Polaris Sportsman XP 1000 S 2021 User 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.
2020-2021 Sportsman XP 1000 S
Service Manual

Polaris Sportsman XP 1000 S 2021 Specifications

General

Brand	Polaris
Model	Sportsman XP 1000 S 2021
Category	Offroad Vehicle
Language	English

Summary

General Information

Master Torque Table

Provides torque specifications for various maintenance and engine/cooling system components for proper assembly and safety.

General Diagnostics

Outlines a general diagnostics information overview and a guided symptom diagnostic procedure for troubleshooting.

Digital Wrench

Provides an overview of the Digital Wrench software, special tools, and guided diagnostics for vehicle troubleshooting.

Maintenance

Engine

Covers engine oil level checks, oil and filter changes, breather hose inspection, and valve clearance adjustment procedures.

Engine / Cooling System

Crankshaft Installation

Details the procedure for installing the crankshaft, including bearing preparation and torque specifications.

Engine Electrical

Digital Wrench Diagnostic Connector

Explains the location and connection procedure for the diagnostic connector to use Digital Wrench®.

EFI System

Provides general information on the Electronic Fuel Injection system and its principal components.

Electronic Control Unit (ECU)

Details ECU operation overview, service, removal, replacement, and pinouts for domestic and international models.

Crankshaft Position Sensor (CPS)

Explains CPS operation, service procedures, and static testing for accurate engine timing.

Fuel System

Fuel Pump

Covers fuel pump operation, sender test, pump test, and replacement procedures for reliable fuel delivery.

PVT System

Drive Clutch Service

Provides assembly views, disassembly steps, and inspection procedures for the drive clutch components.

Driven Clutch Service

Details assembly views and disassembly procedures for the driven clutch components.

Transmission

Transmission Removal

Outlines the step-by-step procedure for removing the transmission from the vehicle.

Transmission Disassembly

Provides detailed instructions for disassembling the transmission, including component removal.

Transmission Assembly

Details the procedures for assembling the transmission, including shaft installation and case sealing.

Final Drive

Front Gearcase Removal / Installation

Provides detailed steps for removing and installing the front gearcase, including wiring and linkage connections.

Front Bearing Carrier Inspection / Removal

Details the procedure for inspecting and removing the front bearing carrier, including related suspension components.

Gearcase Disassembly / Inspection

Outlines steps for disassembling and inspecting the rear gearcase, including gear and bearing checks.

Steering / Suspension

EPS Unit Removal

Details the procedure for removing the Electronic Power Steering (EPS) unit from the vehicle.

Front Control Arms

Shows the assembly view of the front control arms and details removal/installation procedures.

Rear Control Arms

Provides assembly views and removal/installation procedures for the rear control arms.

Shock Service

Details the Walker Evans™ shock assembly view and provides shock service information.

Brake System

Brake Fluid Bleeding

Front Brake Master Cylinder

Rear Brake Master Cylinder (Domestic Models)

Brake Caliper Service

Brake Disc Service

Body / Frame

Body Electrical

Battery Service

Instrument Cluster

Troubleshooting

Electronic Power Steering (EPS)

Fuse / Relays