  • Page 481 ................12.42 CAN TROUBLESHOOTING 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.3 © Copyright Polaris Inc.

  • Page 482: General Information

    GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION Fluke™77 Digital Multimeter PV-43568 Test Relay PA-49466 PV-43526 Connector Test Kit Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.4 © Copyright Polaris Inc.

  • Page 483: Chassis Harness

    BODY ELECTRICAL CHASSIS HARNESS HARNESS RETENTION LOCATIONS FRONT RETENTION POINTS REAR RETENTION POINTS 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.5 © Copyright Polaris Inc.

  • Page 484: Harness Routing

    BODY ELECTRICAL HARNESS ROUTING NOTICE If replacing the harness, noting routing during removal will aid in proper installation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.6 © Copyright Polaris Inc.

  • Page 485: Switches / Controls

    B and C; A and D. • Turn the ignition key to START. There should be continuity between switch pins A and B; C and D; E and F. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.7 © Copyright Polaris Inc.

  • Page 486: Drive Line Switch

    Use a multimeter to test for continuity when the LH switch is moved to the RUN position. If the test fails, replace the LH control assembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.8 © Copyright Polaris Inc.

  • Page 487: Left-Hand Switch Controls

    LEFT-HAND SWITCH CONTROLS Use a multimeter to test for continuity for each of the LH switch functions. If any test fails, replace the LH control assembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.9 © Copyright Polaris Inc.

  • Page 488: Reverse / Mode Button

    Push the Reverse Override / Mode button. There should be continuity between pins M (BN) and E (GY/OG). Move the switch to LOW. There should be continuity between pins YE/DG and DG. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.10 © Copyright Polaris Inc.

  • Page 489: Gear Selector Resistor Module

    3. Reference the Resistance Table for specifications. If any of the tests fail, replace the resistor module. MODULE RESISTANCE ±5% RESISTANCE (Ω) GEAR POSITION HIGH NEUTRAL REVERSE PARK 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.11 © Copyright Polaris Inc.

  • Page 490: Battery Service

    BATTERY REMOVAL 1. Unlatch the front rack latches and open the front rack. Polaris recommends maintaining battery charge by using a Polaris battery trickle charger or by charging once a month using the battery charge port . The Polaris offered battery trickle charger can be left connected...

  • Page 491: Battery Installation

    (-) cable last. 6. Carefully lift the battery out of the battery support bracket. 7. Charge the battery. TORQUE Battery Strap Fastener 8 ft-lbs (11 N·m) 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.13 © Copyright Polaris Inc.

  • Page 492: Battery Identification

    Battery must be fully charged before use or battery life will be significantly reduced 10-30% of the battery's full potential. To activate a Lead Acid Conventional battery, do the following: 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.14 © Copyright Polaris Inc.

  • Page 493: Lead Acid Conventional Battery Inspection

    CHARGING AND TESTING 7. Once the battery is fully charged, replace cap plugs Polaris recommends using a BatteryMINDer® 1510- 1.5 by hand. Do NOT use a tool to install the cap plugs. AMP charger (or a similar charger), which can be ordered through your normal parts channel.

  • Page 494: Lead Acid Conventional Battery Maintenance

    2. Remove the electrolyte container from the package. 5. Place the electrolyte container with the foil seals facing down into the cell filler ports on the battery. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.16 © Copyright Polaris Inc.
  • Page 495 9. Allow battery to stand for 1-2 hours. This allows the electrolyte to permeate the plates for optimal performance. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.17 © Copyright Polaris Inc.

  • Page 496: Dry Shipped Agm Battery Charging And Testing

    To charge a Dry Shipped AGM battery, do the following: maintain the Absorbent Glass Mat (AGM) battery with the BatteryMINDer® 2012 AGM - 2 AMP charger. 1. Charge the battery for 1 hour using the Polaris recommended charger. BatteryMINDer® 2012 AGM - 2 AMP battery charger...

  • Page 497: Lead Acid Low Maintenance Battery Maintenance

    CHARGED (BELOW 3 VOLTS) CHARGING AGM batteries discharged to a voltage of 3 volts or less Polaris recommends using the BatteryMINDer® 2012 may not be recognized by the recommended automatic AGM - 2 AMP battery charger to charge and maintain battery charger.

  • Page 498: Agm Low Maintenance Battery Testing

    Battery Charging - Deeply Discharged (Below 3 Volts) with the BatteryMINDer® 2012 AGM - 2 AMP charger page 12.19. and inspect the battery every 60 days. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.20 © Copyright Polaris Inc.

  • Page 499: Charging System

    7. Remove the seat. during assembly as this will be used to install the new 8. Remove the left side panels. regulator wiring. 9. Remove the left footwell. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.21 © Copyright Polaris Inc.

  • Page 500: Voltage Regulator Installation

    4. Install the left footwell. Torque screws to specification. IMPORTANT TORQUE Charging system damage will occur if incompatible Footwell Screws components are installed. Always reference the Polaris 36 in-lbs (4 N·m) Electronic Parts Catalog for the proper part numbers. 5. Install the left side panels and seat. NOTICE 6.

  • Page 501: Battery Charge Test

    4. The meter display should read approximately 14.0 - 14.4 Vdc at idle. 5. If the voltage is lower than 14.0 - 14.4 Vdc, the alternator should be tested. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.23 © Copyright Polaris Inc.

  • Page 502: Lights

    6. Connect lamp to main wiring harness. 7. Install front half of the pod. Torque fasteners until fully 6. Adjust the headlight to the desired position, then seated. tighten the screw. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.24 © Copyright Polaris Inc.

  • Page 503: Headlight Adjustment, Bumper

    Before replacing the lamp, use a digital multimeter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.25 © Copyright Polaris Inc.

  • Page 504: Taillights

    NOTICE The LED taillights are not serviceable and must be replaced as an assembly. 1. Open the rear storage compartment and remove the rear rack. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.26 © Copyright Polaris Inc.

  • Page 505: License Plate Light Replacement (International Models)

    5. Connect the taillight to the main wiring harness. 6. Align the rear rack with the mounting holes and torque fasteners to specification. See Rear Rack Installation page 11.15. 7. Verify proper operation. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.27 © Copyright Polaris Inc.

  • Page 506: Displays

    If this occurs, immediately clean the instrument cluster lens. CAN High CAN Low Switched Power (Vdc) Constant Power (Vdc) Ground Fuel Level Sensor 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.28 © Copyright Polaris Inc.

  • Page 507: Troubleshooting

    BODY ELECTRICAL TROUBLESHOOTING INSTRUMENT CLUSTER - KEY OFF / NO POWER 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.29 © Copyright Polaris Inc.

  • Page 508: Instrument Cluster - Key On / No Power

    BODY ELECTRICAL INSTRUMENT CLUSTER - KEY ON / NO POWER 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.30 © Copyright Polaris Inc.

  • Page 509: Instrument Cluster - No High Beam Indicator

    BODY ELECTRICAL INSTRUMENT CLUSTER - NO HIGH BEAM INDICATOR 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.31 © Copyright Polaris Inc.

  • Page 510: Instrument Cluster - No / Incorrect Fuel Level

    BODY ELECTRICAL INSTRUMENT CLUSTER - NO / INCORRECT FUEL LEVEL 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.32 © Copyright Polaris Inc.

  • Page 511: Speed Sensor

    9. Pass the blade of a screwdriver back and forth across the sensor tip. The timing light tool LED should illuminate each time the blade passes the sensor face. 10. If the test fails, replace the speed sensor. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.33 © Copyright Polaris Inc.

  • Page 512: All Wheel Drive (Awd) And Adc Coils

    17 in the ECU connector (circuit E217) if the issue is with AWD. If the issue is with ADC, check the BN/YE back to ECU terminal 49 (circuit E249). 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.34 © Copyright Polaris Inc.
  • Page 513 A high percentage of electrical issues are caused by bad/failed connections and grounds. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.35 © Copyright Polaris Inc.

  • Page 514: Fuse / Relays

    High / Low LH control 12 Vdc battery -Lights 20A Fuse voltage to relay coil. -Drive 20A Fuse LH / RH front bumper lights power. -Accessory 20A Fuse 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.36 © Copyright Polaris Inc.

  • Page 515: Start Solenoid Relay

    Low LH control 12 Vdc battery voltage DG (2) to relay coil. DG (4) Low beam lights power. BRN (5) Ground for relay coil. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.37 © Copyright Polaris Inc.

  • Page 516: Fuse / Relay Box Layout

    To gain access, remove the front rack / storage box assembly by releasing the two anchor latches. The cover label identifies the location of each relay and fuse. 7185159 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.38 © Copyright Polaris Inc.

  • Page 517: Electronic Power Steering (Eps)

    EPS system is detected, the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system. The system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the vehicle’s diagnostic port.

  • Page 518: Winch

    WINCH ASSEMBLY VIEW IMPORTANT Disconnect battery prior to servicing winch. Always disconnect the negative (BLACK) cable from battery first during disassembly, and last during assembly. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.40 © Copyright Polaris Inc.

  • Page 519: Winch Contactor

    Clips Screws 20 ft-lbs (27 N·m) Screws Carriage Bolts Flange Nuts 20 ft-lbs (27 N·m) Washers Lock Washers Bolts 20 ft-lbs (27 N·m) WINCH CONTACTOR 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.41 © Copyright Polaris Inc.

  • Page 520: Controller Area Network (Can)

    CAN High (YELLOW) and CAN Low (GREEN) wires on the diagnostic connector. If 120 ohms is measured at the connector, there is a break somewhere within the CAN circuit. 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual 12.42 © Copyright Polaris Inc.
  • Page 521 Steering ..............9.5 Disassembly ............10.34 Transmission............7.22 Inspection............10.35 Valve ..............3.29 Installation ............10.36 Valve Cover ............3.27 Piston Bore I.D............. 10.35 Water Pump ............3.40 Removal............. 10.34 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.1 © Copyright Polaris Inc.
  • Page 522 Removal...............3.48 Camshaft Bore Warp Inspection .............3.49 Inspection.............3.48 Camshaft Chain Removal...............3.58 Camshaft Timing Quick Reference ............3.77 Decal Charging System Replacement............11.3 Overview ............12.21 Diagnostic ...............1.27 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.2 © Copyright Polaris Inc.
  • Page 523 ECU Reprogramming ..........1.42 Feature Map............1.41 Operation Overview ..........4.12 Guided Diagnostics ..........1.38 Electronic Fuel Injection (EFI) Polaris Mobile Digital Wrench® (PMDW) .....1.42 General Information ..........4.3 Serial Number Location ...........1.40 Identification / Location ..........4.6 Software Installation and Updates ......1.39 Initial Priming / Starting Procedure ......4.4 Software Overview ..........1.38...
  • Page 524 Headlight Replacement Removal...............8.16 Pod ..............12.24 Heat Front Rack Installation ............11.9 Shields..............3.23 Removal............... 11.8 High Tension Lead Front Shock Replacement............4.28 Assembly View ............9.35 Fuel 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.4 © Copyright Polaris Inc.
  • Page 525 Special Tools and Supplies ........6.2 Maintenance Troubleshooting .............1.60 Fuel Lines.............2.20 Fuel System ............2.20 Intervals ..............2.5 Quick Reference ............2.16 Misc. Specifications / Charts Radiator Conversion Table ...........1.22 Cleaning...............3.12 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.5 © Copyright Polaris Inc.
  • Page 526 Rocker Arm Troubleshooting .............4.32 Assembly View ............3.28 Static Testing ..............1.71 Rocker Arm / Rocker Arm Shaft Stator / Alternator Inspection.............3.47 Rocker Carrier Installation ............4.30 Removal...............3.46 Removal...............4.29 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.6 © Copyright Polaris Inc.
  • Page 527 Valve Clearance Adjustment ............2.24 Alignment .............2.39 Valve Cover Torque Assembly View ............3.27 Removal...............3.46 Master ..............1.14 Torque Sequence Valve Guide Drive Coupler / Starter Gear ........3.38 Inspection.............3.50 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.7 © Copyright Polaris Inc.
  • Page 528 Seal Replacement ..........3.14 Wheel Installation ............2.31, 8.4 Removal............2.30, 8.4 Stud Service............8.5 Winch Assembly View ............ 12.40 Contactor Connections .......... 12.41 Wiring Diagrams..............43 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual IX.8 © Copyright Polaris Inc.

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