Crankcase Disassembly - Polaris Sportsman XP 1000 S 2020 Service Manual

ENGINE / COOLING SYSTEM
8. Clean all filings from the area with hot soapy water.
Rinse and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the
face of the valve.
NOTICE
Lapping not required if an interference angle
reconditioning method is used.
10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated,
and repeat process for the other valve(s).
12. Thoroughly clean cylinder head and valves.

CRANKCASE DISASSEMBLY

The rotor contains powerful magnets. Use caution
when removing and installing the stator cover. Do NOT
place fingers between cover and crankcase at any time
during the removal / installation process or injury could
IMPORTANT
Do NOT attempt to lift the upper crankcase / cylinder
from the lower crankcase for piston / ring access
without first removing the lower crankcase and
connecting rod caps from the crankshaft. Pistons must
be removed through the top of the cylinders with the
connecting rod attached.
1. Remove cylinder head. See Cylinder Head Removal
page 3.48.
NOTICE
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.
3.54
CAUTION
result.
2. Remove all water pump cover screws
w
cover screws , noting location of hose retainer
3. Remove the retaining bolts
NOTICE
Due to the inherent motion of the damper / ring gear
hub in relation to the gear body, the holes to access the
bolts are not likely to align well. You may need to use a
ball hex and a screwdriver to carefully pry through the
holes to align the tool to the fasteners. Take care not to
damage the threads in the crankshaft when doing so.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
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and stator
e
.
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and starter gear.
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