Polaris Sportsman XP 1000 S 2020

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3.2

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual

STATOR COVER ASSEMBLY VIEW . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ..3.39

WATER PUMP COVER ASSEMBLY VIEW . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..3.40

ENGINE SERVICE . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ..3.41

ACCESSIBLE ENGINE COMPONENTS . . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . .3.41

TOP-END SERVICE (ENGINE IN CHASSIS) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .3.41

ENGINE REMOVAL .. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... .3.41

ENGINE INSTALLATION NOTES . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . .3.45

ENGINE DISASSEMBLY / INSPECTION.. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . .3.46

VALVE COVER REMOVAL / INSPECTION . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ...3.46

ROCKER CARRIER / CAMSHAFT REMOVAL. ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .3.46

ROCKER ARM / ROCKER ARM SHAFT INSPECTION .. . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ..3.47

CAMSHAFT / CAMSHAFT BORE INSPECTION. ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ...3.48

CYLINDER HEAD REMOVAL . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . .3.48

CYLINDER HEAD CLEANING . . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . ..3.48

CYLINDER HEAD WARP INSPECTION.. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . .3.49

CYLINDER HEAD DISASSEMBLY . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .3.49

VALVE INSPECTION . . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .3.50

COMBUSTION CHAMBER . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . ..3.51

VALVE GUIDE REMOVAL / INSTALLATION . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .3.51

VALVE SEAT RECONDITIONING . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .3.51

CRANKCASE DISASSEMBLY .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .3.54

CRANKCASE (LOWER) / OIL PUMP DISASSEMBLY .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . ..3.55

CRANKCASE DISASSEMBLY (UPPER) . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ..3.56

PISTON / CONNECTING ROD REMOVAL . . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . ..3.56

COUNTERBALANCE SHAFT REMOVAL / INSPECTION . . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .3.57

CRANKSHAFT / CAM CHAIN REMOVAL . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .3.58

CAM CHAIN / SPROCKET INSPECTION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..3.58

CRANKCASE INSPECTION - LOWER . . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .3.58

CRANKSHAFT INSPECTION . . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... .3.58

CONNECTING ROD INSPECTION . . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ..3.59

CONNECTING ROD BIG END BEARING SELECTION . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . .3.60

PISTON RING TO GROOVE CLEARANCE INSPECTION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..3.62

PISTON RING REMOVAL. . .. . . ... . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . .3.62

PISTON RING INSTALLED GAP . . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .3.62

PISTON PIN BORE INSPECTION. .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .3.63

CYLINDER INSPECTION . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. .3.63

PISTON-TO-CYLINDER CLEARANCE . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . .3.64

ENGINE ASSEMBLY . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . .3.65

CRANKCASE PREPARATION - UPPER .. . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . .3.65

PISTON RING INSTALLATION. . .. . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . .3.65

PISTON / CONNECTING ROD ASSEMBLY ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... .3.66

PISTON / CONNECTING ROD INSTALLATION . . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .. . . ... . ... . ... . ... . ..3.66

CRANKSHAFT INSTALLATION . . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . ..3.67

OIL PASSAGE TUBE . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . .3.67

BALANCE SHAFT INSTALLATION . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .3.68

BALANCE SHAFT TIMING. . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .3.69