Polaris ACE 900 SP User manual

PMS 419
Failure to heed the warnings and safety precautions
contained in this manual can result in severe injury or death.
Read this manual carefully.
POLARIS ACE 900 SP
™
Owner's Manual
for Maintenance and Safety

WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.

1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Review the
safety DVD that came with your vehicle. POLARIS also recommends
that all drivers take the ROHVA safety e-course and a ROHVA hands-on
safety training course. Visit www.rohva.org or call 866-267-2751.
Your manual contains instructions for minor maintenance, but
information about major repairs is outlined in the POLARIS Service
Manual and can be performed by a factory certified Master Service
Dealer® (MSD) Technician.
Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Your POLARIS dealership can provide for all of your
service needs during, and after, the warranty period.
• Snowmobiles • RZR®sport vehicles
• All-terrain vehicles (ATVs) • GEM® electric vehicles
• Low emission vehicles (LEVs) • VICTORY® motorcycles
•RANGER®utility vehicles • INDIAN® motorcycles
•BRUTUS®work vehicles • POLARIS POWER® generators
• SLINGSHOT® three wheel
motorcycles • POLARIS DEFENSE® combat vehicles

2
POLARIS® and POLARIS ACE™ are trademarks of POLARIS Industries Inc.
Copyright 2015 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. 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.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2016 POLARIS ACE 900 SP Owner’s Manual
P/N 9926082

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Emission Control Systems . . . . . . . . . . . . . . . 74
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 120
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 122
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 123
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4
INTRODUCTION
This POLARIS vehicle is an off-road vehicle. Familiarize yourself with
all laws and regulations concerning the operation of this vehicle in your
area.
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and
symbols are used. Become familiar with their meanings before reading
the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5
INTRODUCTION
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your local
POLARIS dealer. Understand all safety warnings, precautions and operating
procedures before operating the vehicle. Keep this manual with the vehicle.
• Never operate this vehicle without proper instruction. Take an authorized
training course. Visit www.rohva.org or call 866-267-2751.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and
have a valid driver’s license to operate this vehicle.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the New Operator Driving Procedures outlined on pages 51-52.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.
• Never permit a guest to operate this vehicle unless the guest has reviewed the
owner’s manual and all safety labels and has completed a safety training
course.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as
indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many
factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING

6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Vehicle Identification Number (VIN): _________________________________________
Engine Serial Number: ___________________________________________________
Key Number____________________________________________________________
Engine Serial
Number
VIN
(Right Front Frame)

7
SAFETY
Safety Training
Safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding this vehicle
to take a training course.
ROHVA (Recreational Off-Highway Vehicle Association) provides both
an online safety e-course and a hands-on safety course. Visit
www.rohva.org or call 866-267-2751.
Your POLARIS vehicle is considered an off-road vehicle. Familiarize
yourself with all laws and regulations concerning the operation of this
vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your
vehicle are thoroughly inspected at specific intervals.
For more information about recreational off-road vehicle safety in
the United States, visit www.rohva.org, call 866-267-2751 or call
POLARIS at 800-342-3764.

8
SAFETY
Safe Riding Gear
Always wear helmet, eye protection, gloves, long-sleeve shirt, long
pants, over-the-ankle boots and seat belt at all times. Protective gear
reduces the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada bear a
U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial number will also be
displayed on the label.
E
4
051039
0006.31
Helmet
Eye Protection
Gloves
Over-the-Ankle
Boots
Long Pants
Long
Sleeves

9
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this POLARIS vehicle, always wear shatterproof
goggles or use a shatterproof helmet face shield. POLARIS
recommends wearing approved Personal Protective Equipment (PPE)
bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure
protective eye wear is kept clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and
other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never ride
a POLARIS vehicle with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the rider cab area. The
condition occurs most frequently when a vehicle is being operated in
high ambient temperatures at low speeds and/or high load conditions for
an extended period of time. The use of certain windshield, roof and/or
cab systems may contribute to this condition by restricting airflow. Any
discomfort due to heat buildup in this area can be minimized by wearing
proper riding apparel and by varying speeds to increase airflow.

10
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.
If an informational or graphic label becomes illegible or comes off,
contact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
Maximum Payload Warning
WARNING
Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg).
7181835
General Warning Maximum Payload
Warning

11
SAFETY
Safety Labels and Locations
General Warning
WARNING
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid
driver’s license.
• Do not let people drive after using alcohol or drugs.
• Do not allow operation on public roads (unless
designated for off-highway vehicle access) - collisions with cars and trucks can
occur.
• Do not exceed seating capacity: 1 occupant.
Improper vehicle use can result in SEVERE INJURY or DEATH
Be Prepared
• Fasten seat belt.
• Wear an approved helmet and protective gear.
• ALWAYS use vehicle cab nets and/or doors.
• Driver must be able to sit with back against seat, feet flat on
the floor, and hands on steering wheel. Stay completely
inside the vehicle.
Drive Responsibly
Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways sliding,
skidding or fishtailing, and never do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when turning, even
from a stop.
• Plan for hills, rough terrain, ruts and other
changes in traction and terrain.
• Avoid paved surfaces.
• Avoid sidehilling (riding across slopes).
Be Sure to Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
• Keep a firm grip on the steering wheel and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA
TRAINING (rohva.org). 7180534
Rollovers have caused
severe injuries and death,
even on flat, open areas.

12
SAFETY
Safety Labels and Locations
Load/Passenger/Tire Pressure Warning
WARNING
• Never carry passengers in cargo box.
• Passengers can be thrown off. This can cause serious injury or death.
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
• Reduce speed and allow greater distance for braking when carrying cargo.
• Overloading or carrying tall, off-center, or unsecured loads will increase your
risk of losing control. Loads should be centered and carried as low as
possible in box.
• For stability on rough or hilly terrain, reduce speed and cargo.
7183192
Hitch Capacity Label
TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15 DEGREES
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG) 7170509
ACE
MAXIMUM CARGO BOX LOAD 240 lbs.
(108 kg)
TIRE PRESSURE IN PSI (KPa) FRONT 10 (69)
REAR 10 (69)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF OPERATOR, CARGO AND
ACCESSORIES
575 lbs.
(260 kg)
Read Operation and Maintenance Manual for more detailed loading information.
Load/Passenger/Tire
Pressure Warning Fuel Transport Warning

13
SAFETY
Safety Labels and Locations
Fuel Transport Warning
WARNING
Before transporting flammable liquids in this vehicle,
ALWAYS read your Owner’s Manual.
• Always use containers designed for off-road vehicles.
• Inspect containers for wear, cracks, and leaks before
each ride.
• Always make sure containers are firmly secured to
avoid spills and damage.
Failure to follow proper instructions could lead to burn
injury and other potential fire hazards. 7182513
PVT System Warning
WARNING
Improper service or maintenance of this PVT
system can result in vehicle damage,
SEVERE INJURY or DEATH.
Always look for and remove debris inside and
around clutch and vent system when
replacing belt.
Read owner's manual or see authorized
Polaris dealer. 7177469
Air Box Caution
CAUTION
Use a Polaris approved air filter. The
use of a non-Polaris approved air filter
may cause engine damage. Before
installing filter, ensure there is no dirt or
debris in the clean side of the intake
tube. The air filter must be properly
seated before the lid is reinstalled.
Please reference your owner’s manual
for additional information regarding air
filter service. 7182652
PVT System Warning
Air Box
Caution

14
SAFETY
Safety Warnings
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. See the OPERATION section of the owner’s manual
for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain. Complete the New Operator
Driving Procedures outlined on pages 51-52.
All operators must read and understand the
owner's manual and all warning and instruction
labels before operating the vehicle. Never allow a
guest to operate this vehicle until the guest has
completed the New Operator Driving Procedures
outlined on pages 51-52.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16 years
of age or anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and
both hands on the steering wheel.
Using Alcohol or Drugs
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
WARNING

15
SAFETY
Safety Warnings
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle
is in safe operating condition before
operating increases the risk of an accident.
Always perform the pre-ride inspection
before each use of your vehicle to make
sure it's in safe operating condition. See
page 46.
Always follow the inspection and
maintenance procedures and schedules
described in this owner’s manual. See
page 75.
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in the
event of an accident.
Always wear a helmet, eye protection,
gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of rollover, loss of control, other accident or sudden stop. Seat
belts may reduce the severity of injury in these circumstances.
The operator MUST wear the seat belt at all times.
Cab Doors
Riding in this vehicle without closed and latched cab doors increases the risk of
serious injury or death in the event of an accident or rollover. Always make sure
all cab doors are closed and latched while riding in this vehicle. Cab doors are
NOT intended to be used as arm rests. Always keep hands and feet inside the
vehicle at all times.

16
SAFETY
Safety Warnings
Carrying a Passenger
This POLARIS vehicle is a single-rider
vehicle. Carrying a passenger greatly
reduces the operator's ability to control
the vehicle, which may result in an
accident or rollover. Carrying a
passenger in the cargo box could result
in a fall from the vehicle or contact with
moving components. Never carry a
passenger on this vehicle.
Operating With a Load on the Vehicle
The weight of both cargo and operator impacts vehicle operation and stability.
For your safety and the safety of others, carefully consider how your vehicle is
loaded and how to safely operate the vehicle. Follow the instructions in this
manual for loading, tire pressure, gear selection and speed.
•Do not exceed vehicle weight capacities. The vehicle’s maximum weight
capacity is listed in the specifications section of this manual and on a label on
the vehicle. When determining the weight you are adding to the vehicle,
include the weight of the operator, accessories, loads in the rack or box and
the load on the trailer tongue. The combined weight of these items must not
exceed the maximum weight capacity.
• The recommended tire pressures are listed in the specifications section of this
manual and on a label on the vehicle.
Always follow these guidelines:
Under ANY of these conditions: Do ALL of these steps:
Operator and/or cargo exceeds half the
maximum weight capacity 1. Slow down.
2. Verify tire pressure.
3. Use extra caution when
operating.
Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing

17
SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this vehicle with improper tires or
with improper or uneven tire pressure could
cause loss of control or accident.
Always use the size and type of tires specified
for your vehicle.
Always maintain proper tire pressure as
described in the owner's manual and on safety
labels.
Operating on Pavement
This vehicle's tires are designed for off-road
use only, not for use on pavement. Operating
this vehicle on paved surfaces (including
sidewalks, paths, parking lots and driveways)
may adversely affect the handling of the
vehicle and may increase the risk of loss of
control and accident or rollover. Avoid
operating the vehicle on pavement. If it's
unavoidable, travel slowly, travel short
distances and avoid sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets,
roads or highways could result in a collision
with another vehicle. Never operate this
vehicle on any public street, road or highway,
including dirt and gravel roads (unless
designated for off-highway use).
Operating at Excessive Speeds
Operating this vehicle at excessive speeds
increases the operator's risk of losing
control. Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions and your skills and
experience.

18
SAFETY
Safety Warnings
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this
owner’s manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
Jumps and Stunts
Exhibition driving increases the risk of an
accident or rollover. DO NOT do power slides,
“donuts”, jumps or other driving stunts. Avoid
exhibition driving.
Improper Hill Climbing
Improper hill climbing could cause loss of
control or rollover. Use extreme caution when
operating on hills. Always follow proper
procedures for hill climbing as described in this
owner's manual. See page 54.
Descending Hills Improperly
Improperly descending a hill could cause loss
of control or rollover. Always follow proper
procedures for traveling down hills as
described in this owner’s manual. See page
56.