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ACE 900 XC 2017
Polaris ACE 900 XC 2017 User Manual
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8.50
9929422
R02
-
2017-2019
ACE
900
Service
Manual
©
Copyright
Polaris
Industries
Inc.
42.
Reinstall
spherical
bearing
O-rings
and
polyurethane
bushings.
NOTE
After
installation,
be
sure
to
RIDE
SLOWL
Y
initially
to
ensure
the
shock
and
the
vehicle’s
suspension
is
performing
correctly
.
STEERING
/
SUSPENSION
381
383
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
5
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Polaris ACE 900 XC 2017 Specifications
General
Brand
Polaris
Model
ACE 900 XC 2017
Category
Offroad Vehicle
Language
English
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