Polaris Sportsman XP 1000 S 2021 - Chapter 3 Engine; Cooling System

3
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
3.1
ENGINE / COOLING SYSTEM
CHAPTER 3
ENGINE / COOLING SYSTEM
GENERAL INFORMATION - ENGINE . . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . . 3.4
SPECIAL TOOLS . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . . 3.4
ENGINE LUBRICATION SPECIFICATIONS .. . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . . 3.4
OIL PRESSURE TEST. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . 3.5
OIL FLOW DIAGRAM... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . .. 3.6
ENGINE SPECIFICATIONS. ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 3.7
GENERAL INFORMATION - COOLING SYSTEM . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . 3.9
SPECIAL TOOLS . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . . 3.9
COOLING SYSTEM LAYOUT AND TESTING . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . 3.9
COOLING SYSTEM SPECIFICATIONS . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..3.10
COOLING SYSTEM BLEEDING PROCEDURE .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .3.10
COOLANT DRAIN / RADIATOR SERVICE . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . 3.11
COOLING SYSTEM ASSEMBLY VIEW . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .3.11
COOLANT DRAIN / FILL . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .3.12
RADIATOR CLEANING .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...3.12
RADIATOR REMOVAL. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..3.13
RADIATOR INSTALLATION . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .3.13
WATER PUMP SERVICE . . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..3.14
WATER PUMP IMPELLER REMOVAL .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .3.14
WATER PUMP MECHANICAL SEAL REPLACEMENT . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . .3.14
STATOR COVER INSTALLATION ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .3.16
THERMOSTAT . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . .3.17
THERMOSTAT REPLACEMENT . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..3.17
INTAKE / EXHAUST SYSTEM .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..3.18
AIR INTAKE ASSEMBLY VIEW . . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .3.18
EXHAUST ASSEMBLY VIEW .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . .3.19
INTAKE REPLACEMENT . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .3.21
HEAT SHIELDS .. . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...3.23
ENGINE ASSEMBLY VIEWS . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ..3.25
TORQUE SEQUENCE - MAIN ENGINE COMPONENTS . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .3.25
VALVE COVER ASSEMBLY VIEW . . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .3.27
CAMSHAFT / CAMSHAFT CARRIER / ROCKER ARM ASSEMBLY VIEW . . .. . . .. . . .. . . .. . . .. . . .. . . .. .3.28
CYLINDER HEAD / VALVES / INTEGRATED THROTTLE BODY ASSEMBLY VIEW . . .. . . .. . . .. . . .. . . ..3.29
VALVE AND SPRING HEIGHT DETAIL... . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. .3.30
PISTON / CONNECTING ROD. ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . ..3.31
CRANKSHAFT .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. .3.32
CRANKCASE ASSEMBLY VIEW. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... .3.33
CRANKCASE - UPPER .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. .3.35
CRANKCASE (LOWER) WITH OIL PUMP. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . ..3.36
BALANCE SHAFT / BALANCE SHAFT TIMING . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ..3.37
DRIVE COUPLER / STARTER GEAR . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .3.38