User Manuals: Polaris ACE 900 2019 Off-road vehicle

Manuals and User Guides for Polaris ACE 900 2019 Off-road vehicle. We have 1 Polaris ACE 900 2019 Off-road vehicle manual available for free PDF download: Service Manual

Polaris ACE 900 2019 Service Manual

Polaris ACE 900 2019 Service Manual (512 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 67 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Vehicle Indentification
  8
- Model Number Designation (2015 +)
  8
- Vehicle Identification Number (Vin) Designation
  8
- Vin and Engine Serial Number Locations
  9
- Reference Information
  10
- Replacement Keys
  10
- Publication Part Numbers
  10
- Special Tools
  11
- General Specifications
  12
- 2017 Ace 900 XC Clutch Chart
  13
- 2018 Ace 900 Clutch Chart
  15
- 2019 Ace 900 Clutch Chart
  17
- Misc. Specifications and Charts
  18
- Master Torque Table
  18
- Conversion Table
  22
- Sae Tap / Drill Sizes
  23
- Metric Tap / Drill Sizes
  23
- Decimal Equivalents
  24
Maintenance Chapter 2 Maintenance 2

25
- Lubricants / Service Products
  27
- Maintenance
  27
- Periodic Maintenance - General
  28
- Pre-Ride Inspection
  28
- Maintenance Intervals
  29
- Maintenance Quick Reference
  39
- Grease Lubrication Points
  41
- Break-In Period
  42
- Engine
  43
- Engine Oil Level
  43
- Engine Oil and Filter Change
  44
- Engine Breather Hose
  45
- Engine Cylinder Leakdown Test
  45
- Valve Clearance Inspection
  46
- Cam Chain Tensioner Inspection
  48
- Spark Arrestor Service
  49
- 50/50 Extended-Life Engine Antifreeze
  50
- Cooling System
  50
- Coolant Strength
  51
- Cooling System Overview
  51
- Coolant Level Inspection
  52
- Cooling System Pressure Test
  52
- Coolant Drain / Fill
  53
- Radiator Inspection / Cleaning
  53
- Cooling System Hoses
  54
- Fuel System - Ace: Warnings and Cautions
  55
- Fuel System and Air Intake
  55
- Fuel Tank Vent Line
  55
- Fuel Lines
  56
- Fuel Pump / Fuel Filters
  56
- Engine Intake Pre-Filter Service
  57
- Throttle Pedal Inspection
  57
- Air Filter Service
  58
- Intake Duct Drain Inspection
  58
- Air Box / Air Filter Assembly View
  59
- Drive Clutch / Driven Clutch / Belt Service
  60
- Pvt
  60
- Pvt Drying
  60
- Pvt Intake Pre-Filter Service
  60
- Maintenance
  61
- Transmission
  61
- Transmission Lubricant Change
  61
- Transmission Lubricant Level Check
  61
- Transmission Lubrication
  61
- Final Drive / Wheel / Tire
  62
- Front Gearcase Fluid Change
  62
- Front Gearcase Fluid Level Check
  62
- Front Gearcase Lubrication
  62
- Drive Shaft Boot Inspection
  63
- Wheel and Hub Torque Table
  63
- Wheel Removal
  63
- Tire Inspection
  64
- Tire Pressure
  64
- Wheel Installation
  64
- Steering
  65
- Steering Inspection
  65
- Steering Wheel Freeplay
  65
- Tie Rod End / Wheel Hub Inspection
  65
- Wheel Toe Alignment Inspection
  66
- Wheel Toe Adjustment
  67
- Suspension
  68
- Walker Evans Front / Rear Spring Preload
  68
- Walker Evans Shock Preload Adjustment
  69
- Walker Evans Front / Rear Shock Compression
  70
- Brake Fluid Inspection
  71
- Brake Hose and Fitting Inspection
  71
- Brake Pad / Disc Inspection
  71
- Brake System
  71
- Battery Charging / off Season Storage
  72
- Battery Maintenance
  72
- Electrical / Ignition System
  72
- Engine / Chassis Electrical Ground
  72
- Spark Plug Service
  73
- Extended Storage
  75
- Storage Tips
  75
Chapter 3 Engine / Cooling System

77
- General Information
  80
- Torque Specifications - Engine
  80
- Engine Lubrication Specifications
  81
- Engine Special Tools
  81
- Oil Pressure Test
  82
- Oil Flow Chart
  83
- Engine Service Specifications
  84
- Engine Specifications
  84
- Engine Torque Sequences
  86
- Air Box / Air Filter Assembly View
  88
- Intake / Exhaust System
  88
- Air Box Removal / Installation
  89
- Exhaust Assembly View
  91
- Muffler Removal
  92
- Exhaust Pipe Installation
  93
- Exhaust Pipe Removal
  93
- Muffler Installation
  93
- Cooling System
  94
- Cooling System Assembly
  94
- Cooling System Flow
  94
- Cooling System Pressure Test
  95
- Cooling System Specifications
  95
- Pressure Cap Test
  95
- Radiator Inspection
  95
- Radiator Removal / Installation
  96
- Thermostat Replacement
  97
- Cooling System Bleeding
  98
- Water Pump Removal
  99
- Water Pump Service
  100
- Water Pump Installation
  103
- Engine Mount Inspection
  104
- Engine Service
  104
- Crankshaft Pto Seal Replacement
  106
- Removal
  106
- Engine Removal
  108
- Engine Installation
  112
- Camshaft Removal
  116
- Engine Disassembly / Inspection - Top End
  116
- Valve Cover Removal
  116
- 9929422 R02 - 2017-2019 ACE 900 Service Manual
  118
- Camshaft / Camshaft Bore Inspection
  118
- Camshaft Sprocket Inspection
  118
- Cylinder Head Inspection
  120
- Cylinder Head Removal
  120
- Cylinder Head Warp Inspection
  120
- Cylinder Head Disassembly
  121
- Valve Inspection
  122
- Combustion Chamber Cleaning
  123
- Valve Seat Reconditioning
  123
- Engine Disassembly / Inspection - Bottom End
  127
- Stator Cover Removal / Inspection
  127
- Flywheel Removal
  128
- Water Pump Housing Removal
  128
- Starter One-Way Clutch Disassembly
  129
- Starter One-Way Clutch Assembly
  130
- Crankcase Disassembly
  131
- Balance Shaft Removal / Inspection
  134
- Crankshaft Removal / Inspection
  135
- Crankcase Inspection
  137
- Cylinder / Piston Removal
  138
- Cylinder Inspection
  139
- Piston Disassembly / Inspection
  140
- Piston Ring Removal
  141
- Piston Ring to Groove Clearance Inspection
  141
- Piston Ring Installed Gap
  142
- Piston-To-Cylinder Clearance
  142
- Connecting Rod Inspection
  143
- Bearing Selection Identification Letters and Numbers
  144
- Engine Assembly - Bottom End
  144
- Connecting Rod Bearing Selection
  145
- Crankshaft Main Bearing Selection
  145
- Piston Ring Installation
  146
- Upper Crankcase Preparation
  146
- Piston / Connecting Rod Assembly
  147
- Cylinder / Piston Installation
  148
- Crankshaft Installation
  149
- Balance Shaft Installation
  150
- Crankcase Assembly
  151
- Lower Crankcase Preparation
  151
- Flywheel Installation
  155
- Stator Cover Installation
  156
- Cylinder Head Assembly
  157
- Engine Assembly - Top End
  157
- Valve Sealing Test
  158
- Cylinder Head Installation
  159
- Camshaft Installation / Timing
  160
- Camshaft Timing - Quick Reference
  164
- Valve Clearance Adjustment
  165
- Valve Lash - Tappet Selection
  168
- Valve Cover Installation
  169
- Engine Cooling System
  170
- Troubleshooting
  170
Chapter 4 Fuel System

173
- General Information
  175
- Special Tools - Fuel System
  175
- Torque Specifications - Efi / Fuel System
  175
- Efi Overview
  176
- Efi System Components / Locations
  176
- Efi Operation Overview
  177
- Efi Service Notes
  177
- Initial Priming / Starting Procedure
  178
- Ecu Overview
  179
- Ecu Rpm Limits
  179
- Ecu Service
  179
- Electronic Control Unit (Ecu)
  179
- Ecu Replacement
  180
- Ecu Pinouts
  181
- Fuel Injector
  182
- Fuel Injector O-Rings
  182
- Fuel Injector Overview
  182
- Fuel Injector Test
  183
- Fuel Injector Troubleshooting
  183
- Fuel Injector Replacement
  184
- Fuel Tank
  187
- Fuel Tank Assembly View
  187
- Fuel Line - Quick Connect Removal / Installation
  188
- Fuel Tank Removal
  188
- Fuel Tank Installation
  190
- Fuel Line
  191
- Fuel Supply Line Routing
  191
- Fuel Vent Line
  193
- Fuel Vent Line Routing
  193
- Vent Line Termination Fitting
  194
- Fuel Pump
  195
- Fuel Pump Test
  195
- Fuel Sender Test
  195
- Operation Overview
  195
- Fuel Pump Replacement
  197
- Air Box / Air Filter Assembly View
  200
- Air Box / Intake System
  200
- Air Box Removal / Installation
  201
- Fuel System
  203
- T-Map Overview
  203
- T-Map Sensor Replacement
  203
- T-Map Sensor Test
  203
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  203
- Cps Overview
  204
- Cps Test
  204
- Crankshaft Position Sensor (Cps)
  204
- Resistance Test
  204
- Air Gap Test
  205
- Encoder Flywheel / Keyway Inspection
  205
- Cps Replacement
  207
- Electronic Throttle Control (Etc)
  208
- Etc Overview
  208
- Etc Replacement
  208
- Etc Test
  208
- Etc Learn Procedure
  209
- Location
  210
- Operation Overview
  210
- Pedal Position Sensor
  210
- Pps Replacement
  210
- Pps Test
  210
- Efi Diagnostics
  212
- Fuel Starvation / Lean Mixture
  212
- Fuel System Troubleshooting
  212
- Poor Idle
  212
- Rich Mixture
  212
- Diagnostic Code
  213
- Diagnostic Trouble Code Chart
  214
- Digital Wrench® - Diagnostic Connector
  217
- Digital Wrench® - Download Website
  217
- Digital Wrench® Diagnostic Softwarepu-47063
  217
- Digital Wrench® Operation
  217
- Digital Wrench® Smartlink Module Kitpu-47471
  217
- Digital Wrench® Diagnostic Software Overview
  218
- Digital Wrench® Version and Update
  218
- Digital Wrench® Updates
  219
- Digital Wrench® Communication Errors
  220
- Digital Wrench® Serial Number Location
  220
- Guided Diagnostics
  220
- Digital Wrench® Feature Map
  221
- Ecu Replacement
  222
- Ecu Reprogramming (Reflash)
  222
- Polaris Mobile Digital Wrench (Pmdw)
  225
Chapter 5 Pvt System

227
- 2017 Ace 900 XC Clutch Chart
  228
- 2018 Ace 900 Clutch Chart
  228
- General Information
  228
- Special Tools and Supplies
  228
- Torque Specifications - Pvt System
  228
- Drive Clutch Operation
  229
- General Operation
  229
- Pvt System Overview
  229
- Driven Clutch Operation
  230
- Maintenance / Inspection
  230
- Belt Inspection
  231
- Belt Removal
  231
- Drive Belt
  231
- Belt Installation
  232
- Pvt Break-In (Drive Belt / Clutches)
  232
- Pvt System Assembly View
  233
- Pvt System Service
  233
- Pvt Disassembly
  234
- Pvt Assembly
  236
- Drive Clutch Assembly View
  237
- Drive Clutch Service
  237
- Drive Clutch Disassembly
  238
- Bearing Inspection
  239
- Button to Tower Clearance
  240
- Shift Weight Inspection
  240
- Roller, Pin and Thrust Washer Inspection
  241
- Spider Removal
  241
- Drive Clutch Inspection
  242
- Moveable Sheave Bushing Inspection
  243
- Bushing Service
  244
- Drive Clutch Assembly
  246
- Driven Clutch Assembly View
  248
- Driven Clutch Service
  248
- Driven Clutch Disassembly
  249
- Driven Clutch Slider Inspection
  249
- Driven Clutch Assembly
  251
- Troubleshooting
  253
- Overheating / Diagnosis
  255
Chapter 6 Transmission

257
- General Information
  258
- Lubrication Specifications - Transmission
  258
- Special Tools - Transmission
  258
- Torque Specifications - Transmission
  258
- Shift Lever
  259
- Shift Lever Removal
  259
- Shift Cable Inspection
  260
- Shift Lever Installation
  260
- Shift Cable Adjustment
  261
- Transmission Vent Line
  262
- Transmission Vent Line Routing
  262
- Vent Line Termination Fitting
  262
- Transmission / Torque Values
  264
- Transmission Service
  264
- Transmission Removal
  265
- Transmission Installation
  270
- Transmission Disassembly
  275
- Gear / Shaft / Bearing Inspection
  280
- Transmission Assembly / Snorkel Gear Backlash Procedure
  281
- Transmission Troubleshooting
  287
- Troubleshooting Checklist
  287
- Transmission Assembly View
  288
Chapter 7 Final Drive

291
- Gearcase Fluid / Capacity
  292
- General Information
  292
- Special Tools - Final Drive
  292
- Torque Specifications - Final Drive
  292
- Bearing Carrier
  293
- Front Bearing Carrier Removal
  293
- Front Bearing Carrier Assembly
  295
- Front Bearing Carrier Disassembly
  295
- Front Bearing Carrier Installation
  296
- Rear Bearing Carrier Removal
  298
- Rear Bearing Carrier Disassembly
  299
- Rear Bearing Carrier Assembly
  300
- Rear Bearing Carrier Installation
  301
- Drive Shaft
  303
- Front Drive Shaft Removal
  303
- Front Drive Shaft Installation
  305
- Rear Drive Shaft Removal
  307
- Rear Drive Shaft Installation
  308
- Drive Shaft / CV Joint Handling Tips
  310
- Outer CV Joint / Boot Replacement
  310
- Inner Plunging Joint / Boot Replacement
  312
- Prop Shaft
  315
- Prop Shaft Removal and Installation
  315
- U-Joint Assembly
  316
- U-Joint Disassembly
  316
- Front Gearcase
  317
- Front Gearcase Assembly View
  317
- All Wheel Drive Operation
  318
- Awd Diagnosis
  319
- Front Gearcase Removal
  320
- Front Gearcase Disassembly / Inspection
  322
- Front Gearcase Assembly
  325
- Front Gearcase Installation
  327
- Front Gearcase Vent Line
  330
- Front Gearcase Vent Line Routing
  330
- Front Hub Assembly View
  331
- Rear Hub Assembly View
  331
- Wheel Hubs
  331
Chapter 8 Steering / Suspension

333
- General Information
  335
- Special Tools - Steering / Suspension
  335
- Torque Specifications - Steering / Suspension
  335
- Domestic Eps Assembly View
  336
- Steering System
  336
- Upper Steering Shaft Removal (Eps)
  338
- Power Steering Unit (Eps) Removal
  340
- Lower Steering Shaft Removal (Eps)
  341
- Lower Steering Shaft Installation (Eps)
  342
- Power Steering Unit (Eps) Installation
  344
- Upper Steering Shaft Installation (Eps)
  345
- Eps Torque Offset Procedure
  348
- Front Suspension
  349
- Front Suspension Assembly View
  349
- Front Shock Assembly View
  350
- Front Stabilizer Bar Assembly View
  351
- Upper A-Arm Removal / Replacement
  352
- Lower A-Arm Removal / Replacement
  353
- Front Stabilizer Bar Removal
  355
- Front Stabilizer Bar Installation
  356
- Ball Joint Removal
  357
- Ball Joint Service Preparation
  357
- Ball Joint Installation
  358
- Rear Suspension
  360
- Rear Suspension Assembly View
  360
- Rear Shock Assembly View
  361
- Rear Stabilizer Bar Assembly View
  362
- Rear Upper Control Arm Removal / Installation
  363
- Rear Lower Control Arm Removal / Installation
  365
- Rear Stabilizer Bar Installation
  367
- Rear Stabilizer Bar Removal
  367
- Front Shock Removal / Installation
  368
- Rear Shock Removal / Installation
  368
- Shocks / Springs
  368
- Walker Evans Front / Rear Spring Preload
  369
- Walker Evans Shock Preload Adjustment
  370
- Walker Evans Front / Rear Shock Compression
  371
- General Service Information
  372
- Shock Service
  372
- Walker Evans 1.5" Front Shock Information
  372
- Walker Evans 1.5" Rear Shock Information
  373
Chapter 9 Brake System

383
- General Information
  385
- General Specifications
  385
- Special Tools
  385
- Torque Specifications - Brake System
  385
- Brake System Overview
  386
- Brake System View
  386
- Brake System Service Notes
  387
- Hydraulic Brake System Operation
  387
- Master Cylinder
  388
- Master Cylinder Removal
  388
- Master Cylinder Installation
  389
- Brake Bleeding / Fluid Change
  390
- Brake Pedal
  391
- Pedal Installation
  391
- Pedal Removal
  391
- Front Brake Service
  392
- Pad Removal
  392
- Pad Assembly / Installation
  393
- Pad Inspection
  393
- Caliper Exploded View
  394
- Caliper Disassembly
  395
- Caliper Removal
  395
- Caliper Inspection
  396
- Caliper Assembly
  397
- Caliper Installation
  397
- Disc Inspection
  398
- Disc Runout
  398
- Brake Burnishing Procedure
  399
- Disc Replacement
  399
- Pad Removal
  400
- Rear Brake Service
  400
- Pad Assembly / Installation
  401
- Pad Inspection
  401
- Caliper Exploded View
  402
- Caliper Disassembly
  403
- Caliper Removal
  403
- Caliper Assembly
  404
- Caliper Inspection
  404
- Caliper Installation
  405
- Disc Inspection
  405
- 9929422 R02 - 2017-2019 ACE 900 Service Manual
  406
- Disc Replacement
  406
Chapter 10 Body / Frame

409
- General Information
  411
- Plastic Push Rivet Removal
  411
- Torque Specifications - Body
  411
- Decal Replacement
  412
- Decals
  412
- Body Assembly Views
  413
- Rops Assembly
  413
- Doors
  414
- Front Bumper
  415
- Upper Cab / Dash
  416
- Front Storage Box
  417
- Front Cab / Fenders
  418
- Floor and Rocker Panels
  419
- Rear Bumper
  420
- Rear Cargo Box / Fenders
  421
- Main Frame Assembly View
  422
- Body Component Removal
  423
- Seat
  423
- Seat Adjustment / Removal / Installation
  423
- Seat / Seat Belt Assembly View
  424
- Seat Belt Removal / Installation
  425
- Front Tube Removal / Installation
  426
- Roll over Protection System (Rops)
  426
- Side Bolster Removal / Installation
  426
- Rear Tube Removal / Installation
  427
- Engine Compartment Access Panel
  428
- Engine Compartment Panel Removal / Installation
  428
- Right Side Seat Panel Removal / Installation
  429
- Side Seat Panels
  429
- Left Side Seat Panel Removal / Installation
  430
- Left Rocker Panel Removal / Installation
  431
- Right Rocker Panel Removal / Installation
  431
- Rocker Panels
  431
- Floorboard Panels
  432
- Main Floorboard
  432
- Upper Floorboard
  432
- Instrument Cluster Pod
  433
- Instrument Cluster Pod Removal / Installation
  433
- Front Storage bin
  434
- Front Storage bin Removal / Installation
  434
- Body / Frame
  435
- Fender Flares
  435
- Front Fender Flare Removal / Installation
  435
- Rear Fender Flare Removal / Installation
  435
- Front Cab
  436
- Front Cab Removal / Installation
  436
- Front Bumper
  437
- Front Bumper Removal / Installation
  437
- Rear Bumper / Storage Box
  438
- Rear Bumper Removal / Installation
  438
- Rear Storage Box Removal / Installation
  438
Chapter 11 Electrical

441
- General Information
  444
- Special Tools
  444
- Torque Specifications - Electrical
  444
- Electrical Service Notes
  445
- Break-Out Diagram Viewing
  446
- Chassis Harness
  447
- Main Harness Component Locations
  447
- Main Harness Retention Locations
  448
- Main Harness Routing
  449
- Digital Multi-Meter (DMM) Notes
  450
- Dynamic Testing
  450
- Electrical Diagnostics
  450
- Electrical Service Notes
  450
- Static and Dynamic Testing
  450
- Static Testing
  450
- Back Probing
  451
- Break out
  451
- Connector Probing Guidelines
  451
- Front Probing
  451
- Testing Continuity/Resistance
  452
- Testing for a Short to Ground
  453
- Testing for a Short to Voltage
  454
- Testing for Intermittent Conditions
  454
- Testing Current Flow (Amperage)
  455
- Testing Parasitic Draw
  455
- Testing Voltage Drop
  456
- Instrument Cluster
  457
- Overview
  457
- Indicator Lamps
  458
- Display Area 1
  459
- Display Area 2
  460
- Options Menu
  461
- Unit Selection Distance
  462
- Unit Selection Temperature
  463
- Clock
  464
- Back Light Color
  465
- Back Light Level
  466
- Service Hours
  467
- Diagnostic Code
  468
- Instrument Cluster Installation
  469
- Instrument Cluster Pinouts
  469
- Instrument Cluster Removal
  469
- Brake Light Switch
  470
- Ignition Key Switch
  470
- Switches / Controls
  470
- Awd / 2Wd Switch
  471
- Transmission (Gear Position) Switch
  471
- Seat Belt Switch
  472
- Coil Testing
  473
- Ignition Coil
  473
- Ignition Coil / Plug Wire Replacement
  473
- Ignition Coil / Wire
  473
- Operation Overview
  473
- Charging System
  474
- Current Draw - Key off
  474
- Charging System "Break Even" Test
  475
- Charging System Tests
  475
- Regulator / Rectifier
  477
- Charging System Testing Flow Chart
  478
- Battery
  479
- Battery Specifications
  479
- General Battery Information
  479
- Battery Removal
  480
- Battery Installation
  481
- Battery Conductance Analyzer
  482
- Battery off Season Storage
  482
- Battery Testing
  482
- Load Test
  482
- Ocv - Open Circuit Voltage Test
  482
- Charging Procedure
  483
- Extreme Use Battery
  483
- Headlight Adjustment
  484
- Headlight Bulb Replacement
  484
- Lighting System
  484
- Headlight Housing Installation
  485
- Headlight Housing Removal
  485
- Taillight Replacement
  485
- Cooling System
  486
- Engine Coolant Temperature Sensor (Ect)
  486
- Engine Coolant Temperature Sensor (Ect) Overview
  486
- Fan Control Circuit Bypass Test
  486
- Fan Control Circuit Operation / Testing
  486
- Ect Sensor Test
  487
- Resistance Vs. Temperature Test
  487
- System Operation Test
  487
- Ect Sensor Replacement
  488
- Starter Motor Removal
  489
- Starting System
  489
- Troubleshooting
  489
- Voltage Drop Test
  489
- Starter Motor Installation
  490
- Starter Solenoid Bench Test
  490
- Starter Solenoid Operation
  490
- Condition: Starter Fails to Turn over the Engine
  491
- Electronic Power Steering (Eps)
  492
- Eps Operation
  492
- Proper Eps System Diagnosing
  492
- Eps Troubleshooting (Power Steering Non-Functional with Mil On)
  493
- Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
  494
- Eps Troubleshooting (Using Digital Wrench®)
  495
- Fueses / Relays
  496
- Fuse / Relay Box Location
  496
- Overview / Operation
  496
- Fuse / Relay Circuits
  497
- Relay Operation
  499
- All Wheel Drive (Awd) Coil
  500
- Diagnosing System Failures
  500
- Misc. Electrical
  500
- Operation Overview
  500
- Speed Sensor Location
  500
- Speed Sensor Testing
  500
- Vehicle Speed Sensor
  500
- Brake Switch Diode
  501
- Diodes
  501
- Terminal Block
  501
- Terminal Block Overview
  501
- Can Communication System
  502
- Can System Overview
  502
- Can System Testing
  502

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