Polaris Sportsman XP 1000 S 2021 - Maintenance Chapter 2 Maintenance 2

2
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
2.1
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . . 2.3
BREAK-IN PERIOD. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .. 2.3
PRE-RIDE INSPECTION . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . . 2.4
MAINTENANCE INTERVALS .. . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... 2.5
GREASE LUBRICATION POINTS. . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..2.15
MAINTENANCE QUICK REFERENCE . . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..2.16
LUBRICANTS / SERVICE PRODUCTS . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ..2.18
POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS . . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .2.18
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ..2.19
FUEL SYSTEM / AIR INTAKE. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .2.20
FUEL SYSTEM . . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .2.20
FUEL LINES. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. .2.20
FUEL FILTER. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..2.20
VENT LINES . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .2.20
AIR FILTER / PRE-FILTER SERVICE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . .2.21
ENGINE .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . . .. . ... . ... . .. . . .. . . ...2.22
ENGINE OIL LEVEL . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..2.22
ENGINE OIL AND FILTER CHANGE . . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . .2.22
ENGINE BREATHER HOSE .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. .2.23
VALVE CLEARANCE ADJUSTMENT. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... .2.24
COMPRESSION AND LEAKDOWN TESTING.. . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..2.26
EXHAUST SILENCER CLEANING . . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ..2.26
ENGINE MOUNT ISOLATOR FASTENER TORQUE . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . .2.27
COOLING SYSTEM . ... . .. . . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .2.28
COOLING SYSTEM OVERVIEW. . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . .2.28
COOLANT LEVEL INSPECTION... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ..2.28
COOLING SYSTEM HOSES .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..2.29
COOLANT STRENGTH / TYPE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..2.29
PVT / FINAL DRIVE / WHEELS / TIRES . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ..2.30
PVT DRYING . . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..2.30
DRIVE SHAFT BOOT INSPECTION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..2.30
WHEEL REMOVAL . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .. . . ... . ... . . .. . ..2.30
WHEEL INSTALLATION . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . ... . .2.31
TIRE PRESSURE . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ...2.31
TIRE INSPECTION . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..2.31
TRANSMISSION / GEARCASE. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. .2.32
TRANSMISSION LUBRICATION . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .2.32
FRONT GEARCASE LUBRICATION . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . .2.33
REAR GEARCASE LUBRICATION. . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ..2.34
ELECTRICAL / IGNITION SYSTEM . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .2.35