2014-2016 Polaris ACE Service Manual PDF – 325 570 900 Repair Guide

Description

2014-2016 Polaris ACE Service Manual PDF

This 2014-2016 Polaris ACE Service Manual PDF is the complete workshop repair guide for every ACE and Sportsman ACE built from 2014 through 2016. Published under part number 9926804 R03 and revised in June 2018, it covers the 325, 570, and 900 ProStar engine platforms across all trim levels, including the base ACE, ACE 570, ACE 570 SP, and ACE 900 SP. Whether you are performing scheduled maintenance, diagnosing an electrical fault, rebuilding a top end, or servicing the transmission and PVT system, this service manual supplies the procedures, torque values, service limits, and illustrations needed to get the job done correctly.

File Details

• Manual Type: Service Manual (Workshop Repair Guide)
• Brand: Polaris
• Models Covered: 2014-2016 ACE / Sportsman ACE
• Engine Platforms: 325, 570, 900
• Language: English
• Page Count: Approximately 727
• File Format: PDF
• Publication Number: 9926804 R03
• Revision: R03 (06/25/2018)

Chapters Covered

• Chapter 1: General Information – Vehicle Identification, Model Number Designation, VIN Designation, Engine Serial Number Locations, Model Specifications, Publication Part Numbers, Replacement Keys, Special Tools, Conversion Table
• Chapter 2: Maintenance – Periodic Maintenance, Break-In Period, Maintenance Interval Chart, Grease Lubrication Points, Pre-Ride Inspections, Engine Oil and Filter Change, Valve Clearance Inspection, Spark Plug Service, Transmission and Front Gearcase Lubrication, Cooling System Service, Battery Maintenance, Steering Inspection, Wheel and Tire Service
• Chapter 3: Engine / Lubrication / Cooling – ACE – Engine Specifications, Oil Pressure Test, Engine Removal and Installation, Top-End Service, Camshaft / Carrier Removal, Cylinder Head Disassembly and Inspection, Piston and Connecting Rod, Lower End Disassembly, Crankcase Assembly, Cooling System, Water Pump Service, Exhaust System
• Chapter 4: Fuel System – EFI Component Locations, Air Box / Intake System, Electronic Control Unit (ECU), Fuel Tank / Pump / Sender, Electronic Throttle Control, T-MAP Sensor, Crankshaft Position Sensor, Ignition Coil, Fuel Injector, Idle Air Control, Throttle Position Sensor, Pedal Position Sensor, EFI Diagnostics, Digital Wrench Operation
• Chapter 5: PVT System – Drive Belt Service, PVT Disassembly and Assembly, Drive Clutch Service, Driven Clutch Service, Driven Clutch (EBS) Service, Troubleshooting
• Chapter 6: Transmission – Specifications, Torque Values, Shift Lever, Transmission Removal and Installation, Transmission Disassembly, Differential Operation, Planetary Differential Service, Gear / Shaft / Bearing Inspection, Transmission Assembly
• Chapter 7: Final Drive – Front Hub, Front Drive Shafts, Front Gearcase, Rear Bearing Carriers, Rear Drive Shafts, CV Joint / Boot Replacement, Prop Shaft Service, U-Joint Service
• Chapter 8: Steering / Suspension – Front Suspension Assembly, Rear Suspension Assembly, Steering Service, Electronic Power Steering (EPS) Service, Front and Rear Suspension Service, Shocks / Springs
• Chapter 9: Brake System – Brake Pedal, Master Cylinder, Brake Bleeding and Fluid Change, Front Brake Pads / Caliper / Disc, Rear Brake Pads / Caliper / Disc, Parking Brake (International Models), Brake System Troubleshooting
• Chapter 10: Body / Frame – ROPS Assembly, Doors, Front Cab / Storage Box, Front Bumper / Instrument Panel, Floorboards, Rear Bumper / Storage Box, Seat and Seat Belt, Engine Compartment Panel, Side Seat Panels, Rocker Panels, Instrument Cluster Pod, Main Frame
• Chapter 11: Electrical – Electrical Diagnostics, Static and Dynamic Testing, Vehicle Speed Sensor, Instrument Cluster, Switches and Controls, Differential Solenoid, AWD Coil, Headlights, Tail / Brake Lights, Cooling Fan, Fuse Box / Relays / Circuit Breaker, Diodes, Charging System, Battery, Starting System, Electrical System Breakouts and Wiring Diagrams

Across these eleven chapters, the manual walks through the entire machine from front to back. It starts with model identification and specification tables so you can confirm exactly which variant you are working on, then moves into routine maintenance schedules and fluid capacities. The engine chapters cover both top-end and bottom-end teardown with torque sequences, valve clearance adjustment, tappet selection matrices, cylinder honing, and crankshaft bearing selection. The fuel and electrical chapters support full EFI diagnosis, sensor testing, and ECU reprogramming through Digital Wrench. The driveline chapters detail the PVT clutches, transmission internals, front gearcase operation, and CV joint servicing. Suspension, steering, and brake chapters provide the procedures and torque values needed for rebuilds and replacements. Throughout the manual, exploded component views, wiring breakout diagrams, and specification tables make it possible to identify every part, torque value, and service limit without guesswork.

Vehicles Covered

This service manual covers the full 2014-2016 Polaris ACE family:

• 2014 Sportsman ACE – 325cc ProStar single cylinder, 4-cycle, DOHC
• 2015 Sportsman ACE – 325cc ProStar single cylinder, 4-cycle, DOHC
• 2015 Sportsman ACE 570 – 567cc single cylinder, 4-cycle, DOHC
• 2015 Sportsman ACE 570 SP – 567cc single cylinder, 4-cycle, DOHC
• 2016 ACE – 325cc ProStar single cylinder, 4-cycle, DOHC
• 2016 ACE 570 – 567cc single cylinder, 4-cycle, DOHC
• 2016 ACE 570 SP – 567cc single cylinder, 4-cycle, DOHC
• 2016 ACE 900 SP – 875cc twin cylinder, 4-cycle, DOHC

Both domestic and international variants are covered, including differences for the international parking brake and differential lock configuration. Engine serial number locations, VIN designations, and model number breakdowns for each year are documented in the General Information chapter.

What This Service Manual Enables You To Do

With this 2014-2016 Polaris ACE repair guide on hand, you can perform the same procedures a factory-trained technician would follow. That includes scheduled maintenance items like oil and filter changes, valve clearance checks, coolant service, brake fluid changes, and lubrication of the A-arm and control-arm pivot points. It also covers the more involved jobs: top-end engine rebuilds with cylinder honing and piston ring installation, camshaft timing and valve shim selection, crankshaft and balance shaft service, transmission teardown with snorkel gear backlash adjustment, PVT clutch disassembly and bushing replacement, front gearcase service with ring gear backlash setting, and full electrical troubleshooting with the diagnostic trouble code chart and wiring breakouts.

Correct procedures and accurate specifications are critical on machines like the ACE. A valve clearance set to the wrong specification, a cylinder head torqued out of sequence, or a clutch reassembled without the limiter spacer can all lead to premature failure and expensive repairs. This manual provides the exact torque values, service limits, and adjustment procedures that Polaris specifies for each engine and model year, so you are not relying on guesswork or generic advice. Whether you are a professional technician or a hands-on owner doing your own maintenance, having the correct information in front of you saves time, prevents mistakes, and helps keep the machine running reliably.

This 2014-2016 Polaris ACE Service Manual PDF is delivered as an instant digital download after purchase. There is no shipping, no waiting, and no physical book to keep track of. The PDF can be viewed on any computer, laptop, tablet, or smartphone, and individual pages or sections can be printed whenever you need a paper copy. Whether you are working in the shop, the garage, or the field, the manual is available on the device you already have with you.