Polaris Sportsman XP 1000 S 2020 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

SAFETY WARNINGS
The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved
when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious
injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.

REVISION INDEX
REV
RELEASE
DATE CHANGES
R01 03/20/2020 Initial release (International Models)
R02 09/11/2020 Initial release (Domestic Models)
R03 12/16/2020
• Updated the Crankshaft Position Sensor (CPS) resistance in the “CPS
Service” topic.
• Updated pins 3 and 4 in the “Instrument Cluster Pinouts” topic.
FEEDBACK FORM
A feedback form has been created for the technician or consumer to provide Polaris
with an overall satisfaction rating for this service manual, provide comments on your
experience or upload pictures/video. This feedback form is viewable on a mobile
device by scanning the QR code or by clicking HERE if viewing this document
electronically.

2020-2021 Sportsman XP 1000 S
Service Manual
Chapter Summary
CHAPTER 1 : GENERAL INFORMATION
CHAPTER 2 : MAINTENANCE
CHAPTER 3 : ENGINE / COOLING SYSTEM
CHAPTER 4 : ENGINE ELECTRICAL
CHAPTER 5 : FUEL SYSTEM
CHAPTER 6 : PVT SYSTEM
CHAPTER 7 : TRANSMISSION
CHAPTER 8 : FINAL DRIVE
CHAPTER 9 : STEERING / SUSPENSION
CHAPTER 10 : BRAKE SYSTEM
CHAPTER 11 : BODY / FRAME
CHAPTER 12 : BODY ELECTRICAL

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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

1.2 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
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MASTER TROUBLE CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.56
FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
FLUID INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
PVT SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60
PVT SYSTEM OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62
TRANSMISSION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.63
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.63
TRANSMISSION ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.63
FINAL DRIVE DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
ALL WHEEL DRIVE (AWD) CONCERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
BRAKE SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
BRAKE VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
POOR BRAKE PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66
STEERING / SUSPENSION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . . . . . . .1.67
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . . . . . . .1.68
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.69
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.70
ELECTRICAL DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72
TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
TESTING FOR A SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74
TESTING FOR INTERMITTENT CONDITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
CURRENT DRAW - KEY OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
GENERAL INFORMATION

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc. 1.3
VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5R U E 57A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION
Example: 4XAKA09A0F3000000
WORLD MFG. ID
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
CHASSIS
DRIVELINE
ENGINE SIZE
ENGINE
MODIFIER
CATEGORY
CHECK DIGIT
MODEL YEAR *
MFG. LOCATION
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A K A 0 9 A 0 G 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J = 2018; K = 2019,
L = 2020, M = 2021
GENERAL INFORMATION
1

1.4 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
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VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS
The vehicle identification number (VIN) qis stamped on
the lower tube frame on the rear RH side of the vehicle.
International Models: The VIN wis stamped on the
lower frame rail on the front LH side of the vehicle.
The engine serial number ecan be found on the rear
portion of the engine located on the valve cover .
GENERAL INFORMATION

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc. 1.5
REFERENCE INFORMATION
PUBLICATION NUMBERS
MODEL YEAR MODEL MODEL NUMBER OWNER’S
MANUAL
2020 Sportsman XP 1000 S A20SLZ95AE 9929998
2021
Sportsman XP 1000 S A21SLZ95AE / AG 9931371
Sportsman XP 1000 S EU (Intl.) A21SLE95FG 9931152
Sportsman XP 1000 S Tractor (Intl.) A21SLS95CG
A21SLS95EG 9931153
Sportsman XP 1000 S ZUG (Intl.) A21SLS95FG 9931152
GENERAL INFORMATION
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1.6 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com
GENERAL INFORMATION

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc. 1.7
MASTER SPECIAL TOOLS TABLE
ENGINE / COOLING SYSTEM
Bench Mount Engine Stand Adapter
PW-47053
Rolling Engine Stand
PU-50624
Engine Stand Adapter
(Mounts To The Engine)
PU-50824-A
Engine Stand Sleeve Adapter
(Use With 2” Bore Stand)
PU-50625
Engine Stand Sleeve Adapter
(Use With 2.375” Bore Stand)
PW-47054
Flywheel Puller / Water Pump Drive
Nut Puller
PA-49316-A
Stator Cover Removal Handles
PA-49317
Valve Spring Compressor
PV-1253 or PV-43513-A
Water Pump Seal Installation Tool
PU-50869
GENERAL INFORMATION
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1.8 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
ENGINE / COOLING SYSTEM
Crankshaft Removal / Installation
Tool Kit
PU-50784
Oil Filter Wrench
PU-50105
Oil Pressure Gauge
PV-43531
Oil Pressure Gauge Adapter
PU-52492
Valve Spring Compressor Adapter
PV-43513-A
Cylinder Leakdown Tester
PV-35667-A
Hydrometer
PU-50338
GENERAL INFORMATION

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc. 1.9
FUEL SYSTEM
Digital Wrench® SmartLink Module
Kit
PU-47471
(Includes: PU-47470, PU-47469, PU-
47468)
Digital Wrench® Wireless Vehicle
Link
PU-51435
Fuel Pressure Gauge Kit
PU-43506-A
Fuel Pressure Gauge Adapter
PS-48762
Fluke 77 Digital Multi-Meter or Fluke
115 DMM
(PV-43568) or (PV-43546)
Fuel Pump Service Tool
PU-50326
GENERAL INFORMATION
1

1.10 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
PVT SYSTEM
Clutch Alignment Tool
PA-49011-A
Clutch Bushing Replacement Tool Kit
2871226
Clutch Center Distance Tool
2871710
Clutch Holding Wrench
9314177-A
Primary Clutch Puller
PU-52907
Drive Clutch Spider Removal and
Installation Tool
2870341
Piston Pin Puller
2870386
Roller Pin Tool
2870910-A
Universal Clutch Compressor
PU-50518-A
GENERAL INFORMATION

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc. 1.11
TRANSMISSION
Backlash Setting Tool
2871695 (Part of 2871702 Kit)
Bearing Seal Driver (50 mm)
2871282
Rear Driveshaft Seal Guide
2871699 (Part of 2871702 Kit)
Rear Output Seal Driver
2871698 (Part of 2871702 Kit)
Snorkel Tool
PA-50231
Transmission Nut Socket
PU-50566
FINAL DRIVE
1 3/4” Straight Wrench
2870772
ADC Gearcase Piston Installation
Tool
PA-48542
CV Boot Clamp Pliers
8700226 or PU-48951
Roller Pin Removal Tool
2872608
GENERAL INFORMATION
1

1.12 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
STEERING / SUSPENSION
Ball Joint Removal / Installation Tool
PU-50506
Strut Compression Tools
2871573, 2871574, 2870623
Shock Absorber Spring Compression
Tool
2870623
BRAKES
Mity Vac® Pressure Test Tool
2870975
BODY / FRAME
Multi-Function Pliers
2876389
GENERAL INFORMATION

9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc. 1.13
ELECTRICAL
Battery Conductance Analyzer
PU-50296
Battery Hydrometer
2870836
Fluke® 77 Digital Multimeter
PV-43568
Hall Sensor Probe Harness
2460761
Static Timing Light Harness
2871745
Timing Light
2870630
Relay Bypass
PU-49466
Connector Test Kit
PV-43526
GENERAL INFORMATION
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1.14 9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
MASTER TORQUE TABLE
MAINTENANCE
ITEM TORQUE
Front Gearcase Drain /
Fill Plug 19 ft-lbs (26 N·m)
Oil Drain Plug 12 ft-lbs (16 N·m)
Oil Filter
Turn by hand until filter
O-ring contacts sealing
surface, then turn an
additional 3/4 turn.
Plenum to Throttle Body
Fasteners 89 in-lbs (10 N·m)
Rear Gearcase Drain / Fill
Plug 12 ft-lbs (16 N·m)
Rocker Jam Nut 89 in-lbs (10 N·m)
Spark Arrestor Fasteners 8 ft-lbs (11 N·m)
Spark Plug 15 ft-lbs (20 N·m)
Transmission Drain / Fill
Plug 14 ft-lbs (19 N·m)
Valve Cover Bolts 89 in-lbs (10 N·m)
ENGINE / COOLING SYSTEM
ITEM TORQUE
Engine Components
Breather Cover Screws 15 ft-lbs (21 N·m)
Cam Chain Tensioner
Cap Bolts 7 ft-lbs (9 N·m)
Camshaft Carrier Bolts
(M8)
12 ft-lbs (17 N·m)
Torque 1 and 2 again
after 1 through 10
sequence is complete.
Camshaft Sprocket Bolt 28 ft-lbs (38 N·m)
Connecting Rod Bolts
Torque in Sequence:
Step 1: 9 ft-lbs (12 N·m)
Step 2: 20 ft-lbs (27
N·m)
Step 3: Tighten an
additional 90°
Connecting Rod Bolts:
For Measurement 16 ft-lbs (22 N·m)
Crankcase Bolts (M6) 89 in-lbs (10 N·m)
Crankcase Bolts (M9) Torque in Sequence:
ENGINE / COOLING SYSTEM
ITEM TORQUE
Step 1: 71 in-lbs (8 N·m)
Step 2: 26 ft-lbs (35
N·m)
Crankcase Oil Gallery
Plug 12 ft-lbs (16 N·m)
Cylinder Head Bolts (M6) 89 in-lbs (10 N·m)
Cylinder Head Bolts
(M11)
Torque in Sequence:
Step 1: 89 in-lbs (10
N·m)
Step 2: 43 ft-lbs (59
N·m)
Step 3: Tighten an
additional 90°
ECU Bracket Mount
Fasteners
Torque Until Fully
Seated
Engine Mount Bracket
Fasteners 19 ft-lbs (26 N·m)
Engine Mount Isolator
Fasteners 27 ft-lbs (37 N·m)
Flywheel Retaining Bolt 74 ft-lbs (100 N·m)
Oil Pressure Relief Valve 20 ft-lbs (27 Nm)
Oil Pump Cover Bolts 9 ft-lbs (12 N·m)
Oil Sump Baffle
Fasteners 89 in-lbs (10 N·m)
PFA Nut 70 ft-lbs (95 N·m)
Spark Arrestor Fasteners 8 ft-lbs (11 N·m)
Spark Plug 15 ft-lbs (20 N·m)
Stator Cover Fasteners 89 in-lbs (10 N·m)
Thermostat Housing
Fasteners 89 in-lbs (10 N·m)
Valve Cover Bolts 89 in-lbs (10 N·m)
Exhaust System
Exhaust Head Pipe Nuts
18 ft-lbs (24 N·m)
(Domestic Models)
14 ft-lbs (19 N·m)
(International Models)
Front Exhaust Bracket
Bolts 10 ft-lbs (14 N·m)
Lambda Sensor 35 ft-lbs (47 N·m)
Silencer End Cap Bolts 10 ft-lbs (14 N·m)
GENERAL INFORMATION