Required Tools and Supplies:
- Shop Rags
- Safety Glasses
- Nitrile Gloves
- Brake Pad Measurement Tool
- Brake Rotor Measurement Tool
- 19mm Socket
- T20 TORX® Socket
- Breaker Bar
- Torque Wrench
Always wear safety glasses and nitrile gloves when servicing your Polaris ATV. To inspect the wheels and brake system and perform a tire rotation on your Sportsman XP 1000 S, follow these steps:
1. Take a close look at each tire.
- Verify there is sufficient tread depth. Tires should be replaced once they reach one-eighth inch or 3 millimeters of tread depth.
- Inspect for damage that may compromise the integrity of the tire.
- Next, inspect the tire pressure and verify it is set to specification. The tire pressure should be 10 psi (69 kPa) on all tires.
- Lastly, take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.
2. To remove the tires:
- Start by loosening the lug nuts with a 19mm socket before the vehicle is off the ground, but do not remove.
- Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
- Remove the lug nuts and set aside.
- Then remove the wheels and set aside.
3. Now is a great time to look at the brake system.
- First inspect the fluid level and condition in the front master cylinder, located on the left handlebar.
- Add fluid as needed by removing the two T20 TORX® fasteners. Caution: After opening a bottle of brake fluid, always discard any unused portion. Brake fluid rapidly absorbs moisture from the air, which causes the boiling temperature to drop. This can lead to early brake fade and the possibility of an accident or serious injury.
- Follow the lines all the way to the front junction block in the center of the chassis frame.
- Continue inspecting the brake lines to both front calipers, looking for any leaks, kinks or damage.
- Also, ensure the brake line retainers are properly secured.
- Inspect the connections at the front brake calipers for leaks or damage.
4. Next take a look at the brake pads and rotors. Caution: Brake discs can become extremely hot after operation. Always allow the discs to cool completely before performing maintenance to prevent risk of burns.
- Check the brake pad thickness at each wheel using a suitable tool. Be sure to check the thickness on the inside pads as well. Replace any brake pads that are worn beyond their minimum thickness of 0.180 inches (4.6 mm).
- Use a brake rotor measurement tool to measure the thickness of the brake discs at each wheel and replace if worn below the minimum thickness of 0.167 inches (4.24 mm).
5. Unlatch the front rack and pull it open. Then turn the quarter-turn latches and remove the storage tray to access the rear brake reservoir.
- Ensure the fluid level is between the min and max marks.
- Next follow the brake lines back to the rear of the vehicle, looking for leaks, kinks and damage.
- Reinstall the front storage compartment. Verify the sealing gasket is seated before closing the front storage rack.
- Close and lock the front storage rack.
- Inspect the connections at the junction block in the right rear wheel well.
- Continue following the brake lines to the rear brake calipers, ensuring the brake line retainers are properly secured.
- Inspect the rear brake calipers. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
6. Once the brake system inspection has been completed, the tires can be rotated, if applicable, and reinstalled.
7. Rotate the wheels as needed based on wheel configuration. Caution: Due to different configurations, some wheels may not be able to be rotated. Always pay attention to all markings and directional indicators on the tires.
- Install the wheels on the vehicle and hand-tighten the lug nuts.
- Safely lower the vehicle until the tires begin to touch the ground. Reference your Owner’s Manual for proper lowering techniques.
- Torque the lug nuts to 120 ft-lbs (162.7 Nm) in a crisscross pattern.
- Safely lower the vehicle completely.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
TORX® is a registered trademark of Acument Intellectual Properties, LLC