Description
This Official printed 2014 2015 2016 Polaris Sportsman Ace ATV Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for your Polaris Sportsman Ace ATV.
Table of Contents
General Information
Maintenance
Engine
EFI
Transmission
PVT
Final Drive
Body
Frame
Steering
Suspension
Brakes
Electrical
Index of Topics
A
ACE Brake System
International
ACE Brake System Assembly View
Domestic
ACE Brake System Assembly Views
ACE Front Bumper/Winch Cover
ACE Front Suspension
ACE Parking Brake Service
ACE Rear Suspension
ACE ROPS / Body Assembly Views
ACE Seat
Adjustment / Removal / Installation
ACE Seat / Seat Belt Assembly View
ACE Steering
Air Box
Assembly View
Removal / Installation
Air Box / Intake System
Service
Air Filter
Assembly View
Pre-Filter Service
Service
Air Intake Duct Drain
Alignment
Wheel
Authorization Key
Authorization, Reflash
AWD Coil
Axle
Front Drive
Rear Drive
B
Balance Shaft
Installation
Timing
Balance Shaft Removal / Inspection
Battery
Installation
Load Test
Maintenance
Removal
Service
Storage
Tester
Testing
Battery Activation
Battery Charging Procedure
Bearing Inspection
Brake Burnishing
Brake Caliper Assembly, Front
Brake Caliper Assembly, Rear
Brake Caliper Inspection, Front
Brake Caliper Installation, Front
Brake Caliper Removal, Front
Brake Disc, Front
Brake Disc, Rear
Brake Fluid Inspection
Brake Hose and Fitting Inspection
Brake Light Switch
Brake Pad Assembly, Front
Brake Pad Inspection
Brake Pad Thickness, Front
Brake Pads, Front
Brake Pads, Rear
Brake Pads, Removal, Front
Brake Pedal, Installation
Brake Pedal, Removal
Brake System, Bleeding
Brake System, Operation
Brake, Front Pad Assembly
Break Even Test
Break-In Period
Breather Hoses Engine
c
Caliper, Front
Caliper, Rear
Camshaft
Bore Inspection
Inspection
Installation / Timing
Removal
Sprocket Inspection
Timing – Quick Reference
Camshaft Carrier Disassembly
Camshaft Oil Jet
Charging System
Stator Tests
Testing Flow Chart
Clutch Weights
Clutch, Starter One Way
Communication Problems, Digital Wrench
Conversion Table
Coolant
Drain / Fill
Level Inspection
Coolant Drain / Radiator Removal
Coolant Strength and Type
Cooling Fan Bypass Test
Cooling System
ACE
Hoses
Cooling System Bleeding Procedure
Cooling System Overview
Cooling System Pressure Test
Cooling System Specifications
CPS Replacement
CPS Testing
Crankcase
Assembly
Crankcase Sealant Pattern
Crankcase, Disassembly
Crankcase, Inspection
Crankcase, Separation
Crankshaft
Inspection
Removal
Crankshaft Position Sensor (CPS)
CV Shaft
Front
Front Axle Installation
Front Axle Removal
Rear
Cylinder Head
Combustion Chamber Cleaning
Disassembly
Inspection
Removal
Warp
Cylinder Head Assembly
Cylinder Installation – Piston in Cylinder
Cylinder Leakdown Test
D
Decal Replacement
Decimal Equivalent Chart
Diagnostic Trouble Codes
Instrument Cluster Display
Diagnostic Trouble Codes (DTCs)
Differential Solenoid (INT’L)
Digital Wrench
Engine Controller Reprogramming
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software
Digital Wrench Versions
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Diode
Brake Switch
Chassis Relay
Diodes
Disassembly, Engine Lower End
Drive Belt
Inspection
Installation
Removal
Drive Clutch
Assembly
Assembly View
Bushing Service
Button to Tower Clearance
Disassembly
Spider Removal
Drive Clutch, Operation
Drive Clutch, Service
Drive Shaft
Boot Inspection
CV Joint Handling
Service (Rear)
Driven Clutch
Assembly
Assembly View
Disassembly
Service
Driven Clutch, Operation
E
ECT Sensor
ECU
Connector Pinouts
Service
EFI Component Locations
Left View
Right View
EFI wiring diagram
EFI, Service Notes
Electrical
AWD Breakout Diagram
Charging System Breakout Diagram
Chassis Power Breakout Diagram
Cooling System Breakout Diagram
Key-On Power Breakout Diagram
Lights Breakout Diagram
Speed Sensor Breakout Diagram
Electrical System Breakouts
Electronic Control Unit (ECU)
Engine
Break-In Period
Cam Shaft Removal
Camshaft Bore Inspection
Camshaft Inspection
Camshaft Installation / Timing
Camshaft Sprocket Inspection
Camshaft Timing – Quick Reference
Combustion Chamber Cleaning
Coolant Temperature Sensor (ECT)
Cylinder Head Inspection
Cylinder Head Installation
Cylinder Head Removal
Cylinder Head Warp
Cylinder Inspection
Cylinder Removal
Decompression Mechanism
Installation
Installed Gap Measurement, Piston
Lower End Assembly
Lower End Disassembly
Lubrication Specifications
Oil Pressure Test
Piston / Connecting Rod Assembly
Piston / Rod Inspection
Piston Removal
Piston Ring Installation
Piston Ring Installed Gap
Piston-to-Cylinder Clearance
Removal
Top End Disassembly
Valve Cover Installation
Valve Cover Removal
Valve Inspection
Valve Sealing Test
Valve Seat Reconditioning
Valve Spring
Valve Spring Removal
Engine / VIN Number Locations
Engine Assembly Top End
Engine Compartment Panel
Removal / Installation
Engine Controller Reprogramming
Engine Coolant Temperature Sensor (ECT)
Engine Cooling System
Engine Detail
Cylinder Head / Crankcase
Engine Detail – Torque Values / Sequences
Engine Fastener Torque Specifications
Engine Lubrication
Engine Model Number
Engine Mount Inspection
Engine Oil / Oil Filter Change
Engine Oil Flowchart
Engine on Connecting Rod
Cylinder Installation – Piston Installed
Engine Service
Engine Service Specifications
Engine
ENGINE SERVICE SPECIFICATIONS
Engine to Transmission Coupler Service
Engine Torque
Stator Cover
Engine Torque Sequences
Engine / Transmission Bracket
Oil Sump Cover
Stator Cover
Engine, Cylinder Head Assembly
Exhaust System Assembly View
F
Fan Control Circuit Bypass Test
Fan Control Circuit Operation
Floorboard Panels
Flywheel Installation
Flywheel, Removal
Frame Assembly
Front Bumper/ Winch Cover Installation
Front Bumper/Winch Cover Removal
Front Cab Removal / Installation
Front Caliper
Disassembly
Front Caliper, Piston Bore ID
Front Control Arm
ACE
Front Disc
Replacement
Runout Inspection
Thickness Inspection
Front Gearcase
Back Lash Pad Adjustment
Coil Resistance
Disassembly / Inspection
Exploded View
Installation
Lubrication
Operation
Reassembly / Inspection
Removal
Front Hub
Assembly
Disassembly
Front Strut Assembly View
Front Strut Ball Joint Replacement
Front Strut Service
Front Suspension Service
ACE
Fuel Filter
Fuel Injector
Overview
Fuel Injector Replacement
Fuel Injector Test
Fuel Line
Fuel Pump
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Fuel System Troubleshooting
Fuel Tank
Assembly View
Installation
Removal
Vent Line and Filter
Fuse / Relay Box
Circuits
Fuse Box
Fuse Box Detail
G
Gearcase
Front Capacity and Fluid Type
General Information
General Specifications, Brakes
General Vehicle Inspection / Maintenance
Ground
Engine /Chassis
Guided Diagnostics
H
Hazard Switch (INT’L)
Head Lights
Headlamp Bulb Replacement
Headlamp Housing Installation
Headlamp Housing Removal
IAC
IAC Testing
Idle Air Control (IAC)
Ignition Coil / Wire
Ignition Coil / Wire Overview
Ignition Coil / Wire Testing
Ignition Key Switch – ACE
Inner Plunging Joint / Boot
Replacement
Inspections
Pre-Ride / Daily
Instrument Cluster
Diagnostic Mode
Information Display Area
Installation
Overview
Pinouts
Removal
Rider Information Display
Instrument Cluster Pod
Removal
International Steering Assembly
K
Key-off Current Draw Test
Key, Reprogramming Authorization
L
Leakdown Test
Left / Right Floorboard Removal / Installation
Leftside Seat Panel, Removal / Installation
Level Check
Engine Oil
Lights
Front
Rear
Lower Control Arm Service
Front Suspension
Lubrication Grease Points
M
Main Floorboard Removal / Installation
Main Frame
Assembly View
Maintenance
Brake System
Electrical / Ignition System
Engine
PVT/Clutch
Steering
Transmission and Gearcase
Maintenance / Service Products
Maintenance Quick Reference Chart
Maintenance, Chart Key
Maintenance, Fuel System / Air Intake
Maintenance, Intervals
Master Cylinder, Installation
Master Cylinder, Removal
Metric Bolt Torque Specification
Model Number
Model Specifications, 2014 ACE
o
Oil Flowchart
Oil Pickup Assembly Inspection
Oil Pressure Regulator (Bypass) Valve Inspection
Oil Pressure Test
Oil Pump
Assembly
Oil Pump, Removal
Open Circuit Voltage Test
Outer CV Joint / Boot Replacement
P
Parking Brake
International
Parking Brake Caliper Assembly
Parking Brake Caliper, Installation (INT’L)
Parking Brake Caliper, Removal (INT’L)
Parking Brake Disc (INT’L)
Parking Brake Switch (INT’L)
Parking Brake, Adjustment (INT’L)
Parking Brake, Exploded View (INT’L)
Parking Brake, Inspection – International)
Periodic Maintenance
Pivot Tube Service
Pressure Cap Test
Prop shaft
Removal
PTO and MAG Side Crankcase Bearing Service
Publication Part Numbers
Keys, Replacement
Publication Part Numbers, Sportsman ACE
PVT
Drying
Filter Service
PVT System
Assembly
Disassembly
Drive Clutch Disassembly
Overview
Service
Troubleshooting
PVT System Assembly View
PVT System Fastener Torques
R
Radiator
Radiator Inspection / Cleaning
Rear Bearing Carrier
Assembly
Disassembly
Installation
Removal
Rear Bumper
Removal / Installation
Rear Bumper/ Storage Box
Rear Control Arms Assembly View
Rear Drive Shaft Installation
Removal
Rear Lower Control Arm Service
Rear Shock Assembly View
Rear Shock Removal / Installation
Rear Storage Box Removal / Installation
Rear Suspension Service
ACE
Rear Sway Bar Assembly View
Rear Upper Control Arm Service
Reflash Authorization
Regulator / Rectifier Location
Relays
Replacement
Replacement Keys
Reprogramming Authorization
Right Side Seat Panel
Removal / Installation
Rocker Panels
Left Removal / Installation
Right Removal / Installation
ROPS
Front Tube Removal / Installation
Side Bolsters
ROPS / Body Assembly Views
Floorboards Overhead View
Floorboards Rear View
Floorboards View 1
Floorboards View 2
Front Bumper / Instrument Panel
Front Cab / Storage Box
Rear Bumper / Storage Box View 1
Rear Bumper / Storage Box View 2
ROPS
s
Seat Belt
Seat Belt Assembly
Seat Side Panels
Sensor
Setting TDC
TDC
Shift Lever, Installation
Shift Lever, Removal
Shift Weights
Shocks Pre-Load Adjustment
Shocks / Springs Rear
Software Version
Solenoid Rear Differential (INT’L)
Spark Arrestor Service
Spark Plug Service
Special Tools
ACE
Steering / Suspension
Electrical
Engine
Final Drive
Push Rivet Removal Tool
PVT/Clutching
Special Tools, Body / Frame
Special Tools, Brakes
Special Tools, EFI
Specification
Wheel Toe-Out
Specifications
Camshaft
Cooling System
Cylinder Head Warp
Engine Lubrication
Engine Oil Pressure
Final Drive Torque Values
Front Gearcase Lubrication Type/Capacity
Transmission and Front Gearcase
Valve Seat Contact Width
Valve Spring
Valve Stem Diameter
Valve Stem Guide I D
Specifications, Transmission
Speed Sensor
Standard Bolt Torque Specification
Starter Drive, Removal
Starter Motor
Installation
Removal
Starter Solenoid
Operation
Test
Starter System
Troubleshooting
Stator Cover / Flywheel Removal
Stator Cover Oil Seal Inspection
Stator Installation
Stator Removal
Stator Tests
Steering
Inspection
Steering Assembly
Domestic
Steering Shaft Service
Steering Wheel Freeplay
Sway Bar Service
Switch
AWD/2WD
Brake Light
Gear Position
Hazard (INT’L)
Parking Brake (INT’L)
Turn Signal (INT”L)
T
T-MAP
Tail Lights
Taillamp Bulb Replacement
Tap/Drill Sizes
Tappet Selection Matrix
Exhaust
Intake
Terminal Block
Overview
Test
Thermostat Inspection / Replacement
Throttle Cable Service
Throttle Pedal Cable Adjustment
Throttle Pedal Cable Routing
Throttle Position Sensor
Throttle Position Sensor (TPS)
Tie Rod End Inspection
Tire Inspection
Pressure
TMAP Sensor
Testing
Toe Adjustment
Torque Specification
Crank / Balance Shaft / Cam Chain Guides
Torque Specifications
Body
Cam / Cam Chain / Cam Chain Tensioner
Clutching
Engine / Transmission Bracket
Engine Mounting
Spark Plug / Starter / Throttle Body / Valve
Cover
Steering / Suspension
Wheel and Hub
Torque Specifications, Brakes
Torque Values
Transmission Mounting
TPS
TPS Replacement
TPS Resistance Testing
TPS Tester
Transmission
Assembly View
International
Assembly View
Lubrication
Transmission Disassembly
Transmission Disassembly (INTL)
Transmission Gear Cluster Disassembly
Transmission Gear Cluster Disassembly (INTL)
Transmission Installation
Transmission Removal
Transmission Switch
Transmission, Assembly
Transmission, Assembly (INTL)
Transmission, Output Shaft Backlash (INTL)
Transmission, Output Shaft Backlash Procedure
Transmission, Snorkel Shaft Removal
Transmission, Snorkel Shaft Removal (INTL)
Transmission, Troubleshooting
Troubleshooting
Clutching
Cooling System
Engine
Engine / Cooling System
Front Gearcase (NON-ADC)
Troubleshooting, Brake Noise
Troubleshooting, Brake System
Troubleshooting, Transmission
Turn Signal Switch (INT’L)
u
U-joint
Disassembly and Assembly
V
Valve Clearance Adjustment
Valve Clearance Inspection
Valve Cover Installation
Removal
Valve Cover Inspection
Valve Sealing Test
Valve Seat Reconditioning
Valve Spring Removal
Vehicle Identification
Vehicle Identification Number (VIN)
Version, Software
Voltage Drop Test
w
Water Pump Service
Wheel Installation
Removal
Wheel Alignment
