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Polaris ACE 150 EFI 2019, Owner'S Manual, Page: 73 / 119

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Polaris ACE 150 EFI 2019 Owner'S Manual Download Page 73

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

w

. Turn the in-line adjuster nut

q

outward to decrease freeplay.

Turn the adjuster nut inward to
increase freeplay.

5. Tighten the jam nut against the

adjuster nut.

71

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Summary of Contents for ACE 150 EFI 2019

Page 1: ...2019 Owner s MAnual POLARIS ACE 150 EFI Downloaded from ManualsNet com search engine...

Page 2: ...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 WARNING Rea...

Page 3: ...ng 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 headin...

Page 4: ...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 omiss...

Page 5: ...ears 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 su...

Page 6: ...4 WELCOME Downloaded from ManualsNet com search engine...

Page 7: ...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 5 Downloaded from Manual...

Page 8: ...6 Downloaded from ManualsNet com search engine...

Page 9: ...ld 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 o...

Page 10: ...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...

Page 11: ...n 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 t...

Page 12: ...ehicle 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...

Page 13: ...ements to all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 2006 42 EC as amended Machinery Directive EN ISO 12100 2010 Hazard Analysis EN 15997 2011 AC 2012 Driver Perceived...

Page 14: ...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 q Vehicle Identification Number LH re...

Page 15: ...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 q Helmet w Eye Protection e...

Page 16: ...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...

Page 17: ...FORMATION 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...

Page 18: ...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 throw...

Page 19: ...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 drug...

Page 20: ...ING 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 Ne...

Page 21: ...perate 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 an...

Page 22: ...d 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 a...

Page 23: ...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 b...

Page 24: ...n 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 ho...

Page 25: ...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...

Page 26: ...bels 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...

Page 27: ...otective 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...

Page 28: ...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 stabil...

Page 29: ...ly 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 Alway...

Page 30: ...u Cab Frame a Brush Guard i Steering Wheel s Muffler Spark Arrester o Running Lights 28 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine...

Page 31: ...ensure the latch is engaged Before operating the vehicle always make sure the seat is securely installed SEAT REMOVAL 1 To remove the driver s seat lift the seat latch lever 2 While holding the lever...

Page 32: ...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...

Page 33: ...ch 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...

Page 34: ...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 q is located on the left hand side o...

Page 35: ...y can be removed from the switch when it is in the OFF position OFF ON START The engine is off Electrical circuits are off except accessory 12V Electrical circuits are on Electrical equipment can be u...

Page 36: ...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...

Page 37: ...h the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal w returns normally before starting the engine TIP If...

Page 38: ...orward 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 i...

Page 39: ...ng 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 sl...

Page 40: ...river 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 38 FEATURES AND CONTROLS Downloaded from ManualsNet com s...

Page 41: ...e 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 39 FEATURES AND CONTROLS Downloaded from ManualsNet com searc...

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Page 43: ...ents 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 Neve...

Page 44: ...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...

Page 45: ...page 80 Tires Inspect condition and pressure page 26 page 83 Wheels fasteners Inspect ensure fastener tightness page 83 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper...

Page 46: ...operation page 30 Cab Nets Check for wear or damage ensure proper installation page 32 Grass and Leaves Remove grass leaves and other flammable material or debris especially near the HOTexhaust syste...

Page 47: ...O NOTattempt 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...

Page 48: ...pletely 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 c...

Page 49: ...ding 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 ski...

Page 50: ...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...

Page 51: ...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 o...

Page 52: ...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 1...

Page 53: ...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 i...

Page 54: ...ways 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 ov...

Page 55: ...rse 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...

Page 56: ...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 t...

Page 57: ...ng 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 o...

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Page 59: ...e 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 r...

Page 60: ...ine 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 w...

Page 61: ...nge D Valve Clearance Valve lash adjustment Every 40 hours after first 10 hour adjustment XU General Lubrication Lubricate all fittings pivots cables etc Shift Linkage Inspect lubricate adjust XU Stee...

Page 62: ...cap fuel lines rail and fuel pump replace lines every two years XU Spark Plug Inspect replace as needed XU Engine Mounts Inspect Exhaust Muffler Pipe Inspect XU Wiring Inspect for wear routing securi...

Page 63: ...for proper sealing air leaks 175 HOUR 1750 MILE 2800 KM SERVICE ITEM REMARKS Fuel System Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion Battery Check termina...

Page 64: ...as needed D Brake fluid Change every two years 225 HOUR 2250 MILE 3600 KM SERVICE ITEM REMARKS Fuel System Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion Ba...

Page 65: ...KS D Steering Lubricate XU Front Suspension Lubricate XU Rear Suspension Lubricate Throttle Body Intake Duct Inspect duct for proper sealing air leaks 63 MAINTENANCE Downloaded from ManualsNet com sea...

Page 66: ...e Oil See the page 65 for details Brake Fluid DOT 4 Brake Fluid See the page 78 for details Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See the page 67 for details Drive C...

Page 67: ...within the safe range on the dipstick Do not overfill q Dipstick w Safe Range 1 Position the vehicle on a level surface 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick co...

Page 68: ...ained 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 fi...

Page 69: ...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...

Page 70: ...ated on the side of the transmission gearcase Access the fill plug on the right hand side of the gearcase The drain plug w is located on the bottom of the transmission gearcase Access the drain plug f...

Page 71: ...ll 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...

Page 72: ...rive components Always make sure the chain adjusted within the stated specifications 1 Loosen upper nut q on the chain tensioner bracket 2 Turn lower nut w clockwise in 1 2 turn increments then turn u...

Page 73: ...ver 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 w Turn the in lin...

Page 74: ...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 a...

Page 75: ...ine 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 combus...

Page 76: ...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 specificatio...

Page 77: ...e 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 Ver...

Page 78: ...e 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...

Page 79: ...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 ne...

Page 80: ...ss 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...

Page 81: ...ibility 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 th...

Page 82: ...thorized 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...

Page 83: ...ace 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...

Page 84: ...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 w...

Page 85: ...ling 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 DE...

Page 86: ...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 wh...

Page 87: ...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...

Page 88: ...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 c...

Page 89: ...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...

Page 90: ...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 o...

Page 91: ...ft rear wheel well q 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...

Page 92: ...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 n...

Page 93: ...d 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 de...

Page 94: ...cture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At lea...

Page 95: ...o 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 A...

Page 96: ...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...

Page 97: ...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 Rein...

Page 98: ...k 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...

Page 99: ...he 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 q or attach a t...

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Page 101: ...47 3 cm 58 in Wheelbase 165 cm 65 in Ground Clearance 22 9 cm 9 in Engine Type 4 Stroke Displacement 150 cc Cooling Air Oil Bore x Stroke 57 4 mm x 57 8 mm Alternator Output 180 watts Compression Rati...

Page 102: ...ire Size Rear 22x10 10 Tire Pressure Front 20 7 kPa 3 psi Tire Pressure Rear 41 4 kPa 6 psi Brakes Front Rear Foot Activated hydraulic disc Parking Brake Mechanical Rear Lever Daytime Running Lights D...

Page 103: ...Lubricant Transmission Fluid gal 3 8 l 2872348 Chain Lube Aerosol Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Seas...

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Page 105: ...the PVT Prevent water from entering the PVT inlet and outlet ducts Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction Your POLARIS dealer can assist Poor engine performance...

Page 106: ...k from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recommended fuel Replace with fresh recommended fuel Incorr...

Page 107: ...Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction Your POLARIS dealer can assist Electronic throttle control malfunction Your POLARIS dealer can assist Other mechanica...

Page 108: ...plug s Inspect clean and or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition...

Page 109: ...xtend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration...

Page 110: ...n improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs or repairs made after t...

Page 111: ...OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTIC...

Page 112: ...urchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered...

Page 113: ...NANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 111 MAINTENANCE LOG Downloaded from ManualsNet com search...

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Page 115: ...iving Downhill 50 Driving Downhill Improperly 19 Driving in Reverse 53 Driving on a Sidehill Sidehilling 50 Driving on Slippery Surfaces 47 Driving Over Obstacles 52 Driving Through Water 51 Driving U...

Page 116: ...il Check 65 Operating at Excessive Speeds 18 Operating Improperly in Reverse 20 Operating in Unfamiliar Terrain 20 Operating on Frozen Bodies of Water 21 Operating on Pavement 17 Operating on Public R...

Page 117: ...While Climbing a Hill 19 Starting the Engine 45 Steering Wheel 30 Stopping the Engine 46 Storage 94 Storage Area 95 T Tail Light Lamp Replacement 86 Throttle Pedal 35 Tire Tread Depth 83 Tires 83 Toe...

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Page 119: ...ris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Sales Europe Sarl Place de l Industrie 2 1180 Rolle Switzerland Printed in China Part No 9929351 Rev 02 Downloaded from ManualsN...

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