Polaris ACE 150 EFI (2019) Owner's Manual

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2019

Owner’s MAnual

POLARIS ACE® 150 EFI

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

Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of California

to cause cancer and birth defects or other reproductive harm. To minimize

exposure, avoid breathing exhaust, do not idle the engine expect as

necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

2019 Owner’s Manual

ACE 150 EFI

IMPORTANT SAFETY INFORMATION

Scan this QR code with your smartphone to see an

important Safety Video regarding your Polaris ACE vehicle.

This safety video can also be found at

http://www.polaris.com/en-us/rider-support/safety. If you are

on the homepage of the Polaris website, click on the Rider

Community heading and select “Product Safety and Training

Information” from the dropdown menu to access this page.

POLARIS®, ACE™, OUTLAW®, and SPORTSMAN® are trademarks of POLARIS Industries Inc.

Copyright 2018 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 China 9929351

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.

• Snowmobiles

• SPORTSMAN® All-terrain vehicles

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• BRUTUS® work vehicles

• SLINGSHOT® three wheel motorcycles

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, making it the finest machine we’ve ever produced.

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.

• RZR® sport vehicles

• GEM® vehicles

• INDIAN® motorcycles

• POLARIS POWER® generators

• POLARIS DEFENSE® combat vehicles

• Timbersled® Snow Bikes

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 perform all of your service needs during, and after, the warranty period.

WELCOME

Introduction . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . 13

Features and Controls . . . . . . . . . . . . . . 27

Operation . . . . . . . . . . . . . . . . . . . . 41

Emission Control Systems . . . . . . . . . . . . . 55

Maintenance . . . . . . . . . . . . . . . . . . 57

Specifications . . . . . . . . . . . . . . . . . . 99

POLARIS Products . . . . . . . . . . . . . . . . 101

Troubleshooting . . . . . . . . . . . . . . . . . 103

Warranty . . . . . . . . . . . . . . . . . . . . 107

Maintenance Log . . . . . . . . . . . . . . . . 111

INTRODUCTION

LETTER TO PARENTS

We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We encourage you to teach your children to ride safely, and to help ensure the future of recreational sports, please teach them to show respect for our environment and for the rights of others while operating the vehicle.

This vehicle is not a toy and can be hazardous to operate. We've provided this owner’s manual and an instructional video to help you and your children learn about the safe operation and care of your new POLARIS vehicle. Before your children drive or ride in the vehicle, please read and make sure they read this owner’s manual. Watch the instructional video with them. Make sure all

operators and passengers understand and follow all of the instructions and warnings contained in this owner’s manual and video. Make sure they

understand that the vehicle must be used under adult supervision at all times.

After reading this owner’s manual and watching the video, help your child practice the steps in the New Operator Driving Procedures section.

Never allow a child under age 10 to operate or ride as a passenger in this vehicle. Children differ in skills, physical abilities and judgement. Please

supervise the use of the vehicle at all times. Permit continued use only if you determine that your child has the ability and maturity to operate safely.

For your child’s safety, be sure your child can reach and operate all ACE 150 controls, including steering wheel, accelerator and brake pedals, and ignition switch. Make sure your child is not too tall to ride safely in this vehicle. See the Age Restrictions section.

The vehicle’s speed control system allows adults to limit vehicle speed for new and inexperienced operators. Please see the Speed Control System section for more information.

The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's vehicle are thoroughly inspected at specific intervals. Always follow all of the instructions and recommendations in this manual to ensure the vehicle remains in safe operating condition at all times.

This POLARIS vehicle is not designed for adult use. Serious damage may occur if the maximum weight capacity is exceeded. Refer to vehicle labels and to the Specifications section for the maximum weight capacity.

INTRODUCTION

LETTER TO YOUNG OPERATORS

Before you ride your new POLARIS vehicle, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you're riding.

Your parents and POLARIS want you to be safe while you enjoy riding your new vehicle, and that's why it’s very important that you read this owner’s manual and watch the instructional video. Make sure you understand and follow all of the instructions and warnings in this owner’s manual and video. Ask your parents to explain anything you don't understand.

Your safety and the safety of others is the most important thing to think about at all times. Pay attention when you see this symbol:

IMPORTANT

This is the safety alert symbol. When you see this symbol on your vehicle or in

this manual it means PAY ATTENTION because you could die or be seriously

injured if you don't follow the instructions.

After reading this owner’s manual and watching the video, complete the steps in the New Operator Driving Procedures section. Show your parent that you understand how to drive safely.

Enjoy riding your new POLARIS vehicle!

INTRODUCTION

SAFETY SYMBOLS AND SIGNAL WORDS

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.

DANGER

DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING

SAFETY ALERT WARNING indicates a hazardous situation which, if not

avoided, COULD result in serious injury.

CAUTION

SAFETY ALERT CAUTION indicates a hazardous situation which, if not

avoided, COULD result in minor to moderate injury.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle

damage or property damage.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

NOTICE

NOTICE provides key information by clarifying instructions.

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.

INTRODUCTION

WARNING

Failure to follow 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.

• Never operate this vehicle without proper instruction. All operators and supervising adults must watch the instructional video that was provided with the vehicle. 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.

• For your child’s safety, be sure your child can reach and operate all ACE 150 controls, including steering wheel, accelerator and brake pedals, and ignition switch. All operators must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel.

• Always follow the age guidelines for your vehicle. Operation is prohibited for anyone under age 10. Never operate with a passenger under age 10.

• 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.

• Complete all steps in the New Operator Driving Procedures section of this manual. Never allow a guest to operate this vehicle until the guest has watched the instructional video and has completed the New Operator Driving Procedures.

• Passengers are prohibited at all times. Never allow someone other than the current driver to occupy this vehicle.

DECLARATION OF CONFORMITY

Polaris Sales Europe Sàrl Place de l’Industrie 2 1180 Rolle, Switzerland Telephone +41213–218–700

DECLARATION OF CONFORMITY

Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements to all terrain vehicles.

INTRODUCTION

APPLICABLE EUROPEAN

DIRECTIVES

2006/42/EC as amended

(Machinery Directive)

2004/108/EC as amended

(EMC Directive)

MODEL COMMERCIAL NAME VEHICLE SERIAL

A_ _HA_15_ _

(All combinations)

ACE 150 (See Product

TEST / EVALUATION METHODS:

EN ISO 12100:2010 Hazard Analysis

EN 15997: 2011/AC: 2012

Driver Perceived Noise Level &

Vibration

UNECE R10

NUMBER

Identification Label)

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 Identification Number

(LH rear wheel well)

Key Number

Vehicle Model Number:

Engine Serial Number

Vehicle Identification Number (VIN):

Engine Serial Number:

Key Number

SAFETY

SAFE RIDING GEAR

Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, overthe-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury.

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.

Helmet

Eye Protection

Long Sleeves

Gloves

Long Pants

Over-the-Ankle Boots

CLOTHING

Wear long sleeves and long pants to protect arms and legs.

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. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.

Parents should verify that young operators have a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.

SAFETY

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.

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.

SAFETY

SAFETY WARNINGS

WARNING

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.

Be sure to read all of the following warnings about driving hazards and how to

avoid them. These warnings are provided for your child's safety. Be sure to

explain to your young driver that the hazards outlined in this section of this

owner’s manual MUST be avoided at all times. See the OPERATION section

of this owner’s manual for proper operating procedures.

FOR MORE INFORMATION ABOUT SAFETYcall POLARIS at 1–800–342–

3764.

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.

All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle.

All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www.rohva.org).

AGE RESTRICTIONS

This vehicle is for recreational use by young operators under adult supervision ONLY.

Operation is prohibited for anyone under age 10. Operators must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel.

SAFETY

RIDER HEIGHT

Some riders may be too tall to ride safely in this vehicle. Do not operate or ride in this vehicle if the clearance between the top of your helmet and the overhead cab frame is less than 2 inches (5 cm).

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. Operators must wear seat belts at all times. Always make sure the seat belt is secured for the operator before riding.

PASSENGERS

Passengers are prohibited on this vehicle. Never carry passengers in the vehicle cab or in the cargo box. Passengers can be thrown off. This can cause serious injury or death.

FAILURE TO INSPECT BEFORE OPERATING

WARNING

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.

Always follow the inspection and maintenance procedures and schedules described in this manual and your Vehicle Manual.

SAFETY

PROTECTIVE APPAREL

Riding in this vehicle without wearing an approved helmet and protective eye wear 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.

CAB NETS

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and

feet inside the vehicle at all times.

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.

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.

SAFETY

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.

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.

PHYSICAL CONTROL OF THE VEHICLE

Removing hands from the steering wheel or removing feet from the floor while riding increases the risk of loss of control and accident or rollover.

The operator should always keep both hands on the steering wheel during operation.

Always keep hands and feet inside the vehicle at all times.

SAFETY

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.

DRIVING DOWNHILL IMPROPERLY

Driving down a hill improperly could cause loss of control or rollover. Always follow proper procedures for driving down a hill as described in this owner’s manual.

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. Never operate the vehicle on hills steeper than 15 degrees.

CROSSING HILLSIDES

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual.

STALLING WHILE CLIMBING A HILL

Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

SAFETY

OPERATING IN UNFAMILIAR TERRAIN

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

OPERATING ON SAND OR SLIPPERY TERRAIN

Operating on sand or on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover.

Always use extra caution when operating on sand or on rough, slippery or loose terrain. Do not operate on excessively rough, slippery or loose terrain.

OPERATING IMPROPERLY IN REVERSE

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual.

Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

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.

SAFETY

OPERATING OVER OBSTACLES

Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

OVERLOADING THE VEHICLE

Overloading the vehicle or carrying/towing loads may cause changes in stability and handling, which could cause loss of control or an accident.

• Never tow objects or carry loads with this vehicle.

• Never exceed the maximum weight capacity for this vehicle.

OPERATING A DAMAGED VEHICLE

Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems.

OPERATING ON FROZEN BODIES OF WATER

Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

SAFETY

REFUELING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

• Never carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

EXPOSURE TO EXHAUST

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.

HOT EXHAUST SYSTEMS

WARNING

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush and other tall ground cover. Promptly remove any grass or debris clinging to the vehicle.

UNAUTHORIZED USE OF THE VEHICLE

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 10 or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.

SAFETY

EQUIPMENT MODIFICATIONS

Your POLARIS vehicle is designed to provide safe operation when used as directed.

WARNING

Modifying this vehicle in any way can change the top speed, stability and

handling performance of this vehicle. Modifications that increase speed,

decrease stability or change performance may present a greater risk to

inexperienced or younger operators and could result in loss of control and

serious injury or death. Use only POLARIS-approved accessories to modify

this vehicle. Review all vehicle changes with your child prior to operating.

The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS-approved equipment and/or modifications have been added to the vehicle that increase speed or power.

SAFETY

SAFETY LABELS AND LOCATIONS

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown 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.

Dash Warning Label

Rear Warning Label

SAFETY

DASH WARNING LABEL (7186510)

WARNING

• Operation of this vehicle by children under age 10 increases the risk of severe injury or death.

• Adult supervision required for children under age 16.

• NEVER permit children under age 10 to operate in this vehicle.

General Alert

• Read the owner’s manual.

• Always wear seat belts.

• Always use cab nets or doors.

• Wear approved helmet, goggles, and protective clothing.

• Never allow anyone under 10 years of age to operate this vehicle.

• Never use alcohol or drugs before or while driving or riding.

• Do not allow operation on public roads (unless designated for off-highway vehicle access).

• Exhibition driving increases the risk of accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.

• Always follow proper operating procedures.

• Never exceed seating capacity.

• Do not operate vehicle on grades exceeding 15 degrees of incline.

SAFETY

REAR WARNING LABEL (7191281)

WARNING

• Passengers are prohibited on this vehicle.

• Read the owner’s manual.

• Never carry fuel on this vehicle.

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 or injury. Loads should be centered and carried as low as possible in box.

• For stability on rough or hilly terrain, reduce speed and cargo.

ACE 150

MAXIMUM CARGO BOX LOAD

TIRE PRESSURE IN KPa (bar)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, CARGO, AND ACCESSORIES

22 kg (50 lbs)

FRONT – 20.7 (3)

REAR – 41.4 (6)

104 kg (230 lbs)

FEATURES AND CONTROLS

COMPONENT LOCATIONS

Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by the operator at all times. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized POLARIS dealer. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets.

Seat Belt

Fuel Tank Cap (LH side)

Dash

Parking Brake

Shifter

Hip Bar

FEATURES AND CONTROLS

Cab Frame

Steering Wheel

Running Lights

Brush Guard

Muffler (Spark Arrester)

FEATURES AND CONTROLS

SEATS

DRIVER’S SEAT ADJUSTMENT

1. Lift the seat latch lever under the right front edge of the driver’s seat.

2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever.

3. Slide the seat forward and rearward to ensure the latch is engaged. Before operating the vehicle, always make sure the seat is securely installed.

located

SEAT REMOVAL

1. To remove the driver’s seat, lift the seat latch lever.

2. While holding the lever upward, slide the seat completely forward, remove 10mm bolts, and remove seat from the seat mounting rails.

3. Before operating the vehicle, always make sure the driver’s seat is installed and securely latched.

FEATURES AND CONTROLS

STEERING WHEEL

The steering wheel can be adjusted upward or downward for rider preference.

1. Loosen and remove the steering wheel adjustment bolt

2. Move steering wheel upward or downward to the desired position by aligning the mounting holes.

3. Tighten bolt to 13.5 Nm (10 ft-lbs).

Ensure bolt is fully tightened prior to operating the vehicle.

CAUTION

SEAT BELTS

This POLARIS vehicle is equipped with three-point lap and diagonal seat belt for the operator. Always make sure the seat belt are secured for the operator before riding. The driver’s seat belt is equipped with an interlock. Vehicle speed will be limited if the seat belt is not secured.

FASTENING THE SEAT BELT

To wear the seat belt properly, follow this procedure:

1. Pull the seat belt latch and across your chest toward the buckle seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self-tighten.

at the inner edge of the

downward

4. Press the red release latch on the buckle to release the seat belt.

FEATURES AND CONTROLS

SHOULDER STRAP POSITION ADJUSTMENT

The position of the shoulder strap can be adjusted to the height of the operator. Have an adult relocate the mounting bolt making sure the nut and bolt are tightened securely. Nut and bolt should be tightened to 40.6 Nm (30 ft-lbs).

to a different position,

SEAT BELT INSPECTION

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents.

FEATURES AND CONTROLS

CAB NETS

Riding in this vehicle without using the cab nets (or doors) increases the risk of serious injury or death in the event of an accident or rollover.

Screw

Adjusters / Latches

Cab nets must be used by the operator at all times. Make sure all latches are secure before operating the vehicle.

Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized dealer.

FUEL CAP

WARNING

Never allow a child to refuel or handle gasoline.

The fuel tank filler cap the left-hand side of the vehicle.

Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See the POLARIS Products chapter for part numbers.

is located on

When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Non-ethanol fuel is recommended. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

IGNITION SWITCH

The ignition switchqis a threeposition, key-operated switch. Use the ignition switch to start the engine. See the Starting the Engine section for starting procedures.

The key can be removed from the switch when it is in the OFF position.

OFF ON START

FEATURES AND CONTROLS

The engine is off. Electrical circuits are off, except accessory 12V.

Electrical circuits are on. Electrical equipment can be used.

Turn the key to the START position to engage the electric starter. The key returns to the ON position when released.

FEATURES AND CONTROLS

GEAR SELECTOR

F: Forward

N: Neutral

R: Reverse

The gear selector is located on the side of the seat. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

TIP

Maintaining shift linkage adjustment is important to assure proper transmission

function. Your authorized dealer can assist in resolving any shifting problems.

NOTICE

Do not attempt to shift the transmission while the vehicle is moving or damage

to the transmission could result. Always shift when the vehicle is stationary and

the engine is at idle.

FEATURES AND CONTROLS

BRAKE PEDAL

Depress the brake pedalqto slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.

1. Turn the ignition switch to the LIGHTS ON position.

2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.

THROTTLE PEDAL

Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.

TIP

If the throttle pedal and brake pedal are applied simultaneously, engine power

may be limited.

WARNING

Never start or operate this vehicle if it has a sticking or improperly operating

throttle pedal. Immediately contact your POLARIS dealer or other qualified

person for service if throttle problems arise.

FEATURES AND CONTROLS

PARKING BRAKE

1. Apply the brakes.

2. When the vehicle is fully stopped, pull the parking brake lever rearward as far as possible to set the parking brake.

3. Stop the engine.

4. To release the parking brake, apply the brakes and push the lever toward the passenger seat and forward.

5. See Parking Brake Adjustment section for details on adjustment.

TIP

Always set the parking brake whenever the vehicle is left unattended.

WARNING

Operating the vehicle while the parking brake is engaged could cause an

accident resulting in serious injury or death. It could also result in driveline or

engine damage. Always be sure to disengage the parking brake before

operating the vehicle.

FEATURES AND CONTROLS

SPEED CONTROL SYSTEM

This vehicle has an adjustable speed control system that controls the speed of the vehicle. The speed of this vehicle is restricted to 16 km/h (10 MPH) at manufacture. The speed limiting device may be adjusted by supervising adults when they determine that their child is capable of safely handling additional speed.

Electronic Speed Control System

Adjust speed modes by moving the jumper fuse between the assigned speed slots inside the fuse box.

JUMPER CONDITION

Speed 1 47 km/h (29 mph)

Speed 2 35 km/h (22 mph)

Speed 3 24 km/h (15 mph)

Speed 4 16 km/h (10 mph)

RESTRICTED MAXIMUM SPEED

OF VEHICLE

FEATURES AND CONTROLS

1. Slide the driver’s seat forward to access the fuse box.

2. Remove the two push rivets from the retention bracket. Remove bracket.

3. Remove the fuse box cover.

FEATURES AND CONTROLS

4. Move the fuse jumper to desired speed mode slot.

5. Replace fuse box cover.

6. Replace fuse box bracket and replace push rivets.

7. Reposition the seat.

OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control,

accident or rollover, which may result in serious injury or death. Read and

understand all safety warnings outlined in the safety section of this owner’s

manual.

VEHICLE BREAK-IN PERIOD

The break-in period for your new POLARIS vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.

No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.

NOTICE

Excessive heat build-up during the first three hours of operation will damage

close-fitted engine parts and drive components. Do not operate at full throttle

or high speeds during the first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine

damage. Always use the recommended oil. Never substitute or mix oil brands.

ENGINE AND DRIVETRAIN BREAK-IN

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle gasoline.

2. Check the oil level. See the Oil Check section for details. Add the recommended oil as needed to maintain the oil level in the safe operating range.

3. Complete all steps listed in the New Operator Driving Procedures section.

4. Avoid aggressive use of the brakes. See the Brake System Break-in section for details.

5. Vary throttle position. Don’t idle extensively.

6. Perform regular checks on fluid levels, controls and areas outlined in the daily Pre-ride Inspection section.

7. Change the engine oil at 5 hours or one month.

8. Adjust/lubricate drive chain at 5 hours or 1 month.

OPERATION

BRAKE SYSTEM BREAK-IN

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

CVT BREAK-IN (CLUTCHES / BELT)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Avoid aggressive acceleration and high speed operation during the break-in period.

OPERATION

PRE-RIDE INSPECTION

WARNING

Failure to inspect and verify that the vehicle is in safe operating condition

before operating increases the risk of an accident. Always inspect the vehicle

before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/pedal travel Ensure proper operation page 35

page 78

Brake fluid Ensure proper level page 79

Front suspension Inspect, lubricate if necessary page 64

Rear suspension Inspect, lubricate if necessary page 64

Steering Ensure free operation page 80

Tires Inspect condition and

pressure

Wheels/fasteners Inspect, ensure fastener

tightness

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil Ensure proper levels page 32

Grass and debris Remove grass and debris

from the vehicle, especially on the underside and near the exhaust system

Throttle Ensure proper operation page 35

Indicator lights/switches Ensure proper operation

page 26 page 83

page 83

page 65

Air filter Inspect and clean or replace page 77

Daytime running lights Ensure proper operation page 85

Brake light Ensure proper operation

Seat Latches Move the seat forward and

rearward to ensure correct installation

page 29

OPERATION

Seat Belts Check length of belt for

damage, check latches for proper operation

page 30

Cab Nets Check for wear or damage,

ensure proper installation

Grass and Leaves Remove grass, leaves, and

other flammable material or debris, especially near the HOT exhaust system.

page 32

page 22

OPERATION

SAFE OPERATION PRACTICES

1. Complete the steps in the New Operator Driving Procedures section.

2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that are designed for driving in these conditions.

3. Never tow objects or carry loads with this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never allow a child to handle gasoline.

5. Never install accessories not approved by POLARIS for use on this vehicle.

6. Ride this vehicle only in areas permitted by a supervising adult. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. DO NOT attempt to do power slides, “donuts”, jumps or other driving stunts. Keep both hands on the steering wheel at all times.

8. Never consume alcohol or drugs before or while operating this vehicle.

9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

10.Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

11. Never operate the vehicle on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

13.Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

STARTING THE ENGINE

1. Sit in the driver’s seat and fasten the seat belt.

2. Secure the cab nets.

3. Place the transmission in neutral. Set the parking brake.

4. Apply the brakes.

5. Do not press the throttle pedal while starting the engine.

OPERATION

6. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

NOTICE

Operating the vehicle immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating the vehicle.

7. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 6 and 7 until the engine starts.

8. Vary the engine RPM slightly with the throttle to aid in warm-up until the engine idles smoothly.

9. Release the parking brake before driving.

STOPPING THE ENGINE

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in NEUTRAL.

3. Set the parking brake.

4. Stop the engine.

BRAKING

1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.

PARKING THE VEHICLE

1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

2. Place the transmission in NEUTRAL.

3. Set the parking brake.

4. Stop the engine.

5. Remove the ignition key to prevent unauthorized use.

OPERATION

DRIVING ON SLIPPERY SURFACES

When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding.

Follow these precautions when driving in slippery conditions:

1. Slow down before entering slippery areas.

2. Be alert, watch the path ahead and avoid quick turns, which can cause skids.

3. Correct a skid by turning the steering wheel in the direction of the skid. Never

apply the brakes during a skid.

OPERATION

NEW OPERATOR DRIVING PROCEDURES

1. Read and understand this owner's manual and all warning and instruction labels before operating this vehicle.

2. Watch the instructional video with the supervising adult.

3. Review the previous sections of this owner’s manual about starting the engine, stopping the engine, braking, and parking.

4. Perform the steps noted in the Pre-Ride Inspection section.

5. The driver must wear a helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times.

6. Do not operate or ride in this vehicle if the clearance between the top of your helmet and the overhead cab frame is less than 2 inches (5 cm).

7. Select a level open area to practice driving. Make sure you have adult supervision and permission to drive in this area.

8. Sit in the driver's seat and fasten the seat belt.

9. Make sure all cab nets are properly secured.

10.Set the parking brake.

11. Place the transmission in neutral.

12.Start the engine.

13.Apply the brakes and shift into gear.

14.Release the parking brake.

15.Check your surroundings. Make sure the area is clear of people and obstacles.

16.Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your right foot to begin driving.

17.Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

18.Increase speed only after mastering all maneuvers at a slow speed.

19.After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

• Avoid sharp turns. Make turns gradually.

• Never turn while applying heavy throttle.

• Never turn the steering wheel abruptly.

• Operate at speeds appropriate for your skills, the conditions and the terrain.

• DO NOT attempt to do power slides, “donuts”, jumps or other driving stunts.

OPERATION

DRIVING UPHILL

Whenever traveling uphill, follow these precautions:

1. Always check the terrain carefully before ascending a hill. Never drive on hills with excessively slippery or loose surfaces.

2. Avoid excessively steep hills (15° maximum).

3. Drive straight uphill.

4. Drive at a steady rate of speed. Never press the throttle suddenly.

5. Avoid unnecessary changes in speed or direction.

6. Never go over the crest of a hill at a high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

7. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to reverse straight downhill while applying the brakes lightly to control speed.

OPERATION

DRIVING ON A SIDEHILL (SIDEHILLING)

Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or rollover.

If crossing a hill is unavoidable, follow these precautions:

1. Drive slowly and use extreme caution.

2. If the vehicle begins to roll over, or if it feels as if it may roll over, immediately turn downhill.

3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.

4. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.

DRIVING DOWNHILL

Whenever driving down a hill, follow these precautions:

1. Avoid excessively steep hills (15° maximum).

2. Slow down. Never travel down a hill at high speed.

3. Always check the terrain carefully before driving down a hill. Never drive on hills with excessively slippery or loose surfaces.

4. Always drive down a hill with the transmission in forward gear. Never “coast”

or drive down a hill with the transmission in neutral.

5. Avoid driving down a hill at an angle, which would cause the vehicle to lean sharply to one side. Always drive straight downhill.

6. Apply the brakes lightly to keep speed slow.

OPERATION

DRIVING THROUGH WATER

Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water:

1. Check water depth. Never drive through water that is deeper than the floor level

2. After driving through water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

NOTICE

Major engine damage can result if the vehicle is not thoroughly inspected after

operation in water. Perform the services outlined in the Periodic Maintenance

Chart section. Give special attention to engine oil, transmission oil, demand

drive fluid, rear gearcase oil (if equipped) and all grease fittings.

If your vehicle becomes immersed or is operated in water that exceeds the

floor level, service is required before starting the engine. Your POLARIS dealer

can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section, and

take the vehicle in for service at the first opportunity.

OPERATION

DRIVING OVER OBSTACLES

Follow these precautions when driving over obstacles:

1. Always check for obstacles before driving in a new area.

2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches.

3. Drive slowly and use extra caution when driving on unfamiliar terrain. Obstacles are not always clearly visible.

4. Do not drive over large obstacles such as large rocks and fallen trees. If it’s unavoidable, use extreme caution and drive slowly.

DRIVING IN REVERSE

OPERATION

Follow these precautions when driving in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Apply the throttle lightly. Never apply the throttle suddenly.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

OPERATION

PARKING ON AN INCLINE

A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions:

1. Place the transmission in neutral.

2. Set the parking brake.

3. Stop the engine.

4. Always block the rear wheels on the downhill side.

EMISSION CONTROL SYSTEMS

NOISE EMISSION CONTROL SYSTEM

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

CRANKCASE EMISSION CONTROL SYSTEM

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

EXHAUST EMISSION CONTROL SYSTEM

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

The emissions label is located on the frame behind the left front wheel.

ELECTROMAGNETIC INTERFERENCE

This vehicle complies with the EMC requirements of European directives 97/24/ EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

EUROPEAN VIBRATION AND NOISE

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 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

MAINTENANCE

PERIODIC MAINTENANCE

Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s manual.

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service.

Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

SEVERE USE DEFINITION

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Short trip cold weather operation

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.

MAINTENANCE

MAINTENANCE CHART KEY

SYMBOL DESCRIPTION

XU Perform these procedures more often for vehicles subjected to severe use.

D Have an authorized dealer or other qualified person perform these services.

WARNING

Improperly performing the procedures marked with a D could result in

component failure and lead to serious injury or death. Have an authorized

dealer or other qualified person perform these services.

MAINTENANCE INTERVALS

NOTE

The maintenance interval charts outline required maintenance and inspection

based on estimated vehicle engine hours / miles. Each table states the number

of hours / miles that service is required on the vehicle. Some items or

components may need to be serviced more often due to severe use, such as

operation in water or under severe loads. When the vehicle goes beyond 400

hours, return to the 25 hours chart and start the interval process over.

5 HOUR / BREAK-IN SERVICE

ITEM REMARKS

Engine Oil Change (Break-in)

Drive Chain (Break-in) Adjust and lubricate

Brake pad wear (Breakin)

Perform a break-in oil change at one month

Inspect periodically

10 HOUR / 100 MILE (160 KM) SERVICE

ITEM REMARKS

Valve Clearance (Break-in)

Valve lash adjustment: Every 50 hours after first 10–hour adjustment

25 HOUR / 250 MILE (400 KM) SERVICE

ITEM REMARKS

MAINTENANCE

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Fuel System

Battery

Engine Oil Change

50 HOUR / 500 MILE (800 KM) SERVICE

ITEM REMARKS

XU Main Gearcase Oil

D Valve Clearance

XU General Lubrication

Fuel System

Battery

Engine Oil Change

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Inspect level; change yearly

Valve lash adjustment: Every 40 hours after first 10-hour adjustment

Lubricate all fittings, pivots, cables, etc.

Shift Linkage Inspect, lubricate, adjust

Steering

Front Suspension

Rear Suspension

Throttle Body Intake Duct

Lubricate

Inspect duct for proper sealing/air leaks

75 HOUR / 750 MILE (1200 KM) SERVICE

ITEM REMARKS

Fuel System

Battery

XU Main Gearcase Oil

Engine Oil Change

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Inspect level; change yearly

MAINTENANCE

100 HOUR / 1000 MILE (1600 KM) SERVICE

ITEM REMARKS

Battery

D Valve Clearance

XU General Lubrication

Transmission (Main Gearcase)

Engine Oil Change

Shift Linkage Inspect, lubricate, adjust

Steering

Front Suspension

Rear Suspension

Throttle Body Intake Duct

Fuel System / Filter

Check terminals; clean; test

Replace transmission fluid

Valve lash adjustment

Lubricate all fittings, pivots, cables, etc.

Lubricate

Inspect duct for proper sealing/air leaks

Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

Spark Plug Inspect; replace as needed

Engine Mounts Inspect

Exhaust Muffler / Pipe Inspect

Inspect for wear, routing, security; apply

Wiring

Clutches (Drive and Driven)

Drive belt

Front wheel bearings Inspect; replace as needed

dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts

Inspect; replace as needed

125 HOUR / 1250 MILE (2000 KM) SERVICE

ITEM REMARKS

Fuel System

Battery

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

XU Main Gearcase Oil

Engine Oil Change

Inspect level; change yearly

MAINTENANCE

150 HOUR / 1500 MILE (2400 KM) SERVICE

ITEM REMARKS

XU Main Gearcase Oil

D Valve Clearance

XU General Lubrication

Fuel System

Battery

Engine Oil Change

Shift Linkage Inspect, lubricate, adjust

Steering

Front Suspension

Rear Suspension

Throttle Body Intake Duct

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Inspect level; change yearly

Valve lash adjustment

Lubricate all fittings, pivots, cables, etc.

Lubricate

Inspect duct for proper sealing/air leaks

175 HOUR / 1750 MILE (2800 KM) SERVICE

ITEM REMARKS

Fuel System

Battery

XU Main Gearcase Oil

Engine Oil Change

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Inspect level; change yearly

200 HOUR / 2000 MILE (3200 KM) SERVICE

ITEM REMARKS

Battery

XU Main Gearcase Oil

D Valve Clearance

XU General Lubrication

Engine Oil Change

Shift Linkage Inspect, lubricate, adjust

Check terminals; clean; test

Inspect level; change yearly

Valve lash adjustment

Lubricate all fittings, pivots, cables, etc.

Steering

Front Suspension

Rear Suspension

Lubricate

MAINTENANCE

ITEM REMARKS

Throttle Body Intake Duct

D Brake fluid

Fuel System / Filter

Spark Plug Inspect; replace as needed

Engine Mounts Inspect

Exhaust Muffler / Pipe Inspect

Wiring

Clutches (Drive and Driven)

Drive belt

Front wheel bearings Inspect; replace as needed

Inspect duct for proper sealing/air leaks

Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts

Inspect; replace as needed

Change every two years

225 HOUR / 2250 MILE (3600 KM) SERVICE

ITEM REMARKS

Fuel System

Battery

XU Main Gearcase Oil

Engine Oil Change

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Inspect level; change yearly

250 HOUR / 2500 MILE (4000 KM) SERVICE

ITEM REMARKS

XU Main Gearcase Oil

Fuel System

Battery

Engine Oil Change

Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion

Check terminals; clean; test

Inspect level; change yearly

D Valve Clearance

XU General Lubrication

Shift Linkage Inspect, lubricate, adjust

Valve lash adjustment

Lubricate all fittings, pivots, cables, etc.

ITEM REMARKS

MAINTENANCE

Steering

Front Suspension

Rear Suspension

Throttle Body Intake Duct

Lubricate

Inspect duct for proper sealing/air leaks

MAINTENANCE

LUBRICATION RECOMMENDATIONS

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

ITEM LUBE METHOD

Engine Oil PS-4 Synthetic Engine Oil See the page 65 for details

Brake Fluid DOT 4 Brake Fluid See the page 78 for details

Transmission Oil (Main Gearcase)

Drive Chain POLARIS Chain Lube or SAE

A-Arm Pivots POLARIS All Season Grease

AGL Gearcase Lubricant & Transmission Fluid

80/90

or grease conforming to NLGI No. 2

See the page 67 for details

See the page 70 for details

Grease at general lubrication interval, also after washing vehicle or driving in water

A-Arm Pivot Greasing Points (8 total)

MAINTENANCE

ENGINE OIL

OIL RECOMMENDATIONS

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart. POLARIS recommends the use of PS-4 Synthetic Engine Oil for this vehicle.

NOTICE

Mixing brands or using a non-recommended oil may cause serious engine

damage. Always use the recommended oil. Never substitute or mix oil brands.

OIL CHECK

Maintain the oil level within the safe range on the dipstick. Do not overfill.

Dipstick

1. Position the vehicle on a level surface.

2. Remove the dipstick. Wipe it dry with a clean cloth.

3. Reinstall the dipstick completely.

4. Remove the dipstick and check the oil level.

Safe Range

TIP

A rising oil level between checks in cool weather driving can indicate

contaminants such as gas or moisture collecting in the crankcase. If the oil

level is over the full/safe mark, change the oil immediately.

5. Add the recommended oil as needed.

6. Reinstall the dipstick.

MAINTENANCE

OIL CHANGE

1. Position the vehicle on a level surface. Set the parking brake.

2. Clean the area around the pre-filter plug.

3. Start the engine. Allow it to idle for two to three minutes.

4. Stop the engine.

CAUTION

Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

5. Remove the 4 nuts/bolts holding the lower chain guard in place. Remove the lower chain guard to avoid collecting oil as it drains.

6. Place a drain pan under the engine crankcase.

7. Remove the pre-filter plug. Allow the oil to drain completely.

8. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry.

9. The external oil filter is located behind the seat on the right-hand side of the rear swingarm. The screw on the oil filter should be replaced when oil is changed. With the oil drained from the crankcase, unscrew the oil filter and replace with a new one. Ensure that the oil filter gasket is properly seated, lubricated with oil and in good condition. Do not over tighten the oil filter.

10.Clean the pre-filter plug. Install a new sealing washer on the plug. The sealing surfaces on the plug and crankcase should be clean and free of burrs, nicks or scratches.

11. Reassemble the pre-filter screen and spring to the pre-filter plug.

12.Reinstall the pre-filter drain plug. Torque to 15 Nm (11 ft-lbs).

13.Reinstall the lower chain guard.

14.Remove the dipstick. Add 1050 ml (35.5 oz.) of the recommended oil. Do not overfill. See the Specifications section for capacities.

15.Reinstall the dipstick.

16.Start the engine. Allow it to idle for one to two minutes.

17.Stop the engine and inspect for leaks.

18.Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.

19.Dispose of used oil properly.

MAINTENANCE

TRANSMISSION

TRANSMISSION OIL LEVEL CHECK

NOTE

Maximum transmission fluid volume cannot exceed 25oz. (750ml). Fill / check

method is not fill to spill. Follow Fluid Change Procedure to verify transmission

is filled with fluid

Always check and change the fluid at the intervals outlined in the Periodic Maintenance Interval Chart. Polaris recommends the use of AGL Gearcase Lubricant and Transmission Fluid for this vehicle.

The fill plug the transmission gearcase. Access the fill plug on the right-hand side of the gearcase.

is located on the side of

MAINTENANCE

TRANSMISSION OIL CHANGE

NOTE

Maximum transmission fluid volume cannot exceed 25oz. (750ml). Fill / check

method is not fill to spill. Follow Fluid Change Procedure to verify transmission

is filled with fluid. Do not overfill.

Always change the fluid at the intervals outlined in the Periodic Maintenance Interval Chart. Polaris recommends the use of AGL Gearcase Lubricant and Transmission Fluid for this vehicle. The fill plug transmission gearcase. Access the fill plug on the right-hand side of the gearcase. The drain plug gearcase. Access the drain plug from the bottom of the vehicle.

To change the transmission fluid, do the following:

1. Remove the fill plug.

2. Place a drain pan under the transmission drain plug.

3. Remove drain plug

4. Clean the drain plug magnetic surface.

5. Reinstall the drain plug and torque to specification.

is located on the bottom of the transmission

and allow lubricant to drain completely.

is located on the side of the

TORQUE

Transmission Fill / Drain Plug:

14 ft-lbs (19 Nm)

MAINTENANCE

6. Add the recommended amount of lubricant through the fill plug holeq. Do NOT overfill or fill to the bottom of the fill plug hole.

FLUID CAPACITY

Recommended Transmission Lubricant:

Polaris AGL

Capacity:

25 oz. (750 ml)

7. Reinstall the fill plug and torque to specification.

TORQUE

Transmission Fill / Drain Plug:

14 ft-lbs (19 Nm)

8. Check for leaks. Dispose of used lubricant properly.

MAINTENANCE

DRIVE CHAIN LUBRICATION AND ADJUSTMENT

Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Periodic Maintenance Chart. Lubricate more often under severe use, such as in dirty or wet conditions.

IMPORTANT

Washing the drive chain with a high pressure washer or solvents can cause

premature wear and chain failure. Do not use a high pressure washer or

gasoline to clean the drive chain. Operating the vehicle with improper rear

drive chain deflection can result in severe damage to the transmission and

drive components. Always make sure the chain adjusted within the stated

specifications.

1. Loosen upper nut

2. Turn lower nutwclockwise in 1/2 turn increments, then turn upper nut until tight. Follow this procedure until chain is at proper tension. To check for proper tension, press the down on the middle of the chain with thumb using 100N (22 lbs) of force. Chain deflection

on the chain tensioner bracket.

should be within specification.

MEASUREMENT

Chain Deflection:

Using 100N (22 lbs) of force

New Chain: 5 - 10 mm (3/16 - 13/32”)

Broken In Chain: 10 - 15 mm (13/32 - 19/32”)

NOTE

A new chain will stretch after the vehicle is used for a period of time.

3. Repeat these steps until chain is adjusted to desired deflection.

MAINTENANCE

PARKING BRAKE

PARKING BRAKE CABLE FREEPLAY ADJUSTMENT

1. Inspect and perform any needed service on the brake pads before adjusting parking brake cable freeplay.

2. Make sure the parking brake is NOT set (lever is DOWN).

3. Pull the brake cable back to inspect freeplay between the cable end and the caliper bracket. Freeplay should be 1.5-3 mm (1/16" - 1/8").

4. To adjust freeplay, loosen the jam nut

Turn the adjuster nut inward to increase freeplay.

. Turn the in-line adjuster nut

outward to decrease freeplay.

5. Tighten the jam nut against the adjuster nut.

MAINTENANCE

PARKING BRAKE ADJUSTMENT

1. Inspect and perform any needed service on the brake pads before adjusting the parking brake.

2. Position the vehicle on a level surface. Place the transmission in neutral.

3. Carefully elevate the rear of the vehicle slightly. Use an appropriate lift.

4. Loosen the jam nut on the parking brake adjustment bolt

5. While rotating the rear wheels by hand, tighten the adjustment bolt until significant brake drag is detected. Then back the adjustment bolt out 1/4 turn.

6. Hold the adjustment bolt in place and tighten the jam nut securely against the lever arm.

7. Check parking brake lever movement. Verify that the rear wheels rotate freely with the parking brake off (lever in DOWN position) and that the vehicle will not move when the parking brake is applied (lever in UP position).

8. Verify that the park brake lever stays in the UP position when the brake is fully applied.

SPARK PLUG

SPARK PLUG GAP / TORQUE

Electrode Gap New Plug Torque Used Plug Torque

MAINTENANCE

0.6-0.7 mm

12-15 Nm

(9-11 ft. lbs.)

23-27 Nm

(17-20 ft. lbs.)

NOTICE

• Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color.

• Using non-recommended spark plugs can result in serious engine damage. Use POLARIS-recommended spark plugs or their equivalent. See the Specifications section for details.

WARNING

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

SPARK PLUG CONDITION

NORMAL SPARK PLUG

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

TIP

The tip should not be white. A white insulator tip indicates overheating, caused

by use of an improper spark plug or incorrect throttle body adjustments.

WET FOULED SPARK PLUG

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. See your dealer for throttle body adjustments.

MAINTENANCE

SPARK PLUG REMOVAL AND REPLACEMENT

1. Use a spark plug wrench to remove the spark plug.

2. Inspect the spark plug each time you change the oil. The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will reduce proper engine performance. If possible, check the spark plug gap (area between electrodes) using a wire feeler gauge.

3. Reverse the procedure for spark plug installation. Torque to specification as detailed in the Spark Plug Gap/Torque section.

NOTE

It is advisable to replace the spark plug at least once a year to ensure easy

starting and good engine performance.

MAINTENANCE

VALVE ADJUSTMENT PROCEDURE

NOTE

In order to properly set the valves, the engine must be at TDC on the

compression stroke. To find TDC on the compression stroke, roll the engine

over until the intake valve closes and stops at TDC.

INTAKE VALVE CLEARANCE ADJUSTMENT

1. Remove the valve cover.

2. Verify cam lobes are pointed down.

3. Insert correct thickness feeler gauge between end of intake valve stem and adjuster screw.

4. When clearance is correct, hold adjuster screw and tighten locknut securely.

5. Re-check the valve clearance.

6. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

MEASUREMENT

Valve Clearance

0.10 mm (0.004”)

EXHAUST VALVE CLEARANCE ADJUSTMENT

1. Remove the valve cover.

2. Verify cam lobes are pointed down.

3. Insert correct thickness feeler gauge between end of exhaust valve stem and adjuster screw.

4. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge.

5. When clearance is correct, hold adjuster screw and tighten locknut securely.

6. Re-check the valve clearance.

7. Repeat adjustment procedure if necessary until clearance is correct with locknut secured.

MEASUREMENT

Exhaust Valve Clearance

0.12 mm (0.0047”)

MAINTENANCE

CONSTANT VARIABLE TRANSMISSION (CVT) SYSTEM

WARNING

Failure to comply with the instructions in this warning can result in severe injury

or death.

Do not modify any component of the CVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The CVT system has been

precision balanced. Any modification will cause the system to be out of

balance, creating vibration and additional loads on components.

The CVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the

following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your POLARIS dealer, or other qualified person, for service and repair assistance.

• This CVT system is intended for use on POLARIS products only. Do not install it in any other product.

• Always make sure the CVT housing is securely in place during operation.

CVT DRYING

There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bottom of the CVT cover.

1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug.

2. Shift the transmission to neutral. Set the parking brake.

3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

4. Allow the engine RPM to settle to idle speed.

5. Test for belt slippage. If the belt slips, repeat the process.

6. Your vehicle requires service as soon as possible. Your authorized dealer can assist.

NOTICE

Exposure to salt water will cause corrosion to metal components. If your

vehicle is operated in salt water areas, rinse it off frequently with fresh water.

MAINTENANCE

AIR FILTER

Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often. Access the air box near the right rear wheel.

1. Disengage the two cover latchesq.

2. Unlatch the cover and carefully remove it from the air box.

3. Remove the filter

4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean shop towel.

NOTE

If the filter has been soaked with fuel or oil it must be replaced.

5. Inspect the air filter and replace if necessary.

NOTE

DO NOT attempt to clean the air filter with compressed air .

6. Place the air filter into the air box and reinstall the air box cover.

NOTE

Make sure the tabs are properly positioned into the hinge. Ensure the O-ring is

installed inside the lid properly.

7. Engage the cover latches.

MAINTENANCE

BRAKES

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal.

Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding.

If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs.

WARNING

Operating the vehicle with a spongy brake pedal can result in loss of braking,

which could cause an accident resulting in severe injury or death. Never

operate the vehicle with a spongy-feeling brake pedal.

BRAKE INSPECTION

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy feel.

3. Check the brake pads

4. Inspect the brake pad wear surface for excessive wear.

for wear, damage and looseness.

5. Change pads when the friction material is worn to 1 mm (.04")

6. Check the surface condition of the brake discse. Measure the thickness. Replace a disc if the thickness is less than 4.32 mm (.170”).

7. Check brake system hoses and fittings for cracks, deterioration, abrasion and leaks. Tighten any loose fittings and replace any worn or damaged parts.

MAINTENANCE

BRAKE FLUID

Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See the Polaris Products chapter for part numbers.

WARNING

After opening a bottle of brake fluid, always discard any unused portion. Never

store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly

absorbs moisture from the air. The moisture causes the boiling temperature of

the brake fluid to drop, which can lead to early brake fade and the possibility of

accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. Access the brake fluid reservoir through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral. Set the parking brake.

3. View the brake fluid level in the reservoir between the maximum and minimum level lines. Add brake fluid as needed.

4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

. The level should be

MAINTENANCE

STEERING WHEEL INSPECTION

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8"-1.0" (20-25 mm) of freeplay.

4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer or other qualified service facility before operating the vehicle.

SHOCK SPRING ADJUSTMENT

WARNING

Uneven adjustment may cause poor handling of the vehicle, which could result

in an accident. Always adjust both the left and right spring preloads equally or

have your POLARIS dealer perform the adjustments.

The front and rear shock absorber springs are adjustable to increase or decrease spring tension. Rotate the adjuster counter-clockwise to make adjustments. Always apply the same adjustment setting to all four wheels.

either clockwise or

MAINTENANCE

TOE ALIGNMENT INSPECTION

WARNING

Severe injury or death can result from improper toe alignment and adjustment.

Do not attempt to adjust tie rod alignment. All tie rod adjustments should be

performed by an authorized POLARIS dealer or other qualified service facility.

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires approximately 25.4 cm (10″) from the floor or as close to the hub/axle center line as possible

NOTE

It is important the height of both marks be equally positioned to get an accurate

measurement.

3. Measure the distance between the marks and record the measurement. Call this measurement “2”.

MAINTENANCE

4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks and record. Call this measurement “3”. Subtract measurement “3” from measurement “2”. The difference between measurements “2” and “3” is the vehicle toe alignment. The recommended vehicle toe tolerance is 0 to 3.2 mm (0 to 1/8”) toe out. This means the measurement at the front of the tire 8”) wider than the measurement at the reare.

MEASUREMENT

Wheel Toe-Out:

0 to 3.2 mm (0 to 1/8”)

is 0 to 3.2 mm (0 to 1/

If you discover improper alignment, see your authorized dealer for service.

MAINTENANCE

TIRES

WARNING

Operating your vehicle with worn tires will increase the possibility of skidding,

loss of control and an accident, which could result in serious injury or death.

Always replace tires when the tread depth measures 1/8” (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may

adversely affect vehicle handling, which could result in vehicle damage or

personal injury. Always maintain proper tire pressure. Always use POLARIS

approved size and type of tires for this vehicle when replacing tires.

TIRE TREAD DEPTH

Always replace tires when tread depth is worn to 3 mm (1/8”) or less.

FRONT WHEEL HUB TIGHTENING

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer or other qualified service facility.

MAINTENANCE

FRONT WHEEL REPLACEMENT

1. Position the vehicle on a level surface.

2. Place the transmission in neutral. Set the parking brake. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Reverse Steps to install.

MAINTENANCE

REAR WHEEL REPLACEMENT

NOTE

Do not disassemble the castle nuts when you replace the rear wheel and hub

assembly.

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle

handling, which can result in serious injury or death. Always ensure that all

nuts are torqued to specification. Do not service axle nuts that have a cotter pin

installed. Your authorized dealer can assist.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral. Set the parking brake. Stop the engine. Block the front wheel to prevent rolling.

3. Loosen the four (4) lug nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the lug nuts.

6. Remove the wheel.

7. Reverse steps to install.

WHEEL NUT TORQUE SPECIFICATIONS

Check the wheel nut torques occasionally and when they've been loosened for service.

LOCATION NUT TORQUE

All Wheels 41 Nm (30 ft-lbs)

LIGHTS

DAYTIME RUNNING LIGHTS REPLACEMENT

This vehicle’s daytime running lamps operate using LED lights. If they become inoperable, the entire assembly will need to be replaced by your authorized POLARIS dealer or other qualified service facility.

MAINTENANCE

TAIL LIGHT LAMP REPLACEMENT

If the brakelight doesn't work, the light assembly may need to be replaced.

1. Disconnect the tail light from the harness.

2. Remove attachment nuts holding light assembly.

3. Install new light assembly and secure with attachment nuts.

4. Reconnect the light harness.

5. Start the engine to make sure the lights come on. If the lights do not operate, your authorized dealer can assist.

MAINTENANCE

VEHICLE IMMERSION

NOTICE

If your vehicle becomes immersed, major engine damage can result if the

machine is not thoroughly inspected. Take the vehicle in for service before

starting the engine. Your POLARIS dealer can provide this service.

If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land.

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. Thoroughly dry the air pre-filter..

3. Remove the air box drain plug to drain any water. Reinstall the drain plug securely.

4. Remove the spark plug.

5. Turn the engine over several times using the electric start.

6. Dry the spark plug and reinstall it, or install a new plug.

7. Attempt to start the engine. If necessary, repeat the drying procedure.

8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service.

9. If water has been ingested into the transmission follow the procedure in the Constant Variable Transmission (CVT) System section for details on drying.

MAINTENANCE

BATTERY

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

WARNING

Improperly connecting or disconnecting battery cables can result in an

explosion and cause serious injury or death. When removing the battery,

always disconnect the negative (black) cable first. When reinstalling the

battery, always connect the negative (black) cable last.

MAINTENANCE

BATTERY REMOVAL

NOTICE

If electrolyte spills, immediately wash it off with a solution of one tablespoon

baking soda and one cup water to prevent damage to the vehicle.

1. Access the battery through the left rear wheel wellq.

2. On conventional batteries, remove the battery vent tube (sealed batteries do not have a vent tube).

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable last.

5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

MAINTENANCE

BATTERY INSTALLATION

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the steps in the Battery Charging section before installing the battery.

WARNING

Battery gases could accumulate in an improperly installed vent tube and cause

an explosion, resulting in serious injury or death. Always ensure that the vent

tube is free of obstructions and is securely installed as recommended.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. On conventional batteries, install the battery vent tube. The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

4. Coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed.

BATTERY STORAGE

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

TIP

Battery charge can be maintained by using a POLARIS Battery Tender charger

or by charging about once a month to make up for normal self discharge.

Battery Tender can be left connected during the storage period, and will

automatically charge the battery if the voltage drops below a predetermined

point.

MAINTENANCE

BATTERY FLUID (CONVENTIONAL BATTERY)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper lower level

Add only distilled water. Tap water contains minerals that are harmful to a battery.

marks.

and

BATTERY CHARGING (SEALED BATTERY)

The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

WARNING

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

TIP

When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the

guidelines below for recharging.

Always verify battery condition before and 1-2 hours after the end of charging.

MAINTENANCE

STATE OF CHARGE

*(USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY)

100% 12.8-13.0 volts None, check at 3

75%-100% 12.5-12.8 volts May need slight

50%-75% 12.0-12.5 volts Needs charge 5-11 hours

25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

0%-25% 11.5 volts or less Needs charge with

VOLTAGE ACTION CHARGE TIME*

None required mos. from date of manufacture

3-6 hours charge, if no charge given, check in 3 months

verify state of

charge

At least 20 hours desulfating charger

MAINTENANCE

CLEANING AND STORAGE

WASHING THE VEHICLE

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.

NOTE

High water pressure may damage components. POLARIS recommends

washing the vehicle by hand or with a garden hose, using mild soap.

NOTE

Certain products, including insect repellents and chemicals, will damage

plastic surfaces. Do not allow these types of products to contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

WASHING TIPS

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused

cloths and pads may contain dirt particles that will scratch the finish.

• Grease all zerk fittings immediately after washing. Allow the engine to run for

a while to evaporate any water that may have entered the engine or exhaust system.

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items:

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Electrical components and wiring

• Air intake components

MAINTENANCE

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer, or other qualified person, to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.

POLISHING THE VEHICLE

POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.

POLISHING TIPS

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

STORAGE TIPS

NOTICE

Starting the engine during the storage period will disturb the protective film

created by fogging and damage could occur. Never start the engine during the

storage period.

CLEAN THE EXTERIOR

Make any necessary repairs and clean the vehicle as recommended.

STABILIZE THE FUEL

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or

equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse

through the entire fuel delivery system.

OIL AND FILTER

Change the oil and filter. See the Engine Oil section.

AIR FILTER / AIR BOX

Replace the air filter. See Maintenance Chapter. Clean the air box.

MAINTENANCE

FLUID LEVELS

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.

• Rear gearcase fluid

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

INSPECT AND LUBRICATE

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.

FOG THE ENGINE

1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel

treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plug and add 2-3 tablespoons of engine oil. To access the

plug holes, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Do this carefully! If you miss

the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.

3. Reinstall the spark plug. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall

the cap onto the plug at this step.

5. Turn the engine over several times. Oil will be forced in and around the

piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

6. Reinstall the spark plug caps.

7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and

injectors should be completely drained of gasoline.

STORAGE AREA / COVERS

Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

MAINTENANCE

REMOVAL FROM STORAGE

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way.

2. Make sure spark plugs are tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection. Tightness of the

bolts, nuts and other fasteners should be checked by an authorized dealer or other qualified service facility.

5. Lubricate at the intervals outlined in the Periodic Maintenance Chart.

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of

consciousness or death. Never run an engine in an enclosed area.

MAINTENANCE

TRANSPORTING THE VEHICLE

Follow these procedures when transporting the vehicle.

1. Place the transmission in neutral. Set the parking brake.

2. Stop the engine.

3. Remove the key to prevent loss during transporting.

4. Secure the fuel cap and seat. Ensure that the seat is attached correctly and is not loose.

5. Wrap the front tie strap through the frame tubes around each of the tubes.

6. Wrap the rear tie strap around the swing arm.

Step 5

, or attach a tie-down hook

Step 6

Polaris ACE 150 EFI (2019) Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual