Crankcase Disassembly (Upper); Piston / Connecting Rod Removal - Polaris Sportsman XP 1000 S 2020 Service Manual

ENGINE / COOLING SYSTEM
5. Rotate pump gear until rotors are positioned as
shown below. Use a feeler gauge to measure tip
clearance. .
MEASUREMENT
Clearance should not exceed 0.006" (.15 mm)
6. Measure pump rotor clearance to pump cover plate
with a feeler gauge through the pump outlet window
and compare to specification.
MEASUREMENT
Pump to Cover Clearance:
0.0010–0.0027" (0.025–0.070 mm)
7. Measure shaft axial (end) free play with a dial
indicator and compare to specification.
MEASUREMENT
Axial Play:
0.010–0.030" (0.24–0.82 mm)
8. Inspect inner rotor drive pin for wear or damage.
3.56
9. Remove oil pressure relief from crankcase. Replace
if debris has entered, or if oil pressure was outside of
specified range.
TORQUE
Oil Pressure Relief Valve
20 ft-lbs (27 Nm)

CRANKCASE DISASSEMBLY (UPPER)

1. Remove the oil passage connecting tube with O-
rings.
2. Note connecting rod and cap marks so they can be
oriented properly and assembled in the same
manner as matched sets on proper rod journal
New rods can be installed with marks to front or rear.
Rods have no offset.
3. Remove the two connecting rod bolts

PISTON / CONNECTING ROD REMOVAL

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
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