Polaris ACE 900 2017 Service Manual

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2017-2019 ACE 900

Service 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 August 2018 (PN 9929422 R02)

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.

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Polaris ACE 900 2017

Page 1 Publication Printed August 2018 (PN 9929422 R02) © Copyright 2018 Polaris Industries 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.
Page 2 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.
Page 3 04/03/2019 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...
Page 5 2017-2019 ACE 900 Service Manual Chapter Summary CHAPTER 1: GENERAL INFORMATION CHAPTER 2: MAINTENANCE CHAPTER 3: ENGINE / COOLING SYSTEM CHAPTER 4: FUEL SYSTEM CHAPTER 5: PVT SYSTEM CHAPTER 6: TRANSMISSION CHAPTER 7: FINAL DRIVE CHAPTER 8: STEERING / SUSPENSION CHAPTER 9: BRAKE SYSTEM CHAPTER 10:...
Page 8: Vehicle Indentification
INDIVIDUAL SERIAL NO. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 9: Vin And Engine Serial Number Locations
GENERAL INFORMATION VIN AND ENGINE SERIAL NUMBER LOCATIONS Whenever corresponding about a Polaris ORV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front left side of the ORV.
Page 10: Reference Information
A18DCE87BB 9928077 NOTE When ordering service parts be sure to use the correct parts manual. Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 11: 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.
Page 12: General Specifications
575 lbs. / 260 kg Hitch Towing Capacity Towing is not recommended on this model. Do not use this Hitch Tongue Capacity vehicle for towing. Do not remove hitch cap. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 13: 2017 Ace 900 Xc Clutch Chart
Yuasa / YIX30L/ 30 AH / 400 Brakes Hydraulic 4 Wheel Disc DC Outlet Standard Brake Fluid Polaris DOT 4 Brake Fluid Relays EFI / Fan / Fuel Pump / Chassis (Located in Relay/Fuse 2017 ACE 900 XC CLUTCH CHART Box)
Page 14 575 lbs. / 260 kg Hitch Towing Capacity Towing is not recommended on this model. Do not use this Hitch Tongue Capacity vehicle for towing. Do not remove hitch cap. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 15: 2018 Ace 900 Clutch Chart
Yuasa / YIX30L/ 30 AH / 400 Brakes Hydraulic 4 Wheel Disc DC Outlet Standard Brake Fluid Polaris DOT 4 Brake Fluid Relays EFI / Fan / Fuel Pump / Chassis (Located in Relay/Fuse 2018 ACE 900 CLUTCH CHART Box)
Page 16 575 lbs. / 260 kg Hitch Towing Capacity Towing is not recommended on this model. Do not use this Hitch Tongue Capacity vehicle for towing. Do not remove hitch cap. 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.10 © Copyright Polaris Industries Inc.
Page 17: 2019 Ace 900 Clutch Chart
Yuasa / YIX30L/ 30 AH / 400 Brakes Hydraulic 4 Wheel Disc DC Outlet Standard Brake Fluid Polaris DOT 4 Brake Fluid Relays EFI / Fan / Fuel Pump / Chassis (Located in Relay/Fuse 2019 ACE 900 CLUTCH CHART Box)
Page 18: Misc. Specifications And Charts
Thermostat Cover Bolts 7 ft-lbs (10 Nm) Flywheel Retaining Bolt 133 ft-lbs (180 Nm) Coolant Bleed Screw 89 in-lb (10 Nm) Stator Cover Screws 9 ft-lb (12 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.12 © Copyright Polaris Industries Inc.
Page 19 Sector Gear Cover Bolts 12 ft-lb (16 Nm) 620™) Bell Crank Nut 18 ft-lb (24 Nm) 250 ft-lb (339 Nm) Spider Jam Nut (Apply 0.1 mL Loctite® 620™) 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.13 © Copyright Polaris Industries Inc.
Page 20 28 ft-lbs (38 Nm) Fasteners Upper A-arm Fastener 73 ft-lbs (99 Nm) Brake Pressure Switch 180 in-lbs (20 Nm) 42 ft-lbs (57 Nm) Lower A-arm Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.14 © Copyright Polaris Industries Inc.
Page 21 Seat Base Fasteners ELECTRICAL ITEM TORQUE Battery Hold-Down Strap 10 ft-lbs (13.5 Nm) Fastener Voltage Regulator 8 ft-lbs (11 Nm) Fasteners Starter Mounting 7 ft-lbs (10 Nm) Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.15 © Copyright Polaris Industries Inc.
Page 22: Conversion Table
π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.16 © Copyright Polaris Industries Inc.
Page 23: Sae Tap / Drill Sizes
5/16–18 2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.17 © Copyright Polaris Industries Inc.
Page 24: Decimal Equivalents
0.5156″ 17/32 0.5313″ 35/64 0.5469″ 14 mm = 0.5512″ 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 9929422 R02 - 2017-2019 ACE 900 Service Manual 1.18 © Copyright Polaris Industries Inc.
Page 27: Maintenance
3 oz tube (24) U-Joint Grease 14 oz cartridge 2871551 12 oz bottle (12) 2871326 Carbon Clean 2870652 16 oz (12) Fuel Stabilizer 2.5 gal (2) 2872280 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 28: Periodic Maintenance - General
• Verify coolant level is filled to the FULL COLD mark on coolant reservoir (if engine is cold) Coolant Level • Inspect hoses and radiator for leaks 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 29: Maintenance Intervals
Battery Check terminals; clean; test XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual...
Page 30 Inspect; clean; replace as needed Cam Chain Tensioner XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual...
Page 31 Battery Check terminals; clean; test XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual...
Page 32 Inspect; clean; replace as needed Cam Chain Tensioner XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual...
Page 33 Battery Check terminals; clean; test XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual...
Page 34 Inspect; clean; replace as needed Cam Chain Tensioner XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.10...
Page 35 Battery Check terminals; clean; test XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.11...
Page 36 Inspect; clean; replace as needed Cam Chain Tensioner XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.12...
Page 37 Battery Check terminals; clean; test XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.13...
Page 38 Cam Chain Tensioner XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.
Page 39: Maintenance Quick Reference
- Under Front Hood / Access Panel Coolant * More often under severe use, such as operation in water or under severe loads. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.15 © Copyright Polaris Industries Inc.
Page 40 Transmission Polaris AGL 44 oz. (1300 ml) * More often under severe use, such as operation in water or under severe loads. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.16 © Copyright Polaris Industries Inc.
Page 41: Grease Lubrication Points
Grease fittings on each side of thoroughly washing or Polaris All Season Grease Bushings the vehicle submerging the vehicle Propshaft Yoke Grease rear fitting Polaris Premium U-Joint Grease 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.17 © Copyright Polaris Industries Inc.
Page 42: Break-In Period
Do not operate at full throttle or high speeds during the first three hours of use. Use of any oils other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS PS-4 Full Synthetic 5W-50 4-Cycle Oil for your 4-cycle engine.
Page 43: Engine
Do NOT overfill. Access the oil dipstick through the engine service panel. Access the oil fill cap through the cargo box access panel. Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic Engine Oil. FLUID CAPACITY Recommended Engine Oil: PS-4 (PN 2876244) Ambient Temp Range: -35°...
Page 44: Engine Oil And Filter Change
Install the filter and torque to the correct specification. TORQUE Oil Filter: Turn by hand until filter O-ring contacts sealing surface, then turn an additional 3/4 turn. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.20 © Copyright Polaris Industries Inc.
Page 45: Engine Breather Hose
20. When finished, reinstall dipstick and lock the lever. 21. Reinstall the cargo box access panel, engine service panel and seat. 22. Dispose of used oil and filter properly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.21 © Copyright Polaris Industries Inc.
Page 46: Valve Clearance Inspection
Place a clean shop towel into the spark plug cavity to prevent dirt from entering. 2. Remove the air box cover Disconnect the negative (-) battery cable by removing the seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.22 © Copyright Polaris Industries Inc.
Page 47 10. Record the results of each measurement for future reference. 11. If the valve clearances are out of specification, proceed to Valve Clearance Adjustment page 3.89. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.23 © Copyright Polaris Industries Inc.
Page 48: Cam Chain Tensioner Inspection
It should move freely. If it does not move freely, replace the tensioner assembly. 5. Retract the plunger all the way in and install into the cylinder. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.24 © Copyright Polaris Industries Inc.
Page 49: Spark Arrestor Service
4. Inspect the screen for wear and damage. Replace if damaged. 5. Reinstall the spark arrestor. Torque fasteners to specification. TORQUE Spark Arrestor Screw 8 ft-lbs (11 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.25 © Copyright Polaris Industries Inc.
Page 50: Cooling System
COOLING SYSTEM 50/50 EXTENDED-LIFE ENGINE ANTIFREEZE Beginning in the later part of 2014, Polaris began using 50/50 Extended Life antifreeze in some vehicles. All model- year 2015 and newer vehicles will use 50/50 Extended Life antifreeze. Using the 50/50 Extended-life antifreeze extends the service interval from two to five years.
Page 51: Cooling System Overview
• Do not use tap water, straight antifreeze or straight Polaris recommends the use of Polaris 50/50 Extended water in the system. Tap water contains minerals and Life Antifreeze or a 50/50 mixture of high quality impurities which build up in the system.
Page 52: Coolant Level Inspection
5. Remove the pressure cap. Using a funnel, add coolant to the top of the filler neck. 6. Reinstall the pressure cap. 7. Remove recovery bottle cap and add coolant using a funnel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.28 © Copyright Polaris Industries Inc.
Page 53: Radiator Inspection / Cleaning
9. See Cooling System Bleeding page fitting on the front right side of the vehicle. FLUID CAPACITY Recommended Coolant: 50/50 Extended Life Antifreeze 2880514 (Quart) 2880513 (Gallon) 2880512 (Drum) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.29 © Copyright Polaris Industries Inc.
Page 54: Cooling System Hoses
Filler Neck Coolant Pipe – FLOW TO ENGINE Filler Neck Hose Radiator / Fan Assembly Cooling Pipe Bracket Grommets Screw Spring Clamp Oil Cooler Hoses Hose 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.30 © Copyright Polaris Industries Inc.
Page 55: Fuel System And Air Intake
Engine exhaust fumes are poisonous and can result in loss of consciousness ordeath in a short time. Never drain the fuel when the engine is hot.Severe burns may result. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.31 © Copyright Polaris Industries Inc.
Page 56: Fuel Pump / Fuel Filters
EFI System. 3. Be sure fuel lines are routed and retained properly. NOTICE Make sure lines are not kinked or pinched. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.32 © Copyright Polaris Industries Inc.
Page 57: Throttle Pedal Inspection
2. Push the latch down and pull out to disengage the tab from the cargo box. Remove the pre-filter cover. 3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.33 © Copyright Polaris Industries Inc.
Page 58: Air Filter Service
2. Check the drain to ensure it is not plugged with debris so it can drain properly. If needed, remove the drain from the baffle box during inspection. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.34 © Copyright Polaris Industries Inc.
Page 59: Air Box / Air Filter Assembly View
Air Filter Intake Boot Airbox Spring Clamp Intake Box Hose Engine Vent Drain Plugs Small Gear Clamp Bolt Intake Duct Pre-Filter Gear Clamp 2.75 Seal Foam 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.35 © Copyright Polaris Industries Inc.
Page 60: Pvt
If the vehicle has ingested a large amount of water into the PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.36 © Copyright Polaris Industries Inc.
Page 61: Transmission
4. Reinstall the fill plug and torque to specification. 8. Check for leaks. Dispose of used lubricant properly. TORQUE Fill / Drain Plug Torque: 14 ft-lbs (19 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.37 © Copyright Polaris Industries Inc.
Page 62: Final Drive / Wheel / Tire
4. Reinstall the fill plug and torque to specification. TORQUE 8. Check for leaks. Dispose of used fluid properly. Fill / Drain Plug Torque: 10 ft-lbs (14 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.38 © Copyright Polaris Industries Inc.
Page 63: Drive Shaft Boot Inspection
4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.39 © Copyright Polaris Industries Inc.
Page 64: Wheel Installation
ACE TIRE PRESSURE INSPECTION (COLD) Model Front Rear 10 psi (69 kPa) 14 psi (96 kPa) ACE 900 XC 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.40 © Copyright Polaris Industries Inc.
Page 65: Steering
Check front end alignment whenever steering components are replaced. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. NOTICE Typical steering system shown.
Page 66: Wheel Toe Alignment Inspection
Call this measurement 4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.42 © Copyright Polaris Industries Inc.
Page 67: Wheel Toe Adjustment
Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification. TORQUE Tie Rod Jam Nut: 14 ft-lbs (19 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.43 © Copyright Polaris Industries Inc.
Page 68: Suspension
FACTORY PRELOAD SETTINGS LOCATION MEASUREMENT Front 13.1 in. (33 cm) Rear 13.75 in. (35 cm) NOTE The shock must be removed from the vehicle for accurate measurement. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.44 © Copyright Polaris Industries Inc.
Page 69: Walker Evans Shock Preload Adjustment
WARNING Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. Front Shock Rear Shock 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.45...
Page 70: Walker Evans Front / Rear Shock Compression
Clicker knob in fully open position Softest Front: 5-7 clicks from fully open position Factory Rear: 5-7 clicks from fully open position Firmest 1 click from closed 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.46 © Copyright Polaris Industries Inc.
Page 71: Brake System
5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.47 © Copyright Polaris Industries Inc.
Page 72: Electrical / Ignition System
Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.48 © Copyright Polaris Industries Inc.
Page 73: Spark Plug Service
7. Clean with electrical contact cleaner or glass bead spark plug cleaner on. CAUTION A wire brush or coated abrasive should not be used. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.49 © Copyright Polaris Industries Inc.
Page 74 (B). Ensure wires are pushed down all the way so they engage onto the spark plugs. 12. Reinstall the (-) negative battery cable and the driver’s seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 2.50 © Copyright Polaris Industries Inc.
Page 75: Extended Storage
Storage Area/Covers: 5. If POLARIS fuel system additive is not used, the fuel Set the tire pressure and safely support the ATV with the tank, fuel lines, and injectors should be completely tires slightly off the ground.
Page 80: General Information
Water Pump Mounting 7 ft-lb (10 Nm) (Apply Bolts Loctite® 204™ to bolt Camshaft Sprocket Bolts 11 ft-lb (15 Nm) threads) Hydraulic Cam Chain 29 ft-lb (40 Nm) Tensioner 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 81: Engine Special Tools
Engine Stand Sleeve Adapter PW-47054 (Use With 2.375” Bore Stand) Oil Pressure Gauge (0– Commercially Available 10 psi / 6.9–69 kPa) Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/ 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 82: Oil Pressure Test
Oil Pressure Gauge Adapter (PU-50565) or (PU- 52492) to the Oil Pressure Gauge (PV-43531). Test results are based on the use of the recommended engine oil (Polaris PS-4 or PS-4 Extreme Duty) while at Oil Pressure Gauge: PV-43531 operating temperature and may vary considerably if any...
Page 84: Engine Service Specifications
3.6614" ± 0.0003" (93 mm ± 0.008 mm) Cylinder Cylinder Out of Round Limit 0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.0014" - 0.0026" (0.035 - 0.065 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 85 4.9527" ± 0.0078" (125.8 ± 0.2 mm) Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm) Balance Shaft Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 86: Engine Torque Sequences
M6 Bolts: M6 Bolts: 9 ft-lb (12 Nm) VALVE COVER CAM CARRIER Camshaft Carrier Bolts Valve Cover Bolts 7 ft-lb (10 Nm) 7 ft-lbs (10 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.10 © Copyright Polaris Industries Inc.
Page 87 Step 4: M6 bolts: 7 ft-lb (10 Nm) STATOR COVER HEAD PIPE Exhaust Head Pipe Stator Cover Bolts 9 ft-lb (12 Nm) 18 ft-lbs (24 Nm) Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.11 © Copyright Polaris Industries Inc.
Page 88: Intake / Exhaust System
Air Filter Intake Boot Airbox Spring Clamp Intake Box Hose Engine Vent Drain Plugs Small Gear Clamp Bolt Intake Duct Pre-Filter Gear Clamp 2.75 Seal Foam 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.12 © Copyright Polaris Industries Inc.
Page 89: Air Box Removal / Installation
4. Unlatch the cover and carefully remove it from the air box. 5. Remove the seat. 6. Remove the engine compartment access panel. 7. Remove the four screws inside the cargo box. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.13 © Copyright Polaris Industries Inc.
Page 90 Tighten gear clamps to specification. TORQUE Air Intake Hose Gear Clamps: 35 in-lbs (4 Nm) 7. Reinstall the maintenance panel in the rear storage box. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.14 © Copyright Polaris Industries Inc.
Page 91: Exhaust Assembly View
10 ft-lbs (14 Nm) Head Pipe Fasteners Spark Arrestor Fastener Exhaust Springs 18 ft-lbs (24 Nm) 8 ft-lbs (11 Nm) Spark Arrestor Exhaust Seal Push Rivets 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.15 © Copyright Polaris Industries Inc.
Page 92: Muffler Removal
4. Pull muffler towards the rear of the vehicle to remove it from the mounting grommets. 2. Remove the three springs retaining the muffler to the exhaust pipe and muffler bracket. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.16 © Copyright Polaris Industries Inc.
Page 93: Muffler Installation
18 ft-lbs (24 Nm) 3. Install the two springs retaining the muffler to the head pipe. 4. Install the engine compartment access panel. 5. Install the seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.17 © Copyright Polaris Industries Inc.
Page 95: Cooling System Specifications
3. The system must maintain 10 psi for five minutes or reduce heat dissipation, resulting in possible engine longer. If pressure loss is evident within five minutes, damage. Polaris Extended Life 50/50 Antifreeze/ check the filler neck, radiator, hoses, clamps and Coolant is recommended for use in all cooling systems.
Page 96: Radiator Removal / Installation
11. Verify the cooling system is properly bled of air after 5. Place a suitable drain pan underneath the right side installing components. of the radiator, directly under the lower radiator hose fitting. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.20 © Copyright Polaris Industries Inc.
Page 97: Thermostat Replacement
9. Install the thermostat cover bolts. Torque bolts to specification. TORQUE Thermostat Cover Bolts: 7 ft-lbs (10 Nm) 10. Reinstall coolant hose and refill cooling system. Bleed the cooling system. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.21 © Copyright Polaris Industries Inc.
Page 98: Cooling System Bleeding
10. Remove the radiator pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator. 11. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.
Page 99: Water Pump Removal
10. Plug the water pump drive access hole in the engine block with a clean shop towel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.23 © Copyright Polaris Industries Inc.
Page 100: Water Pump Service
PU-50564. Press the new mechanical seal in until it is flush with the housing. 5. Remove impeller from water pump shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.24 © Copyright Polaris Industries Inc.
Page 101 19. Install the water pump cover and three retaining bolts . Torque bolts in sequence to specification. TORQUE Water Pump Cover Bolts: 7 ft-lb (10 Nm) (Apply Loctite® 204™ to bolt threads) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.25 © Copyright Polaris Industries Inc.
Page 102 ENGINE / COOLING SYSTEM Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.26 © Copyright Polaris Industries Inc.
Page 103: Water Pump Installation
Be sure orientation and routing are correct. 10. Connect the (-) negative battery cable. 11. Fill and bleed the cooling system. (see Cooling System Bleeding page 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.27 © Copyright Polaris Industries Inc.
Page 104: Engine Service
The rubber engine mounts can be serviced after supporting the weight of the engine / rear gearcase assembly with blocks of wood. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.28 © Copyright Polaris Industries Inc.
Page 105 Pre-Torque 5 ft-lbs (7 Nm) Flange Nuts – M8 45 ft-lbs (61 Nm) Outer Transmission Brackets Screws – M8x1.25x45 Inner Transmission Mount – Weld Nut Plate – Right 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.29 © Copyright Polaris Industries Inc.
Page 106: Crankshaft Pto Seal Replacement
Use care not to scratch the crankcase while removing seal. 3. Inspect the crankcase and crankshaft surfaces for any burrs or scratches that could damage the new seal or prevent it from sealing properly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.30 © Copyright Polaris Industries Inc.
Page 107 4. Refer to PVT Inner Cover Assembly page the flat side of the seal facing out as shown. 5. Test drive the vehicle and recheck for leaks before putting back into service. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.31 © Copyright Polaris Industries Inc.
Page 108: Engine Removal
5. Depressurize the fuel system at the valve on the fuel rail while holding a clean rag over the valve. 8. Remove the pipe / manifold assembly from the vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.32 © Copyright Polaris Industries Inc.
Page 109 11. Remove the spark plug caps. NOTE The heat shield is retained to the airbox support and can remain attached during removal. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.33 © Copyright Polaris Industries Inc.
Page 110 18. Disconnect the two fuel rail mounting bolts and move the fuel rail off to the driver’s side. NOTE Be careful not to pinch or kink the fuel rail. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.34 © Copyright Polaris Industries Inc.
Page 111 26. Remove the six engine-to-transmission mounting bolts. 27. Remove the four bolts retaining the engine to the front engine mount. 28. Remove the engine from the frame. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.35 © Copyright Polaris Industries Inc.
Page 112: Engine Installation
2015 RZR 900 uses the holes marked with a 4 5. Tighten the two longer bolts into left side mounting holes. Top first, then bottom. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.36 © Copyright Polaris Industries Inc.
Page 113 Drive Clutch Bolt 96 ft-lb (130 Nm) 11. Install the driven clutch and the belt. Torque bolt to specification. TORQUE Driven Clutch Bolt 55 ft-lb (75 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.37 © Copyright Polaris Industries Inc.
Page 114 Torque fasteners to specification. TORQUE Duct Clamp: 35 in-lbs (4 Nm) Air Box Mounting Bolts: 8 ft-lbs (11 Nm) 21. Install the coolant hoses onto the engine. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.38 © Copyright Polaris Industries Inc.
Page 115 ENGINE / COOLING SYSTEM 24. Install or connect the following components to the 28. If the engine oil was completely drained, add Polaris cargo box brace. PS-4 Synthetic Engine Oil into the crankcase. FLUID CAPACITY Recommended Engine Oil: PS-4 (PN 2876244) Ambient Temp Range: -35°...
Page 116: Engine Disassembly / Inspection - Top End
3. Remove the spark plugs . Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.40 © Copyright Polaris Industries Inc.
Page 117 9. Using a paperclip or other tool, hold cam chain up. NOTICE The crankcase has a built-in lower guide to prevent the chain from falling off the crankshaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.41 © Copyright Polaris Industries Inc.
Page 118: Camshaft Sprocket Inspection
Service Limit: 1.5220" (38.66 mm) Exhaust: 1.4961" ± .0015" (38.00 ± .040 mm) Service Limit: 1.4925" (37.91 mm) 3. Visually inspect each camshaft journal for scoring, wear or damage. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.42 © Copyright Polaris Industries Inc.
Page 119 O. D. s from camshaft carrier bore I. D. s. Compare to specification. MEASUREMENT Calculated Camshaft Oil Clearance: 0.0009" - 0.0028" (.022 - .072 mm) Service Limit: .0039" (.10 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.43 © Copyright Polaris Industries Inc.
Page 120: Cylinder Head Removal
Clean sealing surfaces with rubbing alcohol or electrical contact cleaner. Do not touch sealing surfaces of the new head gasket. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.44 © Copyright Polaris Industries Inc.
Page 121: Cylinder Head Disassembly
7. Repeat the previous steps to remove the remaining valves. 8. Clean the combustion chamber and head gasket surface. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.45 © Copyright Polaris Industries Inc.
Page 122: Valve Inspection
Valve Guide I.D.: 0.2165 - 0.2171" (5.500 - 5.515 mm) 7. Be sure to measure each guide and valve combination individually. NOTICE The valve guides cannot be replaced. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.46 © Copyright Polaris Industries Inc.
Page 123: Combustion Chamber Cleaning
2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to areas around spark plug and valve seats. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.47 © Copyright Polaris Industries Inc.
Page 124 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTICE Remove only the amount of material necessary to repair the seat surface. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.48 © Copyright Polaris Industries Inc.
Page 125 Exhaust: 0.059" (1.50 mm) Service Limit: 0.075" (1.9 mm) 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.49 © Copyright Polaris Industries Inc.
Page 126 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s). 12. Thoroughly clean cylinder head and valves. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.50 © Copyright Polaris Industries Inc.
Page 127: Engine Disassembly / Inspection - Bottom End
3. Inspect the condition of the stator windings output wires . If replacement is required, refer to Chapter 10. 4. Inspect the ball bearing that supports the starter motor shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.51 © Copyright Polaris Industries Inc.
Page 128: Water Pump Housing Removal
3. Inspect gear teeth for damage. Inspect fit of shaft inside gear and replace gear assembly is clearance is excessive. Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.52 © Copyright Polaris Industries Inc.
Page 129: Starter One-Way Clutch Disassembly
Grasp clutch gear and rotate clockwise. It should turn smoothly without binding. 9. Rotate one-way gear counterclockwise. The gear should immediately lock in position and not slip. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.53 © Copyright Polaris Industries Inc.
Page 130: Starter One-Way Clutch Assembly
5. If starter gear was replaced, inspect the torque limit gear. STARTER ONE-WAY CLUTCH ASSEMBLY 1. Install one-way clutch in clutch hub with flange of clutch engaged in recess. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.54 © Copyright Polaris Industries Inc.
Page 131: Crankcase Disassembly
6. After assembly, be sure the starter gear rotates in the clockwise direction only. 1. Remove the oil cooler from the crankcase. 2. Remove the crankcase drain plug to drain any oil remaining in the engine. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.55 © Copyright Polaris Industries Inc.
Page 132 If unable to extract the dowel pins from the oil pump, the oil pump sprocket must be removed. Access the sprocket bolt by removing the case plug. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.56 © Copyright Polaris Industries Inc.
Page 133 Carefully lift up and remove the lower crankcase half. NOTICE Oil pump assembly is non-serviceable 13. Rotate the engine so the cylinder is facing up. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.57 © Copyright Polaris Industries Inc.
Page 134: Balance Shaft Removal / Inspection
Balance Shaft Diameter (MAG & PTO): from the crankcase. 1.4939 - 1.4946" (37.946 - 37.962 mm) Service Limit: 1.4921" (37.900 mm) 4. Inspect the balance shaft gear teeth for damage. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.58 © Copyright Polaris Industries Inc.
Page 135: Crankshaft Removal / Inspection
8. If the crankshaft gear is damaged, the crankshaft assembly must be replaced. 9. If the auxiliary sprocket is damaged, remove the sprocket with a 3-jaw puller. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.59 © Copyright Polaris Industries Inc.
Page 136 .001″ (0.025 mm) 12. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.60 © Copyright Polaris Industries Inc.
Page 137: Crankcase Inspection
16. Whether installing a new crankshaft or re-installing the original, refer to the bearing selection chart provided in the “Crankshaft Main Bearing Selection” and “Connecting Rod Bearing Selection” procedures. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.61 © Copyright Polaris Industries Inc.
Page 138: Cylinder / Piston Removal
TOP END” and the “ENGINE DISASSEMBLY / are reassembled in the same cylinder bore and INSPECTION - LOWER END” procedures. direction from which they were removed (MAG / PTO). 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.62 © Copyright Polaris Industries Inc.
Page 139: Cylinder Inspection
3. Inspect taper and out of round with a dial bore Cylinder Out of Round: gauge. Service Limit: 0.001" (.025 mm) MEASUREMENT Standard Bore Size: 3.6614 ± .0003" (93 mm ± .008 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.63 © Copyright Polaris Industries Inc.
Page 140: Piston Disassembly / Inspection
DO NOT apply heat to piston rings or a loss of radial Piston Pin O.D.: tension could result. 0.7872" - 0.7874" (19.995 - 20.000 mm) Service Limit: 0.7866" (19.98 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.64 © Copyright Polaris Industries Inc.
Page 142: Piston Ring Installed Gap
Oil Control Rails: .010 - .040" (.25 - 1.02 mm) Service Limit: .059" (1.50 mm) NOTICE Always check piston ring installed gap when installing new rings and/or a new cylinder. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.66 © Copyright Polaris Industries Inc.
Page 143: Connecting Rod Inspection
8. Whether using new connecting rods or re-installing the original ones, refer to the bearing selection chart provided in the “Connecting Rod Bearing Selection” procedure in this chapter. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.67 © Copyright Polaris Industries Inc.
Page 144: Engine Assembly - Bottom End
ENGINE ASSEMBLY - BOTTOM END BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS Connecting Rod Bearing Identification Number (1 digit) Crankcase Bearing Identification Number (6 digits) Crankshaft Bearing Identification Letters (6 letters) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.68 © Copyright Polaris Industries Inc.
Page 145: Connecting Rod Bearing Selection
CRANKSHAFT Yellow bearing for Main #2 Code Green bearing for Main #3 Blue Blue Green Blue Green Yellow Yellow bearing for Main #4 Green Yellow Yellow 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.69 © Copyright Polaris Industries Inc.
Page 146: Upper Crankcase Preparation
2. Install lower rail with end gap positioned on the intake side of piston 3. Install upper rail with end gap positioned on the exhaust side of piston 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.70 © Copyright Polaris Industries Inc.
Page 147: Piston / Connecting Rod Assembly
Do not compress the new clip more than necessary to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.71 © Copyright Polaris Industries Inc.
Page 148: Cylinder / Piston Installation
10. Carefully place the cylinder and pistons into the upper crankcase. NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.72 © Copyright Polaris Industries Inc.
Page 149: Crankshaft Installation
(PU-50563) onto the cylinder. The cylinder holding tool retains the cylinder and pistons when the engine is rotated. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft & CRANKSHAFT INSTALLATION...
Page 150: Balance Shaft Installation
MAG end gear is visible. 12. Install matching rod cap on connecting rod using markings made upon disassembly. 4. Apply Polaris PS-4 engine oil to both balance shaft journals. 13. Install new bolts and tighten evenly until snug. 14. Torque connecting rod bolts to specification...
Page 151: Lower Crankcase Preparation
LOWER CRANKCASE PREPARATION NOTICE Always replace plain bearings when the crankcase or 3. Apply Polaris PS-4 engine oil to the new bearings connecting rods have been disassembled. Refer to installed in the lower crankcase half. bearing selection procedures.
Page 152 11. Rotate the engine so the cylinder is facing up. 12. Install the two M8 and eleven M6 upper crankcase bolts. Tighten all bolts lightly by hand. NOTICE Install new M10 lower crankcase bolts. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.76 © Copyright Polaris Industries Inc.
Page 154 , if previously removed. Use new O-rings upon installation 23. Install the thirteen M6 and three M8 bolts that retain the oil sump cover to the crankcase. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.78 © Copyright Polaris Industries Inc.
Page 155: Flywheel Installation
50563) is installed, remove it before tightening the flywheel. TORQUE Flywheel Retaining Bolt: 133 ft-lbs (180 Nm) 6. Install the starter torque limit gear as an assembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.79 © Copyright Polaris Industries Inc.
Page 156: Stator Cover Installation
/ installation process or injury could result. 3. Install stator cover and thirteen screws. Torque screws in sequence to specification. TORQUE Stator Cover Screws: 9 ft-lb (12 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.80 © Copyright Polaris Industries Inc.
Page 157: Engine Assembly - Top End
9. Install split keepers with gap even on both sides. 10. Repeat this procedure for remaining valves. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.81 © Copyright Polaris Industries Inc.
Page 158: Valve Sealing Test
3. Repeat for exhaust valves by pouring fluid into each exhaust port NOTICE Oil the tappet prior to installing. If any valve train components were replaced, refer to Valve Clearance Adjustment page 3.89. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.82 © Copyright Polaris Industries Inc.
Page 159: Cylinder Head Installation
Step 1: 9 ft-lbs (12 Nm) Step 2: 26 ft-lb (35 Nm) Step 3: Additional 180° Step 4: M6 bolts: 7 ft-lb (10 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.83 © Copyright Polaris Industries Inc.
Page 160: Camshaft Installation / Timing
Exhaust Camshaft - PN 1204584 an open-end wrench to rotate camshafts slightly if needed. 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.84...
Page 161 15. Remove the Cylinder Holding & Camshaft Timing Plate (PU-50563) from the end of the camshafts. 16. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.85...
Page 162 TORQUE Camshaft Carrier Bolts: 7 ft-lb (10 Nm) 22. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. Use a new tensioner sealing washer. 23. HYDRAULIC TENSIONER ONLY: Install the cam chain tensioner into the cylinder and torque to specification.
Page 163 • Install the plunger bolt. Torque fastener to specification. TORQUE Plunger Bolt: 15 ft-lb (20 Nm) 25. Rotate crankshaft through two revolutions and verify camshaft timing is correct. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.87 © Copyright Polaris Industries Inc.
Page 164: Camshaft Timing - Quick Reference
CAMSHAFT TIMING - QUICK REFERENCE Intake Cam Align Exhaust Marks With Surface Exhaust Cam CPS Mounting Hole Align Intake Marks With Surface Align Flywheel Mark in Mounting Hole 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.88 © Copyright Polaris Industries Inc.
Page 165: Valve Clearance Adjustment
Intake Camshaft - PN 1204583 Exhaust Camshaft - PN 1204584 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. TORQUE Camshaft Carrier Bolts: 89 in-lbs (10 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.89...
Page 166 3-digit tappet number. 13. Refer to the appropriate tappet selection matrix (Intake or Exhaust) on the following pages and select the proper tappet. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.90 © Copyright Polaris Industries Inc.
Page 167 18. If valve clearance is not within specification, repeat this procedure. 19. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to Camshaft Installation / Timing page 3.84. 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.91 © Copyright Polaris Industries Inc.
Page 168: Valve Lash - Tappet Selection
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i. e. 459 should be rounded to 460 since there is a 460 tappet). Available Tappets 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.92 © Copyright Polaris Industries Inc.
Page 169: Valve Cover Installation
6. Install the four valve cover shoulder bolts isolators using a T40 driver. 7. Torque valve cover bolts to specification. TORQUE Valve Cover Bolts: 7 ft-lbs (10 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.93 © Copyright Polaris Industries Inc.
Page 170: Troubleshooting
• Worn rings, piston, or cylinder • Spark plug fouled/weak spark • Worn valve guides or seals • Broken throttle cable • Obstruction in air intake 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.94 © Copyright Polaris Industries Inc.
Page 171 • Spark plug cap cracked / broken • Ignition coil faulty • Ignition or kill switch circuit faulty • Poor connections in ignition system • Ignition timing incorrect • Sheared flywheel key 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.95 © Copyright Polaris Industries Inc.
Page 172 • Thermostat stuck open • Thermostat missing Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 9929422 R02 - 2017-2019 ACE 900 Service Manual 3.96 © Copyright Polaris Industries Inc.
Page 174 POLARIS MOBILE DIGITAL WRENCH (PMDW) ........
Page 175: General Information
Sensor (CPS) Fastener ETC Housing Retaining 7 ft-lbs (10 Nm) Bolts Intake Boot Clamp 3 ft-lbs (4 Nm) Throttle Pedal Mounting 18 ft-lb (24 Nm) Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 176: Efi Overview
The Electronic Throttle Control (ETC) is located under the cargo box access panel attached to the throttle body. The Temperature and Manifold Absolute Pressure (TMAP) Sensor is located on the intake manifold. The Crankshaft Position Sensor (CPS) is located on the MAG cover. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 177: Efi Operation Overview
• Do not charge battery with key switch "on." • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 178: Initial Priming / Starting Procedure
NOTICE Accurate testing of EFI components is recommended utilizing the Digital Wrench® Diagnostic Software (dealer only). 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 179: Electronic Control Unit (Ecu)
The ECU then sends output signals to set the performed. If a problem is encountered, and you injector duration and ignition timing. determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.
Page 180: Ecu Replacement
NOTICE Upon installing the ECU connector, you should hear a “click” when the connector is fully closed. TORQUE ECU Retaining Screws: 24 in-lb (3 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 181: Ecu Pinouts
ECM 1Ground ECM 1 Brown ECM 1Ground ECM 1 Red / DK. Blue Constant Battery Voltage ECM 2 Brown ECM 2 Ground ECM 2 Brown ECM 2 Ground 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 182: Fuel Injector
Always install NEW o-rings when removing the fuel rail injection. or injectors. IMPORTANT Verify that the new top and bottom o-rings are installed in the correct position and are lubricated with clean, silicone-free oil. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.10 © Copyright Polaris Industries Inc.
Page 183: Fuel Injector Troubleshooting
Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.11 © Copyright Polaris Industries Inc.
Page 184: Fuel Injector Replacement
10. Carefully pull up on the fuel rail and injectors and remove them from the throttle body as an assembly. Take care not to damage the fuel injector ends during removal. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.12 © Copyright Polaris Industries Inc.
Page 185 20. Turn key on to allow the fuel system to prime and Intake Plenum Mount Screw: inspect the fuel rail and injectors for fuel leaks. 22 ft-lb (30 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.13 © Copyright Polaris Industries Inc.
Page 186 23. Reinstall the two screws retaining the air box assembly. 24. Position the intake hose onto the air box and tighten the hose clamp. 25. Reinstall the cargo box access panel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.14 © Copyright Polaris Industries Inc.
Page 187: Fuel Tank
75 ft-lbs (92 Nm) Fuel Pump/Regulator Fuel Tank Vent Fuel Tank Mounting Fastener Fuel Sender Float Arm 8 ft-lbs (11 Nm) Fuel Pickup Filter (not serviceable) Fuel Tank Assembly 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.15 © Copyright Polaris Industries Inc.
Page 188: Fuel Line - Quick Connect Removal / Installation
5. Place the connector end over the fitting and push the retainer tabs back into place. NOTICE Confirm connector attachment by pulling up on fuel line connector. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.16 © Copyright Polaris Industries Inc.
Page 189 10. Remove the screws securing the seat channels to the access the fuel tank assembly. frame. 13. Remove two screws securing the fuel tank to the frame. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.17 © Copyright Polaris Industries Inc.
Page 190: Fuel Tank Installation
7. Install the left and right seat covers. Install screws and plastic rivets into the seat panels and rocker panels. 8. Install the engine compartment access panel. 9. Reinstall the seat assembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.18 © Copyright Polaris Industries Inc.
Page 191: Fuel Line
Be sure the fuel supply line is routed properly and secured. Check the fuel tank line for signs of wear, deterioration or damage. Replace fuel supply line if necessary. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.19 © Copyright Polaris Industries Inc.
Page 192 T-clip on the engine mount. 2. Secure the fuel line with a routing clip on the airbox support. NOTE Airbox removed for image clarity. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.20 © Copyright Polaris Industries Inc.
Page 193: Fuel Vent Line
Replace vent line if necessary. Collapsing fuel tank Engine miss or hesitation Symptoms of a restricted fuel tank vent include the following: Loss of engine performance High exhaust temperatures. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.21 © Copyright Polaris Industries Inc.
Page 194: Vent Line Termination Fitting
If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.22 © Copyright Polaris Industries Inc.
Page 195: Fuel Pump
1. Access the top of the fuel pump. Refer to “Fuel FULL position 100 Ω ± 3% Pump Replacement” page for more detail. Measure between the two — pins 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.23 © Copyright Polaris Industries Inc.
Page 196 Normal Fuel Pressure: correct pressure. 58 ± 2 psi (400 ± 14 kPa) NOTICE If the fuel pressure is out of specification, replace the fuel pump assembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.24 © Copyright Polaris Industries Inc.
Page 197: Fuel Pump Replacement
NOTICE A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.25 © Copyright Polaris Industries Inc.
Page 199 Be sure to engage the retainer on fuel line until it snaps into place. Pull on fuel line lightly to confirm connection. 22. Connect the fuel pump electrical harness. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.27 © Copyright Polaris Industries Inc.
Page 200: Air Box / Intake System
Air Filter Intake Boot Airbox Spring Clamp Intake Box Hose Engine Vent Drain Plugs Small Gear Clamp Bolt Intake Duct Pre-Filter Gear Clamp 2.75 Seal Foam 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.28 © Copyright Polaris Industries Inc.
Page 201: Air Box Removal / Installation
4. Unlatch the cover and carefully remove it from the air box. 5. Remove the seat. 6. Remove the engine compartment access panel. 7. Remove the four screws inside the cargo box. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.29 © Copyright Polaris Industries Inc.
Page 202 Tighten gear clamps to specification. TORQUE Air Intake Hose Gear Clamps: 35 in-lbs (4 Nm) 7. Reinstall the maintenance panel in the rear storage box. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.30 © Copyright Polaris Industries Inc.
Page 203: Temp / Manifold Absolute Pressure Sensor (T-Map)
Wiring harness issues are more likely to be the cause of a poor running condition than a faulty T-MAP. The T-MAP sensor is a non-serviceable item. If it is faulty, it must be replaced. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.31 © Copyright Polaris Industries Inc.
Page 204: Crankshaft Position Sensor (Cps)
Check both wires in this matter. engine will stop running. They should both read OL, indicating no shorts to ground. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.32 © Copyright Polaris Industries Inc.
Page 206 Cooling System chapter). 9. Install a NEW or known good CPS. (see CPS Replacement). 10. Fill and bleed the coolant system (see Engine / Cooling System chapter) 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.34 © Copyright Polaris Industries Inc.
Page 207: Cps Replacement
4. Install new sensor using a light coating of oil on the O-ring to aid installation. 5. Torque CPS retaining bolt to specification. TORQUE CPS Retaining Bolt: 9 ft-lbs (12 Nm) 6. Reconnect CPS harness connector. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.35 © Copyright Polaris Industries Inc.
Page 208: Electronic Throttle Control (Etc)
All operating and control functions within the ETC are pre-set. No internal servicing or adjustments may be performed. If a problem is encountered, and you determine the ETC to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ETC without factory authorization.
Page 209: Etc Learn Procedure
4. If the procedure was interrupted at any time, start back at step 1. TORQUE ETC Housing Retaining Bolts: 7 ft-lbs (10 Nm) Intake Boot Clamp: 3 ft-lbs (4 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.37 © Copyright Polaris Industries Inc.
Page 210: Pedal Position Sensor
1. Disconnect the PPS harness connection located on the throttle pedal. 2. Remove the seat and disconnect the negative (-) battery cable. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.38 © Copyright Polaris Industries Inc.
Page 211 18 ft-lb (24 Nm) 7. Manually cycle the throttle pedal to verify the throttle pedal moves freely. 8. Connect the negative (-) battery cable and install the seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.39 © Copyright Polaris Industries Inc.
Page 212: Efi Diagnostics
• Throttle stop screw tampering • Fouled spark plug • Failed sensor or disconnected wiring • Injector failure • Failed sensor or disconnected wiring • Throttle stop screw tampering 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.40 © Copyright Polaris Industries Inc.
Page 213: Diagnostic Code
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.41 © Copyright Polaris Industries Inc.
Page 214: Diagnostic Trouble Code Chart
Driver Circuit Short to B+ P0262 Injector 1 (MAG) Driver Circuit Grounded P1262 Driver Circuit Open / Grounded P0261 Injector 2 (PTO) Driver Circuit Short to B+ P0265 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.42 © Copyright Polaris Industries Inc.
Page 215 Throttle Position Sensor 520276 (1 or 2 Indeterminable) Neither Position Sensor Passed Test P150C Throttle Body Control - Power Not Plausible P151A 520277 Stage Maximum P150D 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.43 © Copyright Polaris Industries Inc.
Page 216 520309 P1534 ECU Fault - Hardware Disruption Condition Exists 520311 P1537 Voltage Too Low C106D Internal Error Of The EPS Unit 524086 Voltage Too High C106E 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.44 © Copyright Polaris Industries Inc.
Page 217: Digital Wrench® Operation
This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench® diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470.
Page 218: Digital Wrench® Diagnostic Software Overview
Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your 2. Proceed to http://polaris. diagsys. com to see if a computer. newer update is available.
Page 219: Digital Wrench® Updates
Updates are released for Digital Wrench® via the update process. Internet at: http://polaris. diagsys. com. The Digital Wrench® website can also be accessed through the NOTICE dealer website at: www.polarisdealers.com.
Page 220: Digital Wrench® Communication Errors
Digital Wrench® as they become available. Check your release version often and upgrade when available to be sure you are using the most current software available. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.48 © Copyright Polaris Industries Inc.
Page 221: Digital Wrench® Feature Map
Perform specialized testing and adjustment functions Run the Help System. service reports. Prints the current screen as Open the ASSERT ASK a formatted printout. form. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.49 © Copyright Polaris Industries Inc.
Page 222: Ecu Replacement
To successfully reprogram the ECU, an Authorization Key must be obtained by entering a Request Code in the box provided on the Reflash • Proceed to http://polaris.diagsys.com for specific Authorization site. The Request Code is automatically information and FAQs on how to troubleshoot generated by Digital Wrench®...
Page 223 7. Select the file you want to load into the ECU then 10. Enter or paste the Request Code into the box. click the “Continue” icon to proceed to the Integrity Check and obtain a Request Code. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.51 © Copyright Polaris Industries Inc.
Page 224 13. Enter or paste the Authorization Key in the box located on the Digital Wrench® screen. Click the ‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure. 9929422 R02 - 2017-2019 ACE 900 Service Manual 4.52 © Copyright Polaris Industries Inc.
Page 225: Polaris Mobile Digital Wrench (Pmdw)
• PMDW will not work on Microsoft Windows 8™ or Apple IOS™ products (PMDW) Polaris Mobile Digital Wrench (PMDW) is a diagnostic • Device must be set to allow the installation of non- market applications software application (app) designed specifically for Android™...
Page 228: General Information
DRIVEN SHIFT ALTITUDE WEIGHT SPRING SPRING 0-1500 29-70 Black / Red Black 104- (0-5000) 5633321 Meters 58- 135 (Feet) 1500-3700 29-59 7044263 7044505 (5000 - 12,000) 5633319 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 229: Pvt System Overview
All PVT maintenance or repairs should be performed by RPM is increased, centrifugal force is created, causing a certified Polaris Master Service Dealer (MSD) the shift weights to push against rollers on the moveable technician who has received the proper training and sheave, which is held open by coil spring preload.
Page 230: Driven Clutch Operation
PVT system changes engine load requirements by either contaminants from entering the PVT area. This is upshifting or backshifting. especially critical on units subjected to frequent water fording. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 231: Drive Belt
See the Troubleshooting Chart at the end 3. Mark the drive belt direction of rotation so that it can of this chapter for possible causes. be installed in the same direction. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 232: Belt Installation
Driven Clutch Retaining Bolt: 43 ft-lbs (58 Nm) 6. Install the outer clutch cover and screws. Torque screws to specification. TORQUE Outer Clutch Cover Retaining Screws: 2 ft-lbs (3 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 233: Pvt System Service
PVT SYSTEM SERVICE PVT SYSTEM ASSEMBLY VIEW Inner Clutch Cover Filter Drive Belt Clip Install so POLARIS can be read from outside of vehicle. Drive Clutch Assembly Intake Box Drive Clutch Bolt: 96 ft-lbs (130 Nm) Outer Cover Seal Foam Seal...
Page 234: Pvt Disassembly
9. Loosen hose clamp attaching the PVT inlet duct to the inner clutch cover. Disengage hose from the inner clutch cover. 6. Install the Drive Clutch Holder. Drive Clutch Holder: PN 9314177 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 235 Moving the left linkage rearward will provide enough clearance to remove the inner cover. 12. Remove the inner clutch cover from the vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 236: Pvt Assembly
6. Clean the splines inside the driven clutch and on the transmission input shaft. 7. Apply a light film of grease to the splines on the shaft 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.10 © Copyright Polaris Industries Inc.
Page 237: Drive Clutch Service
Spider Cover Bushing 290 ft-lb (393 Nm) (Apply 0.4 mL Loctite® 620™) Shift Weight Cover Bolt Cover Bolt 20 in-lb (2 Nm) 8 ft-lb (11 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.11 © Copyright Polaris Industries Inc.
Page 238: Drive Clutch Disassembly
MUST be replaced. spacer. Belt life will be greatly reduced. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.12 © Copyright Polaris Industries Inc.
Page 239: Bearing Inspection
0.177″ (4.50 mm) S4 1000 Drive Clutch Spring Specifications Part Number 7045214 Color Black / Red Free Length 2.874” (73.00 mm) Spring Wire Diameter 0.1870” (4.75 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.13 © Copyright Polaris Industries Inc.
Page 240: Shift Weight Inspection
Button to Tower Clearance: 0.000-.012″ (.000-.304 mm) 2. Inspect the tower sheave surfaces that the buttons slide on. Replace the drive clutch if worn, damaged or cracked. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.14 © Copyright Polaris Industries Inc.
Page 241: Spider Removal
Clutch Spider Removal / Installation Tool (PN 2870341). Spider Removal / Installation Tool: 2870341 Clutch Holding Fixture: 2871358-A 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.15 © Copyright Polaris Industries Inc.
Page 242: Drive Clutch Inspection
2. Remove the moveable clutch sheave. Measure the thickness and compare to specification. Replace if worn or damaged. MEASUREMENT Thrust Washer Thickness: Standard: .030″ (.76 mm) Service Limit: .025″ (.64 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.16 © Copyright Polaris Industries Inc.
Page 243: Moveable Sheave Bushing Inspection
3M™ Scotch-Brite Pad if needed. Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.17 © Copyright Polaris Industries Inc.
Page 244: Bushing Service
Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter Piston Pin Puller: 2870386 3. Remove nut from puller rod and set aside. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.18 © Copyright Polaris Industries Inc.
Page 245 16. Install nut on puller rod and hand tighten. Turn barrel 33. Turn clutch cover counterclockwise on puller rod until to apply additional tension if needed. bushing is seated. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.19 © Copyright Polaris Industries Inc.
Page 246: Drive Clutch Assembly
290 ft-lb (393 Nm) (Apply 0.4 mL Loctite® 620™) 3. Install moveable sheave onto stationary sheave shaft. Be sure the moveable sheave slides freely on the spacer. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.20 © Copyright Polaris Industries Inc.
Page 247 12. Install cover bolts and torque in a cross pattern evenly to specification. TORQUE Drive Clutch Cover Bolts: 8 ft-lb (11 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.21 © Copyright Polaris Industries Inc.
Page 248: Driven Clutch Service
DRIVEN CLUTCH ASSEMBLY VIEW Spring Shoulder Sleeve Bearing Spider Spring Pin Roller Slider Washer E-clip Slider Pin Stationary Sheave Helix (Cam) Helix Screws Moveable Sheave 48 in-lb (5 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.22 © Copyright Polaris Industries Inc.
Page 249: Driven Clutch Slider Inspection
3. Place the driven clutch (helix side up) into the Slider to Sheave Clearance Universal Clutch Compressor. Service Limit: 0.175″ (4.5 mm) Slider Width Service Limit: 0.975″ (24.8 mm) Universal Clutch Compressor: PU-50518-A 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.23 © Copyright Polaris Industries Inc.
Page 250 Remove the spider assembly and spring. 9. Pull out the clutch slider pins and sliders NOTICE Spring is compression only and has no torsional wind. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.24 © Copyright Polaris Industries Inc.
Page 251: Driven Clutch Assembly
DRIVEN CLUTCH ASSEMBLY 1. Align the X’s on the moveable and stationary sheaves. 4. If removed, install the rollers , washers and E- clips onto the spider. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.25 © Copyright Polaris Industries Inc.
Page 252 CAUTION The helix cover is loaded by the spring. Not using a proper compressor may result in personal injury or damage to the clutch. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.26 © Copyright Polaris Industries Inc.
Page 253: Troubleshooting
Belt burnt, thin Dragging brake Inspect brake system. spots Slow, easy clutch engagement Fast, effective use of throttle for efficient engagement. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.27 © Copyright Polaris Industries Inc.
Page 254 Replace belt. Refer to belt burnt troubleshooting Thin spots on belt, worn belt Engagement and instruct operator. erratic or stabby Drive clutch bushings stick Inspect and repair clutches. 9929422 R02 - 2017-2019 ACE 900 Service Manual 5.28 © Copyright Polaris Industries Inc.
Page 255: Overheating / Diagnosis
PVT system. 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift transmission to Low during loading of the vehicle to prevent belt Clutch malfunction.
Page 258: General Information
Snorkel Locking Screw 10 ft-lb (14 Nm) Transmission Case Bolts 20 ft-lbs (27 Nm) Sector Gear Cover Bolts 12 ft-lb (16 Nm) Bell Crank Nut 18 ft-lb (24 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 259: Shift Lever
4. Remove the screws from the support blocks 7. Loosen the shift cable jam nuts from the mount and remove from vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 260: Shift Lever Installation
Front: 18 ft-lb (24 Nm) Rear: 13 ft-lbs (18 Nm) 5. Reinstall knob with the screw. Reinstall the cap. 6. Reinstall the right seat side panel and seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 261: Shift Cable Adjustment
5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTE This procedure may require a few attempts to obtain the proper adjustment. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 262: Transmission Vent Line
Replace vent line if necessary. Leaking seals Symptoms of a restricted transmission vent line include Loss of fluid from vent the following: High transmission temperatures 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 263 If the vent line fitting is removed from the frame, it must be replaced. The ears on the clip (arrows) will not hold properly once it is removed. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 264: Transmission Service
Pre-Torque 5 ft-lbs (7 Nm) Screws – M8x1.25x45 45 ft-lbs (61 Nm) Hose Clamp Pal Nuts Flange Nuts – M8 Transmission Vent 22 ft-lbs (30 Nm) Replace with new when removed. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 265: Transmission Removal
Ignition Coil Fastener Transmission Vent Line 5. Remove the two bolts retaining the air box to the Harness Retainers Heat Shield Push frame support. Rivets 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 266 CAUTION Be careful not to pinch or kink the fuel rail Transmission Switch TMAP Speed Sensor Diff Relay (if equipped) Engine Temperature Sensor 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.10 © Copyright Polaris Industries Inc.
Page 267 14. Raise and support the vehicle off the ground. 15. Remove both rear wheels. 16. Remove the bolts, washers and nuts securing the left and right rear upper control arms to the chassis. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.11 © Copyright Polaris Industries Inc.
Page 268 22. Place a spacer or support between the vehicle frame entering engine. and engine to hold the engine in position. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.12 © Copyright Polaris Industries Inc.
Page 270: Transmission Installation
Torque fasteners to specification. Do not torque the fastener at this time. 4. Support engine and transmission with a block of wood. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.14 © Copyright Polaris Industries Inc.
Page 271 Rear Transmission Mount Bolt: 40 ft-lbs (54 Nm) 10. Remove the clutch center distance tool. 11. Remove the spacer or support between the vehicle frame and engine. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.15 © Copyright Polaris Industries Inc.
Page 272 TORQUE Intake Manifold Mounting Fasteners: 18. Install the three harness clamps on the intake To Engine: 17 ft-lb (23 Nm) manifold. Lower: 22 ft-lb (30 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.16 © Copyright Polaris Industries Inc.
Page 273 TORQUE belt, drive clutch, driven clutch, inner clutch cover and Wheel Lug Nuts: clutch outlet duct. See PVT Assembly page 30 ft-lbs + 90° (41 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.17 © Copyright Polaris Industries Inc.
Page 274 30 ft-lbs (41 Nm) Side Bolster Screws: 14 ft-lbs (19 Nm) 35. Install the engine compartment panel and seat. 36. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris Ignition Coil Fastener Transmission Vent Line FLUID CAPACITY...
Page 275: Transmission Disassembly
6. Remove the compression spring CAUTION Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.19 © Copyright Polaris Industries Inc.
Page 276 18. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. Gear Cluster Disassembly 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.20 © Copyright Polaris Industries Inc.
Page 277 CAUTION Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.21 © Copyright Polaris Industries Inc.
Page 278 Snorkel Tool: PA-50231 31. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.22 © Copyright Polaris Industries Inc.
Page 279 TRANSMISSION 32. Remove the retaining ring to remove the remaining washer, bearing and gear from the snorkel shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.23 © Copyright Polaris Industries Inc.
Page 281: Transmission Assembly / Snorkel Gear Backlash Procedure
NOTICE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.25 © Copyright Polaris Industries Inc.
Page 283 The snorkel shaft cannot be installed after assembling the transmission. 15. Clean both transmission case halves thoroughly. Inspect case half mating surfaces for damage. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.27 © Copyright Polaris Industries Inc.
Page 284 Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.28 © Copyright Polaris Industries Inc.
Page 285 28. Install the spacer and then the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward and skip-tooth aligned. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.29 © Copyright Polaris Industries Inc.
Page 286 Sector Gear Cover Bolts: 12 ft-lb (16 Nm) 34. Install the transmission drain plug and torque to specification. TORQUE Fill / Drain Plug: 14 ft-lbs (19 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.30 © Copyright Polaris Industries Inc.
Page 287: Transmission Troubleshooting
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.31 © Copyright Polaris Industries Inc.
Page 289 54. Input Boss Shaft 82. Seal, Triple Lip, Viton 26. Shim 55. Reverse Shaft, See parts catalog 84. Speed Sensor 27. Shim 28. Bearing, Needle Cage 56. Bellcrank 9929422 R02 - 2017-2019 ACE 900 Service Manual 6.33 © Copyright Polaris Industries Inc.
Page 292: General Information
30 ft-lbs (40 Nm) Fasteners GEARCASE FLUID / CAPACITY Gearcase Cover Plate 11 ft-lbs (15 Nm) FLUID CAPACITY Screws Recommended Front Gearcase Lubricant: Polaris Demand Drive 6.75–7.6 oz. (200–225 ml) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 293: Bearing Carrier
9. Remove the fastener retaining the front stabilizer bar link to the upper control arm. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 295: Front Bearing Carrier Disassembly
Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 4. Inspect the bearing carrier housing for scratches, wear or damage. Replace front bearing carrier if damaged. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 296: Front Bearing Carrier Installation
Lower Control Arm Fasteners: 42 ft-lbs (57 Nm) 4. Attach shock to A-arm with fastener. Torque lower shock bolt to specification. TORQUE Shock Mounting Fastener: 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 297 15. Rotate wheel and check for smooth operation. 12. Torque the tie rod end fastener to specification and install a new cotter pin TORQUE Tie Rod End Fastener: 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 298: Rear Bearing Carrier Removal
6. Remove the rear wheel hub and brake disk assembly. 4. Remove cotter pin , hub nut , and washers 7. Remove the upper and lower control arm fasteners. Discard the flange nuts. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 299: Rear Bearing Carrier Disassembly
4. Inspect bearing housing for wear or damage. Replace housing if damaged. 5. Inspect bearing carrier pivot shafts and bushings. Replace worn or damaged parts. Apply Premium All Season Grease to pivot shafts. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 300: Rear Bearing Carrier Assembly
3. Press bearing into place until outer race bottoms on housing. CAUTION Use an arbor press only on the outer race to avoid bearing damage. 4. Install snap ring into groove. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.10 © Copyright Polaris Industries Inc.
Page 301: Rear Bearing Carrier Installation
Rear Caliper Mounting Bolts: 40 ft-lbs (54 Nm) NOTE Use new nuts upon installation of the rear bearing carrier. TORQUE Control Arm-To-Bearing Carrier Fasteners: 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.11 © Copyright Polaris Industries Inc.
Page 302 30 ft-lbs + 90° (41 Nm) 7. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.12 © Copyright Polaris Industries Inc.
Page 303: Drive Shaft
9. Remove the fastener retaining the front stabilizer bar link to the upper control arm. 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.13 © Copyright Polaris Industries Inc.
Page 304 12. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper joint end. 13. Remove the bearing carrier and lower A-arm from the front drive shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.14 © Copyright Polaris Industries Inc.
Page 305: Front Drive Shaft Installation
4. Attach shock to A-arm with fastener. Torque lower shock bolt to specification. TORQUE Shock Mounting Fastener: 42 ft-lbs (57 Nm) 5. Install the upper joint end into the front bearing carrier. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.15 © Copyright Polaris Industries Inc.
Page 306 15. Rotate wheel and check for smooth operation. 12. Torque the tie rod end fastener to specification and install a new cotter pin TORQUE Tie Rod End Fastener: 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.16 © Copyright Polaris Industries Inc.
Page 307: Rear Drive Shaft Removal
, hub nut , and washers CAUTION Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.17 © Copyright Polaris Industries Inc.
Page 308: Rear Drive Shaft Installation
2. Apply anti-seize compound to the inner race of the bearing. Insert bearing carrier on drive shaft. 8. With a short, sharp jerk, remove drive shaft from the transmission splines. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.18 © Copyright Polaris Industries Inc.
Page 309 Hub Castle Nut: 110 ft-lbs (149Nm) 7. Install wheel and four wheel nuts. Torque wheel nuts to specification. TORQUE Wheel Nuts: 30 ft-lbs + 90° (41 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.19 © Copyright Polaris Industries Inc.
Page 310: Drive Shaft / Cv Joint Handling Tips
Refer to text for grease capacity of CV joints and CV joint boots. 3. Clean the grease from the face of the joint. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.20 © Copyright Polaris Industries Inc.
Page 311 The amount of grease provided in the boot kit is pre- measured. Use entire contents of package. If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.21 © Copyright Polaris Industries Inc.
Page 312: Inner Plunging Joint / Boot Replacement
INNER PLUNGING JOINT / BOOT REPLACEMENT 1. Use a side cutters to cut and discard the boot clamps Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.22 © Copyright Polaris Industries Inc.
Page 313 10. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined in the shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.23 © Copyright Polaris Industries Inc.
Page 314 18. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make CV Boot Clamp Pliers: 8700226 sure the boot is not dimpled or collapsed. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.24 © Copyright Polaris Industries Inc.
Page 315: Prop Shaft
6. Reverse removal procedure to reinstall propshaft. 7. Reference the procedures for reinstalling the fuel tank assembly after propshaft is installed in vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.25 © Copyright Polaris Industries Inc.
Page 316: U-Joint Disassembly
If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.26 © Copyright Polaris Industries Inc.
Page 317: Front Gearcase
10 ft-lbs (14 Nm) Fill / Check Plug Roller Cage 10 ft-lbs (14 Nm) Roller Pinion Gear Spring Retainer Snap Ring Cover Plate Screws O-ring 11 ft-lbs (15 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.27 © Copyright Polaris Industries Inc.
Page 319: Awd Diagnosis
8. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.29 © Copyright Polaris Industries Inc.
Page 320: Front Gearcase Removal
13. Remove the fastener retaining the front stabilizer bar bearings and seals. link to the upper control arm. 7. Remove the four wheel nuts and remove the front wheel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.30 © Copyright Polaris Industries Inc.
Page 321 Remove the gearcase assembly from the right side of the 17. Remove the bearing carrier and lower A-arm from the vehicle. front drive shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.31 © Copyright Polaris Industries Inc.
Page 322: Front Gearcase Disassembly / Inspection
Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate . Refer to AWD Diagnosis page 7.29 for detailed inspection process. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.32 © Copyright Polaris Industries Inc.
Page 323 9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.33 © Copyright Polaris Industries Inc.
Page 324 13. Inspect clutch housing / ring gear for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.34 © Copyright Polaris Industries Inc.
Page 325: Front Gearcase Assembly
6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear. 4. Install the RH output hub into the gearcase housing. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.35 © Copyright Polaris Industries Inc.
Page 326 11. Install a new O-ring on the cover plate assembly. NOTICE Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.36 © Copyright Polaris Industries Inc.
Page 327: Front Gearcase Installation
10. Install lower A-arm assembly onto vehicle frame. Torque new bolts to specification. TORQUE TORQUE Lower Control Arm Fasteners: Cover Plate Screws: 42 ft-lbs (57 Nm) 9 ft-lbs (12 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.37 © Copyright Polaris Industries Inc.
Page 328 Refer to the photo below to ensure proper placement of TORQUE the tie rod end. Stabilizer Link Fasteners: 42 ft-lbs (57 Nm) 15. Apply Anti-Seize to drive shaft axle splines. 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.38 © Copyright Polaris Industries Inc.
Page 329 Wheel Hub Castle Nut: 110 ft-lbs (149Nm) 21. Install wheel and four wheel nuts. Torque wheel nuts to specification. TORQUE Aluminum Wheels: 30 ft-lbs + 90° (41 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.39 © Copyright Polaris Industries Inc.
Page 330: Front Gearcase Vent Line
Replace vent line if necessary. Leaking seals Symptoms of a restricted front gearcase vent line include Loss of fluid from vent the following: High gearcase temperatures 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.40 © Copyright Polaris Industries Inc.
Page 331: Wheel Hubs
Wheel Lug Nut Snap Ring Washer 30 ft-lbs + 90° (41 Nm) Wheel Bearing Valve Stem Wheel Hub Bearing Carrier Cotter Pin Brake Disc REAR HUB ASSEMBLY VIEW 9929422 R02 - 2017-2019 ACE 900 Service Manual 7.41 © Copyright Polaris Industries Inc.
Page 335: General Information
Torque Till Seated CV Shield Fasteners 14 ft-lbs (19 Nm) Tie Rod Jam Nut 42 ft-lbs (57 Nm) Tie Rod Fastener Front Stabilizer Bar 42 ft-lbs (57 Nm) Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 337 Left Side EPS Bracket to Frame Bolt : 19 ft-lbs (26 Nm) Upper Steering Shaft Washers Washers Foam Shield Lock Nut 36 ft-lbs (49 Nm) Replace with new when removed. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 338: Upper Steering Shaft Removal (Eps)
11. To service the pivot tube / steering wheel assembly, place the assembly in a bench vise. 12. Remove the cap and loosen the steering wheel nut half way off of the steering shaft. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 339 18. Drive the bearings out of the pivot tube using a drift punch. 15. On international models, remove the steering lock collar. 16. The steering lock can be removed by removing the two mounting screws. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 340: Power Steering Unit (Eps) Removal
Lift the EPS unit up to remove the lower 6. Remove the EPS base bracket and EPS unit from the steering shaft from the output shaft. vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 341: Lower Steering Shaft Removal (Eps)
7. Use a paint pen to mark the installed location of the steering shaft on the steering rack input shaft. Remove the lower steering shaft from the vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 342: Lower Steering Shaft Installation (Eps)
Steering Rack Mounting Fasteners: 16 ft-lbs (22 Nm) TORQUE Lower Steering Shaft to EPS Pinch Bolt: 15 ft-lbs (20 Nm) 6. Reinstall the winch cover panel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.10 © Copyright Polaris Industries Inc.
Page 343 STEERING / SUSPENSION 7. Reinstall the footwell floorboard and front splash guard. 8. Reinstall the seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.11 © Copyright Polaris Industries Inc.
Page 344: Power Steering Unit (Eps) Installation
3. Position the EPS unit and base plate back into the bolt using a new lock nut. vehicle. NOTICE The base plate cannot be installed on the EPS unit prior to installation. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.12 © Copyright Polaris Industries Inc.
Page 345: Upper Steering Shaft Installation (Eps)
TORQUE Left Side Bracket to Frame Fasteners: 19 ft-lbs (26 Nm) 11. Follow the procedure for reinstalling the upper steering shaft / steering wheel assembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.13 © Copyright Polaris Industries Inc.
Page 346 Install the locking collar. TORQUE Upper Steering Shaft Pinch Bolt: 15 ft-lbs (20 Nm) 5. Apply Loctite 271 to the steering wheel nut and install hand tight. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.14 © Copyright Polaris Industries Inc.
Page 347 12. Reinstall the front cab, front bumper and front ROPS assembly. 13. Test ride the vehicle to verify proper operation prior to returning to service. TORQUE Tilt Shock Fasteners: 7 ft-lbs (10 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.15 © Copyright Polaris Industries Inc.
Page 348: Eps Torque Offset Procedure
4. Click on Set SAS Zero. NOTICE The SAS Position should = 0.0 after clicking Set SAS Zero. 5. Click the Complete button to program this setting into the ECU. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.16 © Copyright Polaris Industries Inc.
Page 349: Front Suspension
Cotter Pin 42 ft-lbs (57 Nm) CV Guard Screws Torque Till Seated Bearing Carrier Lower A-Arm Lower A-Arm Fasteners Ball Joint 42 ft-lbs (57 Nm) Retaining Ring 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.17 © Copyright Polaris Industries Inc.
Page 350: Front Shock Assembly View
STEERING / SUSPENSION FRONT SHOCK ASSEMBLY VIEW Shock Fasteners Shock Assembly 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.18 © Copyright Polaris Industries Inc.
Page 351: Front Stabilizer Bar Assembly View
Stabilizer Bar Link Fasteners Lubrication Fitting 42 ft-lbs (57 Nm) Stabilizer Bar Support Stabilizer Bar Link Stabilizer Bushings Front Stabilizer Bar 16 ft-lbs (22 Nm) Stabilizer Bar Support Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.19 © Copyright Polaris Industries Inc.
Page 352: Upper A-Arm Removal / Replacement
Ball Joint Pinch Bolt: 42 ft-lbs (57 Nm) 5. Remove the brake line retainer from the upper A-arm. 6. Remove the front bumper to allow A-arm bolt removal. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.20 © Copyright Polaris Industries Inc.
Page 353: Lower A-Arm Removal / Replacement
10. Remove lower shock fastener from lower A-arm. 11. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper joint end. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.21 © Copyright Polaris Industries Inc.
Page 354 Ball Joint Pinch Bolts: 42 ft-lbs (57 Nm) NOTE Proceed to Ball Joint Removal or if servicing the lower Ball joint proceed to Lower Ball Joint Removal 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.22 © Copyright Polaris Industries Inc.
Page 355: Front Stabilizer Bar Removal
3. Remove the winch mount 4. Remove the steering post. See Lower Steering Shaft Removal (EPS) page 8.9 5. Remove the tie rod ends from the bearing carrier. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.23 © Copyright Polaris Industries Inc.
Page 356: Front Stabilizer Bar Installation
10.24. bar links to the stabilizer bar. Torque fasteners to specification. 10. Install the front bumper. TORQUE Sway Bar Fasteners: 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.24 © Copyright Polaris Industries Inc.
Page 357: Ball Joint Service Preparation
14. Remove the cotter pin, lower ball joint nut, and washer. 15. Separate the lower ball joint from the bearing carrier using PA-51600. NOTE Image for reference only. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.25 © Copyright Polaris Industries Inc.
Page 358: Ball Joint Installation
CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.26 © Copyright Polaris Industries Inc.
Page 360: Rear Suspension
Lower Control Arm Mounting Fastener 42 ft-lbs (57 Nm) Replace with new when removed. 42 ft-lbs (57 Nm) Replace with new when removed. Bearing Carrier Fasteners Lubrication Fitting Bearing Carrier 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.28 © Copyright Polaris Industries Inc.
Page 361: Rear Shock Assembly View
STEERING / SUSPENSION REAR SHOCK ASSEMBLY VIEW Shock Assembly Hose Clamps Shock Mounting Fasteners 42 ft-lbs (57 Nm) Use new after removal. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.29 © Copyright Polaris Industries Inc.
Page 362: Rear Stabilizer Bar Assembly View
REAR STABILIZER BAR ASSEMBLY VIEW Stabilizer Bar Screw Screw 42 ft-lbs (57 Nm) Sway Bar Bracket / Cap Linkage Linkage Bushing / Nut Brackets 31 ft-lbs (42 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.30 © Copyright Polaris Industries Inc.
Page 363: Rear Upper Control Arm Removal / Installation
Discard the lock nuts. 6. Remove the hose clamps retaining the shock reservoir to the upper control arm. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.31 © Copyright Polaris Industries Inc.
Page 364 9. Inspect the bushings and pivot shafts. Replace if worn or damaged. TORQUE Aluminum Wheels: 30 ft-lbs + 90° (41 Nm) IMPORTANT Test drive vehicle at slow speeds to verify repair. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.32 © Copyright Polaris Industries Inc.
Page 365: Rear Lower Control Arm Removal / Installation
6. Remove the fastener attaching the control arm to the bearing carrier. Discard the lock nut. 7. Disconnect the brake line retainers from the control arm. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.33 © Copyright Polaris Industries Inc.
Page 366 9. Grease control arm pivot shafts with Premium All Season Grease until grease is purged from the bushing joints. IMPORTANT Test drive vehicle at slow speeds to verify control arm replacement repair. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.34 © Copyright Polaris Industries Inc.
Page 367: Rear Stabilizer Bar Removal
7. Carefully remove the stabilizer from the LH wheel well area of the vehicle. 8. Inspect the stabilizer bar for straightness. Inspect the pivot bushings and replace if needed. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.35 © Copyright Polaris Industries Inc.
Page 368: Shocks / Springs
Shock Mounting Bolts: 42 ft-lbs (57 Nm) 5. Reverse the procedure to reinstall the shock. Torque new fasteners to specification. TORQUE Shock Mounting Bolts: 42 ft-lbs (57 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.36 © Copyright Polaris Industries Inc.
Page 369: Walker Evans Front / Rear Spring Preload
FACTORY PRELOAD SETTINGS LOCATION MEASUREMENT Front 13.1 in. (33 cm) Rear 13.75 in. (35 cm) NOTE The shock must be removed from the vehicle for accurate measurement. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.37 © Copyright Polaris Industries Inc.
Page 370: Walker Evans Shock Preload Adjustment
WARNING Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments. Front Shock Rear Shock 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.38...
Page 371: Walker Evans Front / Rear Shock Compression
Clicker knob in fully open position Softest Front: 5-7 clicks from fully open position Factory Rear: 5-7 clicks from fully open position Firmest 1 click from closed 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.39 © Copyright Polaris Industries Inc.
Page 372: Shock Service
1.00 x .006 1.00 x .008 .900 x .006 1.10 x .008 .800 x .006 1.25 x .008 .700 x .006 .625 x .065 .875 x .090 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.40 © Copyright Polaris Industries Inc.
Page 373: Walker Evans 1.5" Rear Shock Information
1.00 x .010 1.00 x 0.10 .625 x .065 .900 x .010 1.10 x .010 .800 x .010 1.25 x .010 .700 x .010 .875 x .090 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.41 © Copyright Polaris Industries Inc.
Page 374 Shock Rod Holding Tool - Front 2872429 Shock Rod Holding Tool - Rear PS-50931 PU-50939 Shock Seal Protector Sleeve - Front PU-50952 Shock Seal Protector Sleeve - Rear 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.42 © Copyright Polaris Industries Inc.
Page 375 Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.43 © Copyright Polaris Industries Inc.
Page 376 13. Use the appropriate shock rod holding tool and a vise to mount the shock rod vertically with the threaded end upward. Front Shock Rod Holding Tool: 2872429 Rear Shock Rod Holding Tool: PU-50931 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.44 © Copyright Polaris Industries Inc.
Page 377 18. Use the appropriate shock body holding tool to properly secure the shock assembly into a vice for service. Front Shock Body Holding Tool: PU-50979 Rear Shock Body Holding Tool: PU-50938 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.45 © Copyright Polaris Industries Inc.
Page 378 Tighten the valve stack fastener securely. NOTE If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.46 © Copyright Polaris Industries Inc.
Page 379 FLUID CAPACITY Recommended Shock Oil: Racing Gas Shock Oil (PN 2874124) (Quart) 10 Weight for Walker Evans Shocks 16. Slowly cycle the IFP up and down. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.47 © Copyright Polaris Industries Inc.
Page 380 27. Using a long 3/32” Allen wrench, install the IFP bleed screw. NOTE Apply grease to the end of the Allen wrench so the bleed screw sticks to it during installation. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.48 © Copyright Polaris Industries Inc.
Page 381 (see Chapter 2 – Walker Evans Front / Rear Shock Compression page 8.39). 41. Remove the shock from the vise. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.49 © Copyright Polaris Industries Inc.
Page 382 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTE After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 9929422 R02 - 2017-2019 ACE 900 Service Manual 8.50 © Copyright Polaris Industries Inc.
Page 385: General Information
Brake Caliper Bleed Fasteners 44 in-lbs (5 Nm) SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION Mity Vac™ Pressure Test Tool 2870975 Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT .300 ± .007" (7.62 ± .178 mm) .030″...
Page 386: Brake System Overview
Front Caliper Bolts 30 ft-lbs (54 Nm) Master Cylinder Mounting Fasteners 23 ft-lbs (31 Nm) Rear Brake Lines Brake Junction Block 35 in-lbs (4 Nm) Sealing Washer Brake Pedal Assembly 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 387: Brake System Service Notes
HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.
Page 388: Master Cylinder
5. Loosen and remove the rear brake banjo bolt from the master cylinder. Allow fluid to drain into a cup. NOTICE Dispose of fluid properly. Do not re-use. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 389: Master Cylinder Installation
Master Cylinder Bolts 23 ft-lbs (31 Nm) 5. Reposition or install the following components: • Front Bumper • Front Cab / Storage Box • Radiator • Brake Pedal 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 390: Brake Bleeding / Fluid Change
4. Add brake fluid to the indicated MAX level of 12. Install master cylinder reservoir cover. reservoir. 13. Field test machine at low speed before putting into Polaris DOT 4 Brake Fluid: service. Check for proper braking action and pedal PN 2872189 reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm).
Page 391: Brake Pedal
, and pin from the pedal mount. Remove the brake pedal lever from the vehicle. 3. Discard cotter pin. Always use a new cotter pin during reassembly. 9929422 R02 - 2017-2019 ACE 900 Service Manual © Copyright Polaris Industries Inc.
Page 392: Front Brake Service
7. Remove the inner pad from the bracket and caliper. CAUTION When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.10 © Copyright Polaris Industries Inc.
Page 393: Pad Inspection
WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new, clean pads. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.11 © Copyright Polaris Industries Inc.
Page 394: Caliper Exploded View
44 in-lbs (5 Nm) Pistons Adjuster Screw Apply DOT 4 Brake Fluid. Square Rings -. 094 Pin/Boot Replace with new parts. Apply DOT 4 Brake Fluid. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.12 © Copyright Polaris Industries Inc.
Page 395: Caliper Removal
NOTE Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.13 © Copyright Polaris Industries Inc.
Page 396: Caliper Inspection
MEASUREMENT Front Caliper Piston O.D.: Std: 1.1860-1.1875” (30.12-30.16 mm) Service Limit: 1.1858” (30.11 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.14 © Copyright Polaris Industries Inc.
Page 397: Caliper Assembly
2. Install the caliper and torque the new mounting bolts to specification. 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing TORQUE inward.
Page 398: Disc Runout
Brake Disc Thickness Variance Service Limit: .002” (.051 mm) difference between measurements NOTICE Image for reference only. MEASUREMENT Brake Disc Runout) Service Limit: .010" (.254 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.16 © Copyright Polaris Industries Inc.
Page 399: Disc Replacement
Disc Fasteners: 18 ft-lbs (24 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.17 © Copyright Polaris Industries Inc.
Page 400: Rear Brake Service
7. Remove the inner brake pad. CAUTION When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.18 © Copyright Polaris Industries Inc.
Page 401: Pad Inspection
CAUTION If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.19 © Copyright Polaris Industries Inc.
Page 402: Caliper Exploded View
Seal Boot Inner Seal- 1.25 Outer Seal- 1.25 Replace with new parts. Apply DOT 4 Brake Fluid. Replace with new parts. Apply DOT 4 Brake Fluid. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.20 © Copyright Polaris Industries Inc.
Page 403: Caliper Removal
5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE Be sure to clean seal grooves in caliper body. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.21 © Copyright Polaris Industries Inc.
Page 404: Caliper Inspection
Replace if damage is evident or if worn beyond may drag upon assembly. service limit. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston with a twisting motion MEASUREMENT while pushing inward.
Page 405: Caliper Installation
Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications. MEASUREMENT Brake Disc Runout Service Limit: .010" (.254 mm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.23 © Copyright Polaris Industries Inc.
Page 406: Disc Replacement
Mounting Bolts: 28 ft-lbs (38 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.24 © Copyright Polaris Industries Inc.
Page 407 • Improper assembly of brake system components • Brake pads dragging • Brake caliper dragging PEDAL VIBRATION • Disc damaged • Disc worn (runout or thickness variance exceeds serv- ice limit) 9929422 R02 - 2017-2019 ACE 900 Service Manual 9.25 © Copyright Polaris Industries Inc.
Page 411: General Information
Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com 27 in–lbs (3 Nm) Seat to Frame Fasteners 11 ft-lbs (15 Nm) Seat Slider Fasteners 30 ft-lbs (41 Nm) Seat Base Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.3 © Copyright Polaris Industries Inc.
Page 412: Decals
2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.4 © Copyright Polaris Industries Inc.
Page 413: Body Assembly Views
42 lb-ft (57 Nm) Replace with new when removed. Bolts Bolts Screws Front ROPS 14 ft-lbs (19 Nm) Right Side Bolster Left Side Bolster Rear ROPS 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.5 © Copyright Polaris Industries Inc.
Page 414: Doors
Door Panel Screws Door Frame 22 In-lbs (2 Nm) Door Latch Screws Latch 8 ft-lbs (11 Nm) Latch Bracket Screws Latch Release 12 ft-lbs (16 Nm) Door Hinge 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.6 © Copyright Polaris Industries Inc.
Page 416: Upper Cab / Dash
BODY / FRAME UPPER CAB / DASH Upper Cab Panel Dash Panel Plastic Push Rivet Dash Panel Screw 24 in-lbs (2.7 Nm) Screw 8 ft-lbs (11 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.8 © Copyright Polaris Industries Inc.
Page 417: Front Storage Box
Front Rack Cover Compartment Plug Front Storage Bin Seal Screw Front Storage Bin Rivet Plastic Push Rivet Front Rack Cable Hinge Pin Latch Grommet Brace 1/4 Turn Latch 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.9 © Copyright Polaris Industries Inc.
Page 418: Front Cab / Fenders
BODY / FRAME FRONT CAB / FENDERS Front Cab / Fenders Fender Flare RH Fender Flare LH Plastic Push Rivet 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.10 © Copyright Polaris Industries Inc.
Page 419: Floor And Rocker Panels
BODY / FRAME FLOOR AND ROCKER PANELS Rocker LH Rear Floor Panel Upper Floor Panel Push Rivet Main Floor Panel Screw 8 ft-lbs (11 Nm) Rocker RH 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.11 © Copyright Polaris Industries Inc.
Page 420: Rear Bumper
BODY / FRAME REAR BUMPER Rear Bumper Lower Rear Bumper Screw Bolt 8 ft-lbs (11 Nm) 14 ft-lbs (19 Nm) Plastic Push Rivet 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.12 © Copyright Polaris Industries Inc.
Page 421: Rear Cargo Box / Fenders
Engine Intake Grill Rear Fender RH Rear Fender Flare RH Rubber Grommet Engine Access Panel Push Rivet Screw Cargo Box Access Panel 8 ft-lbs (11 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.13 © Copyright Polaris Industries Inc.
Page 422: Main Frame Assembly View
Rear Frame Brace Main Frame 14 ft-lbs (19 Nm) Airbox Support Skid Plate 14 ft-lbs (19 Nm) 8 ft-lbs (11 Nm) Rear Bracket 14 ft-lbs (19 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.14 © Copyright Polaris Industries Inc.
Page 423: Body Component Removal
Seat Removal 1. Push and hold the seat adjuster lever down. Slide the seat forward until removed from track guides. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.15 © Copyright Polaris Industries Inc.
Page 424: Seat / Seat Belt Assembly View
Seat Back 11 ft-lbs (15 Nm) Screws, M12x1.75x25 Seat Rubber Bumpers Rear Seat Base Lock Nuts Seat Slider Channel 30 ft-lbs (41 Nm) Seat Belt Buckle 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.16 © Copyright Polaris Industries Inc.
Page 425: Seat Belt Removal / Installation
5. Reinstall seat assembly. 5. Remove the fastener attaching the seat belt base to the chassis. Discard lock nut. 6. Remove the seat belt from the vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.17 © Copyright Polaris Industries Inc.
Page 426: Roll Over Protection System (Rops)
Upper Fasteners: 14 ft-lbs (19 Nm) 2. Insert the front tube assembly into the front cab and Lower Screws: frame mounts. 14 ft-lbs (19 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.18 © Copyright Polaris Industries Inc.
Page 427: Rear Tube Removal / Installation
Discard the lock nuts. 3. Remove the front tube assembly from the vehicle. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.19 © Copyright Polaris Industries Inc.
Page 428: Engine Compartment Access Panel
2. Install the panel and then push it down to engage the tabs. 3. Turn the twist locks clockwise. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.20 © Copyright Polaris Industries Inc.
Page 429: Side Seat Panels
6. Remove the two plastic rivets Right Side Seat Panel Installation Reverse the removal procedure to install the right side seat panel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.21 © Copyright Polaris Industries Inc.
Page 430: Left Side Seat Panel Removal / Installation
6. Remove the side panel from the vehicle. Left Side Seat Panel Installation Reverse the removal procedure to install the left side seat panel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.22 © Copyright Polaris Industries Inc.
Page 431: Rocker Panels
1. Install rocker panel onto vehicle. the rocker panel. 2. Reinstall the screws and plastic rivets. 3. If equipped, reinstall the screw attaching the net to the rocker panel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.23 © Copyright Polaris Industries Inc.
Page 432: Floorboard Panels
Floorboard Screws: Floorboard Screws: 8 ft-lbs (11 Nm) 8 ft-lbs (11 Nm) 3. Reinstall the seat. 3. Reinstall the main floor board. 4. Reinstall the seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.24 © Copyright Polaris Industries Inc.
Page 433: Instrument Cluster Pod
The instrument cluster bezel does not need to be removed to remove the instrument cluster pod from the front cab. 3. Disconnect the instrument cluster wiring harness. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.25 © Copyright Polaris Industries Inc.
Page 434: Front Storage Bin
Torque screws to the specification. TORQUE Storage Bin Screws: 8 ft-lbs (11 Nm) 3. Close the front storage rack. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.26 © Copyright Polaris Industries Inc.
Page 435: Fender Flares
3. Install the fastener that secures the fender flare to the rocker panel. TORQUE Fender Flare Screw: 8 ft-lbs (11 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.27 © Copyright Polaris Industries Inc.
Page 436: Front Cab
Front Bumper Screws: 8 ft-lbs (11 Nm) 5. Reinstall the front ROPS tube assembly. Torque fasteners to specification. TORQUE ROPS Tube Fasteners: 30 ft-lbs (41 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.28 © Copyright Polaris Industries Inc.
Page 437: Front Bumper
2. Align the lower screw holes with the frame and install the screws. 3. Install the plastic rivets. 4. Reconnect the headlight wire harness connectors. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.29 © Copyright Polaris Industries Inc.
Page 438: Rear Bumper / Storage Box
Remove the screws attaching the fenders / 3. Install the plastic rivets. storage box to seat side panels. 4. Torque screws to specifications. TORQUE Bumper Screws: 14 ft-lbs (19 Nm) 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.30 © Copyright Polaris Industries Inc.
Page 439 TORQUE Rear Bumper Fasteners: 14 ft-lbs (19 Nm) 3. If the left and right fenders were removed, reinstall them using the screws and plastic rivets. 9929422 R02 - 2017-2019 ACE 900 Service Manual 10.31 © Copyright Polaris Industries Inc.
Page 444: General Information
Bosch Automotive Service Solutions 1-800-345-2233 Starter Connections 60 in-lbs (7 Nm) or https://polaris.service-solutions.com Tail Light Fasteners 12 in-lbs (1.3 Nm) Battery Terminal 6 ft-lbs (8 Nm) Fasteners 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.4 © Copyright Polaris Industries Inc.
Page 445: Electrical Service Notes
(K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.5 © Copyright Polaris Industries Inc.
Page 446: Break-Out Diagram Viewing
2. If the wiring diagram does not open the Adobe navigation bars, click on the Adobe Icon. 3. Click on the Layers Icon. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.6 © Copyright Polaris Industries Inc.
Page 447: Chassis Harness
Battery (-) Starter (+) Relay / Fuse Block Fuel Pump / Level Starter (-) Ground A Stator AC MAG Injector Ground B Brake Switch Seat Belt Switch 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.7 © Copyright Polaris Industries Inc.
Page 448: Main Harness Retention Locations
ELECTRICAL MAIN HARNESS RETENTION LOCATIONS Front The white tape on the harness signifies a zip tie retention Zip Tie Retention Locations point. Rear 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.8 © Copyright Polaris Industries Inc.
Page 449: Main Harness Routing
ELECTRICAL MAIN HARNESS ROUTING NOTE If harness replacement is required, note the routing of the harness for installation purposes. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.9 © Copyright Polaris Industries Inc.
Page 450: Electrical Diagnostics
• All associated circuits have no shorts to ground. Testing For A Short To Ground page 11.13 Polaris advises to only use a high quality DMM that meets the same standards as the Fluke™ 77 (PV-43568) • All associated circuits have no shorts to voltage.
Page 451: Connector Probing Guidelines
To avoid causing damage, use of the appropriate adapters is required. Most terminals used on Polaris NOTICE machines can be tested using terminal test kit PV–...
Page 452: Testing Continuity/Resistance
Testing For A Short To Voltage page 11.14 For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.12 © Copyright Polaris Industries Inc.
Page 453: Testing For A Short To Ground
9. If the DMM reads OL, there is no short to ground. Leave the harness disconnected on both sides, and proceed to check for a short to voltage. Testing For A Short To Voltage page 11.14 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.13 © Copyright Polaris Industries Inc.
Page 454: Testing For A Short To Voltage
Failure to do so can lead to Serious injury and/or damage to the machine. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.14 © Copyright Polaris Industries Inc.
Page 455: Testing Current Flow (Amperage)
9. If over 10 milliamps, go to the fuse block and start systematically removing one fuse at a time until the value drops, indicating the circuit that requires attention. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.15 © Copyright Polaris Industries Inc.
Page 456: Testing Voltage Drop
For a video demonstration, scan the QR code below, or right click it and select “open in new tab”. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.16 © Copyright Polaris Industries Inc.
Page 457: Instrument Cluster
Fuel Gauge activated. All segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can Service Indicator provide scheduled maintenance. See Service Hours page 11.27 for more information.
Page 458: Indicator Lamps
Check Engine Serious engine damage could result. Your authorized POLARIS dealer can assist. This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS EPS Warning (if equipped) dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.
Page 459: Display Area 1
ELECTRICAL DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 Speed Engine Temperature Ambient Temperature (Optional) 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.19 © Copyright Polaris Industries Inc.
Page 460: Display Area 2
Toggle the Up/Down buttons to change the information displayed in Area 2 Engine Temperature Odometer Ambient Temperature Trip 1 (Optional) Trip 2 Voltage Speed Engine Hours Service Hours 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.20 © Copyright Polaris Industries Inc.
Page 461: Options Menu
Select between 12H or 24H, and set time Backlight Color Select between Blue or Red Backlight Level Set backlight brightness level Service Hours View/Set Service hours Exit Menu Exit 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.21 © Copyright Polaris Industries Inc.
Page 462: Unit Selection Distance
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.22 © Copyright Polaris Industries Inc.
Page 463: Unit Selection Temperature
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.23 © Copyright Polaris Industries Inc.
Page 464: Clock
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.24 © Copyright Polaris Industries Inc.
Page 465: Back Light Color
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.25 © Copyright Polaris Industries Inc.
Page 466: Back Light Level
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.26 © Copyright Polaris Industries Inc.
Page 467: Service Hours
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.27 © Copyright Polaris Industries Inc.
Page 468: Diagnostic Code
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.28 © Copyright Polaris Industries Inc.
Page 469: Instrument Cluster Pinouts
3. Hold the dash securely and insert the instrument cluster into the dash. Apply pressure on the bezel while pressing down on the instrument cluster. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.29 © Copyright Polaris Industries Inc.
Page 470: Switches / Controls
0.5 ohms, clean the switch terminals. Re-test and replace switch if necessary. 4. For switch replacement, refer to Chapter 10 “Brakes”. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.30 © Copyright Polaris Industries Inc.
Page 471: Awd / 2Wd Switch
RESISTANCE VALUE GEAR WHEN MEASURED AT POSITION SWITCH TERMINALS A AND B HIGH 24 Ω 75 Ω 160 Ω 300 Ω PARK 620 Ω 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.31 © Copyright Polaris Industries Inc.
Page 472: Seat Belt Switch
2. Using a multi-meter, measure between both pins on switch. SEAT BELT SEAT BELT DISENGAGED ENGAGED Between both ∞ (OL) < 1 Ω pins on switch 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.32 © Copyright Polaris Industries Inc.
Page 473: Ignition Coil / Wire
4. Install the new ignition coil and/or high tension lead (s). TORQUE Ignition Coil Retaining Bolt: COIL TESTING 75 in-lb (9 Nm) Primary Coil Testing TEST Ω RESISTANCE 0.4 Ω 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.33 © Copyright Polaris Industries Inc.
Page 474: Charging System
CAUTION Maximum of .01 DCA (10 mA) Charging system damage will occur if incompatible components are installed. Always reference Polaris 9. If over 10 milliamps, go to the fuse block and start Electric Parts Catalog for proper part numbers. systematically removing one fuse at a time until the...
Page 475: Charging System "Break Even" Test
TEST 2: Resistance Value of Each Stator Leg to Ground 2. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.35 © Copyright Polaris Industries Inc.
Page 477: Regulator / Rectifier
The unit will turn on again after it has cooled down to at least 212° F or 100° C. If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.37 © Copyright Polaris Industries Inc.
Page 478: Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.38 © Copyright Polaris Industries Inc.
Page 479: Battery
Refer to OCV table (see “OCV - Open Circuit Voltage Test” page 11.42). 5. Charge battery recommended (see “Charging Procedure” page 11.43). 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.39 © Copyright Polaris Industries Inc.
Page 480: Battery Removal
Move the panel away from the battery compartment to access the battery. 4. Disconnect the black (negative) battery cable(s). 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.40 © Copyright Polaris Industries Inc.
Page 481: Battery Installation
TORQUE Seat Cover Panel Screws: 8 ft-lbs (11 Nm) 10. Verify that cables are properly routed and reinstall the driver’s seat. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.41 © Copyright Polaris Industries Inc.
Page 482: Battery Off Season Storage
Battery charge can be maintained by using a Polaris For this reason, a battery capacity or load test should be battery tender charger or by charging once a month to conducted whenever poor battery performance is make up for normal self-discharge.
Page 483: Charging Procedure
Charge NOTICE Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.43 © Copyright Polaris Industries Inc.
Page 484: Lighting System
Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.44 © Copyright Polaris Industries Inc.
Page 485: Headlight Housing Removal
1. Disconnect the wire harness bumper. 2. While holding the taillight assembly, remove the three nuts retaining the taillight assembly and remove it from the rear fascia. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.45 © Copyright Polaris Industries Inc.
Page 486: Cooling System
If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.46 © Copyright Polaris Industries Inc.
Page 487: Ect Sensor Test
NOTICE Use a wire or other type of prop to ensure the sensor is properly supported and the tip of the sensor is touching water only. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.47 © Copyright Polaris Industries Inc.
Page 488: Ect Sensor Replacement
17 ft-lb (23 Nm) 7. Reinstall the throttle body 8. Add the required amount of coolant and bleed the system (see Chapter 3 – Cooling System Bleeding page 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.48 © Copyright Polaris Industries Inc.
Page 489: Starting System
To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the voltage drop tests. Voltage should not exceed 0.1 DC volts per connection 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.49 © Copyright Polaris Industries Inc.
Page 490: Starter Motor Installation
12V power via the Green / White wire. • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.50 © Copyright Polaris Industries Inc.
Page 491: Condition: Starter Fails To Turn Over The Engine
11. If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.51 © Copyright Polaris Industries Inc.
Page 492: Electronic Power Steering (Eps)
Electronic Power Steering (EPS) units are not to a normal mechanically coupled steering system. The interchangeable between ATV and RANGER product system is Polaris Digital Wrench® compatible for lines. simplified diagnostics...
Page 493: Eps Troubleshooting (Power Steering Non-Functional With Mil On)
ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.53 © Copyright Polaris Industries Inc.
Page 494: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)
ELECTRICAL EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.54 © Copyright Polaris Industries Inc.
Page 496: Fueses / Relays
EFI system, and drive system. FUSE / RELAY BOX LOCATION The fuse box is located behind the engine compartment access panel. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.56 © Copyright Polaris Industries Inc.
Page 498 EPS Controller Battery Voltage (Out) - OPTION Brown Relay Ground (Out) - OPTION EPS Battery Voltage, Fused 30A (Out) - OPTION Unswitched Battery Voltage, Fan Relay Power In, Circuit Breaker 15A 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.58 © Copyright Polaris Industries Inc.
Page 499: Relay Operation
PIN 34 (Relay 30) - 30 Amp fuse- protected 12 Vdc battery voltage. Pin 37 (Relay 87) - 12 Vdc Orange battery voltage to EPS controller. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.59 © Copyright Polaris Industries Inc.
Page 500: Misc. Electrical
Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before suspecting a component failure. 80% of all electrical issues are caused by bad/failed connections and grounds. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.60 © Copyright Polaris Industries Inc.
Page 501: Terminal Block
(+) via the starter motor solenoid. Use the terminal block when connecting accessories such as light bars or when installing a winch. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.61 © Copyright Polaris Industries Inc.
Page 502: Can Communication System
60 Ω. A reading of 120 Ω is bad. • An ACE equipped with a PIDD should have a reading of 120 Ω. Anything other than 120 Ω is bad. 9929422 R02 - 2017-2019 ACE 900 Service Manual 11.62 © Copyright Polaris Industries Inc.
Page 503 CV Joint / Boot Break Even Test............11.35 CV Joint Replacement (Inner) ........7.22 Break-In Period............2.18 Replacement (Outer) ..........7.20 Break-Out Cylinder Wiring Diagrams ............ 11.6 Inspection.............3.63 Installation ............3.72 9929422 R02 - 2017-2019 ACE 900 Service Manual IX.1 © Copyright Polaris Industries Inc.
Page 504 Valve Clearance Adjustment ........3.89 Operation Overview ..........4.5 Valve Cover Installation ...........3.93 Service Notes ............4.5 Valve Cover Removal ..........3.40 EFI / Fuel System Valve Inspection.............3.46 9929422 R02 - 2017-2019 ACE 900 Service Manual IX.2 © Copyright Polaris Industries Inc.
Page 505 Front Disc Thickness Inspection ........9.16 Front Capacity and Fluid Type........7.2 Front Bumper General Specifications Removal / Installation ..........10.29 Brakes ..............9.3 Front Cab Ground 9929422 R02 - 2017-2019 ACE 900 Service Manual IX.3 © Copyright Polaris Industries Inc.
Page 506 Replacement............1.4 Removal / Inspection..........3.65 Piston to Cylinder Clearance........3.66 Plunging Joint / Boot Replacement (Inner) ..........7.22 Polaris Mobile Digital Wrench (PMDW) ......4.53 Leakdown Test ............2.21 PPS ...............4.38 Left Side Seat Panel, Removal / Installation ....10.22 Pre-Ride Inspection ............ 2.4 Lubricants..............
Page 507 Replacement............11.37 Disassembly ............3.53 Relay Inspection.............3.52 Operation ............11.59 Starter Solenoid Right Side Seat Panel Operation ............11.50 Removal / Installation ..........10.21 Test ..............11.50 9929422 R02 - 2017-2019 ACE 900 Service Manual IX.5 © Copyright Polaris Industries Inc.
Page 508 Housing Removal ...........3.52 Installation ............3.27 Wheel and Hub ............2.39 Removal...............3.23 Torque Values Transmission Mounting..........6.8 Service ..............3.24 Wheel Transmission Installation ............2.40 Assembly .............6.25 Assembly View ............6.32 Removal...............2.39 9929422 R02 - 2017-2019 ACE 900 Service Manual IX.6 © Copyright Polaris Industries Inc.
Page 509 INDEX Wheel Alignment ............2.42 Wheel Hub Front Hub Assembly View ........7.41 Rear Hub Assembly View.........7.41 Wheel Toe Adjustment..........2.43 9929422 R02 - 2017-2019 ACE 900 Service Manual IX.7 © Copyright Polaris Industries Inc.
Page 510 MY17 ACE 900 XC ETC Schematic MY17 ACE 900 XC ETC Schematic (OPTIONAL LED LH BUMPER LIGHT P/N 2413545) (OPTIONAL LED LH BUMPER LIGHT P/N 2413545) (OPTIONAL LED LH BUMPER LIGHT P/N 2413545) (OPTIONAL LED LH BUMPER LIGHT P/N 2413546) (OPTIONAL LED LH BUMPER LIGHT P/N 2413546) (OPTIONAL LED LH BUMPER LIGHT P/N 2413546) SPEEDOMETER (P/N 3280555)
Page 511 MY18-19 ACE 900 XC ETC SPEEDOMETER (P/N 3280555) Schematic EPS POWER (A) FUNCTION WIRE COLOR LEGEND DIAGNOTSIC AWD SWITCH BATTERY (+) FILE NAME: 2413941.RSD BEIGE (TAN) E = ENGINE GROUND (P/N 4014673) BATTERY (-) BLACK LIGHT BLUE (HEADLIGHT BULB SERVICE P/N 4010253) (HEADLIGHT BULB SERVICE P/N 4010253) DARK BLUE EPS SENSOR (B)
Page 512 MY18-19 ACE 900 XC ETC Schematic WIRE COLOR LEGEND FILE NAME: 2413941.RSD BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN ORANGE NO = SWITCH NORMALLY OPEN PINK HARNESS: 2413941-01 VIOLET (PURPLE)

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Ace 900 2018 Ace 900 2019 Ace 900 xc 2017

Polaris ACE 900 2017 Service Manual

Chapter 1 1 General Information

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling System

Chapter 4 Fuel System

Chapter 5 Pvt System

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Chapters

Troubleshooting

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Summary of Contents for Polaris ACE 900 2017