Fuel Tank Installation - Polaris Sportsman XP 1000 S 2020 Service Manual

FUEL SYSTEM

FUEL TANK INSTALLATION

1. Reinstall the fuel tank assembly through the right
side. Be sure tabs on the bottom of the fuel tank are
sitting in support bracket slots.
2. Reinstall the fuel tank mounting fasteners located on
the upper portion of the fuel tank. Torque fasteners to
specification.
TORQUE
Fuel Tank Mounting Fasteners
Torque Until Fully Seated
3. Connect the fuel line to the fuel pump outlet.
NOTICE
Be sure to engage the white retainer on fuel line until it
snaps into place. Pull on fuel line lightly to confirm
connection.
4. Connect the fuel pump electrical harness.
5. If equipped, engage the bottom lip of the rubber fuel
pump cover fully around the bottom of the fuel pump
nut.
5.10
6. Reconnect the vent line
the fuel tank.
7. Reinstall the (4) screws into the bottom portion of the
RH footwell. Torque to specification.
TORQUE
Footwell Screws
36 in-lbs (4 N·m)
8. Remove the shop towel from the fuel tank inlet and
reinstall the front cab assembly.
9. Connect the fuel fill hose and ensure it is fully seated.
Then torque the upper hose clamp to specification.
TORQUE
Upper Fuel Fill Hose Clamp
24 in-lbs (3 N·m)
10. Reinstall the front cover and front rack / storage box.
11. Reinstall the front mud guards.
12. Reconnect the negative (-) battery cable.
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
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to the fitting on top of
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