Polaris Sportsman XP 1000 S 2021 - Chapter 1 1 General Information; Table of Contents

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9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
1.1
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION .. . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .. 1.3
MODEL NUMBER DESIGNATION (2015 +) . . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. 1.3
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 1.3
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .. 1.4
REFERENCE INFORMATION . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. 1.5
PUBLICATION NUMBERS . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 1.5
SPECIAL TOOLS . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . . 1.6
MASTER SPECIAL TOOLS TABLE . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... 1.7
MASTER TORQUE TABLE . . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .1.14
VEHICLE SPECIFICATIONS . . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .1.18
2020-2021 SPORTSMAN XP 1000 S.. . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .1.18
2021 SPORTSMAN XP 1000 S (INTERNATIONAL MODELS) . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . .1.20
MISC. SPECIFICATIONS AND CHARTS . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..1.22
CONVERSION TABLE . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .1.22
SAE TAP / DRILL SIZES . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . .1.23
METRIC TAP / DRILL SIZES .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ...1.23
DECIMAL EQUIVALENTS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..1.24
GENERAL DIAGNOSTICS. . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . .1.25
GENERAL DIAGNOSTICS INFORMATION OVERVIEW . . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .1.25
GUIDED SYMPTOM DIAGNOSTIC . . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . .1.25
GUIDED SYMPTOM REFERENCES .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..1.26
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES . . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . .1.27
ENGINE CRANKS BUT DOES NOT START . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ..1.30
NO CRANK NO START OR SLOW CRANK . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .1.32
OVER HEATING... . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .1.33
WARNING LIGHTS . . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. .1.34
ENGINE TROUBLESHOOTING. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... .1.35
COOLING TROUBLESHOOTING . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ..1.37
DIGITAL WRENCH . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..1.38
DIGITAL WRENCH® SOFTWARE OVERVIEW . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ..1.38
SPECIAL TOOLS . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .1.38
GUIDED DIAGNOSTICS. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ...1.38
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES . . ... . ... . ... . ... . . .. . ... . ... . .1.39
DIGITAL WRENCH® DIAGNOSTIC CONNECTOR . . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . .1.40
DIGITAL WRENCH® COMMUNICATION ERRORS. . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .1.40
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .1.40
DIGITAL WRENCH® FEATURE MAP . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .1.41
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . ... . ... . ... . ... . .. . . .. . . .. . . .. . . ... . .1.42
POLARIS MOBILE DIGITAL WRENCH® (PMDW) . . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ..1.42
ENGINE ELECTRICAL DIAGNOSTICS . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..1.44
DIAGNOSTIC TROUBLE CODES OVERVIEW . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..1.44