Polaris ACE 900 SP Owner'S Manual Download Page 14

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SAFETY

Safety Labels and Locations

Load/Passenger/Tire Pressure Warning

WARNING

• Never carry passengers in cargo box.
• Passengers can be thrown off. This can cause serious injury or death.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance for braking when carrying cargo.
• Overloading or carrying tall, off-center, or unsecured loads will increase your

risk of losing control. Loads should be centered and carried as low as
possible in box.

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

7183192

Hitch Capacity Label

TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15 DEGREES
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

7170509

ACE

MAXIMUM CARGO BOX LOAD

240 lbs.

(108 kg)

TIRE PRESSURE IN PSI (KPa)

FRONT 10 (69)

REAR 10 (69)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, CARGO AND
ACCESSORIES

575 lbs.

(260 kg)

Read Operation and Maintenance Manual for more detailed loading information.

Load/Passenger/Tire

Pressure Warning

Fuel Transport

Warning

Summary of Contents for ACE 900 SP

Page 1: ...Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death Read this manual carefully POLARIS ACE 900 SP Owner s Manual for Maintenance and Safety ...

Page 2: ...he safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone ...

Page 3: ...Review the safety DVD that came with your vehicle POLARIS also recommends that all drivers take the ROHVA safety e course and a ROHVA hands on safety training course Visit www rohva org or call 866 267 2751 Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service ...

Page 4: ...tween 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 Engli...

Page 5: ...Introduction 4 Safety 7 Features and Controls 24 Operation 44 Winch Guide 63 Emission Control Systems 74 Maintenance 75 Specifications 120 POLARIS Products 122 Troubleshooting 123 Warranty 127 Maintenance Log 134 Index 135 ...

Page 6: ... a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situatio...

Page 7: ... body parts inside the vehicle at all times Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judgment and reduce operator reaction time Complete the New Operator Driving Procedures outlined on pages 51 52 Never allow a guest to operate this vehicle until the guest has completed t...

Page 8: ... your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Vehicle Identification Number VIN _________________________________________ Engine Serial Number ___________________________________________________ Key Number _______________________________________________...

Page 9: ...ehicle is considered an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific inte...

Page 10: ... meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displ...

Page 11: ...support and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can elevate temperatures in the rider cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speed...

Page 12: ...ur vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Maximum Payload Warning WARNING Never exceed 43 MPH 70 km h if total payload exceeds 335 lbs 15...

Page 13: ...at on the floor and hands on steering wheel Stay completely inside the vehicle Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces...

Page 14: ...crease your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo 7183192 Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 DEGREES HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG 7170509 ACE MAXIMUM CARGO BOX LOAD 240 lbs 108 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 ...

Page 15: ...oper service or maintenance of this PVT system can result in vehicle damage SEVERE INJURY or DEATH Always look for and remove debris inside and around clutch and vent system when replacing belt Read owner s manual or see authorized Polaris dealer 7177469 Air Box Caution CAUTION Use a Polaris approved air filter The use of a non Polaris approved air filter may cause engine damage Before installing ...

Page 16: ...perator Driving Procedures outlined on pages 51 52 All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 51 52 Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone...

Page 17: ...juries in the event of an accident Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances The operator MUST wear the s...

Page 18: ...ing tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these ...

Page 19: ...ct the handling of the vehicle and may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any pu...

Page 20: ...nd Stunts Exhibition driving increases the risk of an accident or rollover DO NOT do power slides donuts jumps or other driving stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or rollover Use extreme caution when operating on hills Always follow proper procedures for hill climbing as described in this owner s manual See page 54 Descending H...

Page 21: ...ntain 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 Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an acciden...

Page 22: ...ls Skidding or Sliding Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires r...

Page 23: ...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...

Page 24: ... Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 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 re...

Page 25: ...to provide safe operation when used as directed Modifications to your vehicle may negatively impact vehicle stability Failure of critical machine components may result from operation with any modifications especially those that increase speed or power This vehicle may become less stable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Do not install a...

Page 26: ...D CONTROLS Component Locations Cargo Box Cab Doors Steering Wheel ROPS Frame Front Box Cover Headlights Taillights Radiator Single Rider Seat Brush Guard Engine Intake Pre Filter PVT Intake Pre Filter Receiver Hitch ...

Page 27: ...ine access panel behind the seat Remove the seat and release the access panel latches to remove the access panel Remove the rear access panel to access the air box oil fill cap and spark plugs The rear access panel is located in the bed of the cargo box Pull the rear edge of the access panel upward to remove it Radiator Access Bumper Removal The front bumper can be removed to clean debris from the...

Page 28: ...the steering wheel position does not impede proper operation of the brake pedal throttle pedal and all other controls Front Box Cover Open the front box cover and remove the access panel to access the radiator cap coolant overflow bottle and brake master cylinder reservoir 1 Turn the box cover fasteners 1 4 turn 2 Lift the rear edge of the box cover 3 Using the pliers provided in the tool kit remo...

Page 29: ...arts Your POLARIS dealer can assist Extreme Use Battery An optional extreme use battery may be available for your model If the performance of the factory installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories your POLARIS dealer can assist Your dealer can provide any installation procedures that may differ for an extreme use batte...

Page 30: ... make sure the seat position allows for proper access and operation of the brake pedal throttle pedal and all other controls The seat release lever is located at the left side of the seat Push the release lever downward and slide the seat forward or rearward to the desired position Release the lever The seat will lock into the new position Seat Removal 1 Push the seat release lever downward and sl...

Page 31: ...eat 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 we...

Page 32: ...30 FEATURES AND CONTROLS Switches Drive Mode AWD Switch 12V Accessory Outlet Ignition Switch Light Switch Instrument Cluster ...

Page 33: ...or drive mode AWD operating instructions Auxiliary Outlet The vehicle is equipped with a 12 volt accessory outlet on the dash Use the outlet to power an auxiliary light or other optional accessories or lights For service the dash outlet connection is under the dash OFF Turn the key to the OFF position to stop the engine Electrical circuits are off LIGHTS ON The lights are on Electrical circuits ar...

Page 34: ...Gear H High Gear 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 Using Low Range Always shift into low gear for any of the following conditions Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads Operating consis...

Page 35: ... 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 improper...

Page 36: ...damaged in any way No device can assure occupant protection in the event of a rollover When used with seat belts and cab nets or doors the ROPS helps prevent occupants from being ejected from the vehicle Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that cou...

Page 37: ...rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Engaging AWD AWD can be engaged or disengaged while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until disabled with the drive mode swit...

Page 38: ...l to clean the instrument cluster Do not allow insect sprays to contact the lens Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 40 Mode Button Use the MODE button to toggle through mode options See page 40 for operation of the modes Rider Information Center Speedometer Indicator Lamps MODE Button ...

Page 39: ...N position High Beam if equipped This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to wear helmet and seat belt before operating Check Engine This indicator appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine d...

Page 40: ...t cluster may have shut off to protect the electronic speedometer If this occurs your POLARIS dealer can provide proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 41 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gea...

Page 41: ...his warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 5 Clock The clock displays time in a 12 hour or 24 hour format See page 41 for resetting instructions 6 Service Ind...

Page 42: ...mode that was displayed prior to setting the units 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining dis...

Page 43: ... the new settings and exit the clock mode 6 Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the tr...

Page 44: ...hen the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Your POLARIS dealer can provide for all major repairs The diagnostic mode is accessible only when the check engine warnin...

Page 45: ...s retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and hold the ...

Page 46: ... 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 a...

Page 47: ... change both the oil and the filter at 25 hours or one month 9 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 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 PVT Break in Clutches Belt A prope...

Page 48: ...pect condition and pressure 12 105 Wheels fasteners Inspect ensure fastener tightness 105 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 39 82 Coolant level Ensure proper level 92 93 Coolant hoses Inspect for leaks Throttle Ensure proper operation 33 Indicator lights switches Ensure proper operation 31 Intake pre filters Inspect clean 98 Headlamps Check opera...

Page 49: ...treet road or highway including dirt and gravel roads unless designated for off highway use 7 Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 8 Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your skills and experie...

Page 50: ...e in your area Respect the environment in which you ride your vehicle Find out where the designated riding areas are by contacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for ...

Page 51: ... the ignition switch to the OFF position and wait five seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the vehi...

Page 52: ...firmly Practice starting and stopping using the brakes until you re familiar with the controls Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited 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...

Page 53: ...tion See page 46 4 Do not tow or carry cargo during this period 5 Select an open area that allows room to familiarize yourself with vehicle operation and handling 6 The driver must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times 7 Sit in the driver s seat and fasten the seat belt 8 Always make sure all cab doors are closed and latched ...

Page 54: ...low speed 16 After you become skilled at making turns and begin to operate at faster speeds follow these precautions Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts Turning the Vehicle Your vehicle is equipped with ...

Page 55: ...re entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering...

Page 56: ...f ascending a steeper grade is unavoidable engage all wheel drive before ascending 4 Drive straight uphill 5 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 6 Avoid unnecessary changes in speed or direction 7 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 8 If the v...

Page 57: ...ating on a hill or other irregular terrain Always switch to AWD before ascending or descending a hill 3 Drive slowly and use extreme caution 4 If the vehicle begins to overturn or if it feels as if it may overturn immediately turn downhill 5 Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide 6 If the vehicle begins to slide downhill...

Page 58: ...ll 3 Slow down Never travel down a hill at high speed 4 Always check the terrain carefully before descending a hill Never drive on hills with excessively slippery or loose surfaces 5 Always descend a hill with the transmission in forward gear Never descend a hill with the transmission in neutral 6 Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Tra...

Page 59: ... stopping ability After leaving 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 maintenance chart See page 75 Give special attention to engine oil transmission oil demand drive fluid rear g...

Page 60: ... ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly ...

Page 61: ...opping 5 Avoid making sharp turns 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 PARK 2 Turn the engine off 3 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 4 Block the rear wheels on the downhill side or...

Page 62: ...cured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use e...

Page 63: ...low as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the maximum capacities specified for your vehicle See page 120 Belt Life To extend belt life use low gear when hauling or ...

Page 64: ...creases braking distance Do not operate the vehicle faster than 10 MPH 16 km h when towing 4 Do not tow more than the recommended weight for the vehicle 5 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location which could result in loss of control of the vehicle 6 The total load operator accessories cargo and weight on hitch must not exceed the maximum wei...

Page 65: ...er 16 years of age to operate the winch 4 Always wear eye protection and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 72 7 Always keep the area around the vehicle winch winch cable and ...

Page 66: ... at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 70 to feed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s...

Page 67: ...er Your dealer can provide service on your winch if this occurs 22 Always inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons 25 Never grease or oil the winch cable This wil...

Page 68: ...g strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 69: ...cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load ...

Page 70: ... jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid po...

Page 71: ...slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle I Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the...

Page 72: ...cross the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook strap E Slowly winch the cable in while your assistant moves the end of the winch cable back and fort...

Page 73: ... cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in...

Page 74: ...ging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and pos...

Page 75: ...ctivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be ...

Page 76: ...d 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 emiss...

Page 77: ...ce 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 c...

Page 78: ...nterval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Inspect and make adjustments as need ed See Pre Ride Checklist on page 46 Front suspension Rear suspension Tires Brake fluid level Brake pedal travel Brake system Wheels fasteners Frame fasteners Engine oil level Intake pre filters Winch if equipped See pages 63 73 Coolant Daily Check level Power steering unit if equip...

Page 79: ... fittings pivots cables etc Ź Oil lines fasteners if equipped 50 H 6 M 500 800 Inspect for leaks and loose fittings Shift Linkage 50 H 6 M 500 800 Inspect lubricate adjust Ź Front Suspension 50 H 6 M 500 800 Lubricate Ź Rear Suspension 50 H 6 M 500 800 Lubricate Cooling system 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system yearly Ź Engine oil change 100 H 6 M Change the ...

Page 80: ...0 H 12 M 1000 1600 Inspect clean replace worn parts Drive belt 100 H 12 M 1000 1600 Inspect replace as needed D Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrester 200 H 24 M 2000 3200 Clean daily when driving in mud and water replace a cracked or damaged arrester before operating see page 100 Suspension bushi...

Page 81: ...l on dipstick See page 82 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 102 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 86 Demand Drive Fluid Front Gearcase Demand Drive Fluid See page 85 Prop Shaft U Joint Grease Locate fittings and grease Rear Control Arm Pivot Bushings All Season Grease or grease conforming to NLGI No 2 Locate fit...

Page 82: ...80 MAINTENANCE Lubrication Recommendations Rear Bushings Stabilizer Bar Bushings ...

Page 83: ...m the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 5W 50 4 Cycle Oil or a similar oil Refer to the specifications section beginning on page 120 for capacities Oil may need to be changed more frequently if POLARIS PS 4 engine oil is not used Follow the manufacturer s recommendations for ambient temperature operat...

Page 84: ...ar access panel in the cargo box 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Stop the engine 4 Remove the seat Remove the access panel NOTE Always clean away all dirt and debris from the dipstick area before removing the dipstick 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick fully then remove the dipstick and check the oil level on t...

Page 85: ...a drain pan under the engine crankcase and remove the drain plug Allow the oil to drain completely 4 Using an oil filter wrench turn the filter counter clockwise to remove it 5 Using a clean dry cloth clean the filter sealing surface on the crankcase 6 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 7 Install the new filter ...

Page 86: ... Stop the engine and wait 15 seconds before removing the dipstick 13 Remove the dipstick Wipe it dry with a clean cloth 14 Reinstall the dipstick fully then remove the dipstick and check the oil level on the dipstick 15 Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the dipstick Do not overfill 16 Reinstall the fill cap 17 Reinstall the dipstick 18 Dispose of...

Page 87: ... 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid to the bottom thread of the fill plug hole 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completel...

Page 88: ...the recommended fluid to the bottom of the fill plug hole Do not overfill 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase between the rear tires Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug Allow the fluid to drain completely...

Page 89: ...OTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs or their equivalent Spark Plug Gap Torque Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Level Check Plug Torque Transmission Main Gearcase AGL Gearcase Lubricant Transmission Fluid 44 oz 1300 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm Demand Drive Unit Front Gearcase...

Page 90: ...verse the procedure for spark plug installation Apply anti seize compound to the spark plug threads 6 Torque to specification See page 87 Normal 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 The tip should not be white A white insulat...

Page 91: ...fuse then replace the fuse The fuse box is located under the seat Spare fuses are provided in the fuse box Main Fuse Feature Supported 5A Brake 20A Lights Headlights Taillights 20A Drive AWD 20A Accessory Winch Switch 12V Power Receptacle 10A Fuel Pump 10A EFI 20A Electronic Engine Control Starting 30A Engine Control 30A EPS Optional 10A Constant Vehicle Power 20A Fan Circuit Braker Auto Reset Fus...

Page 92: ...e suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating 4 Reinstall the fuse box cover 5 Reinstall the seat Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thoroughly Release Tabs ...

Page 93: ...e radiator Tip Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50 50 Premix This antifreeze is already premixed and ready to use Do not dilute with water See page 122 for the part num...

Page 94: ...em is not recommended Radiator Coolant Level This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure ca...

Page 95: ...ottle can be viewed through the left front wheel well or in the compartment in the front box 1 Position the vehicle on a level surface 2 View the coolant level in the overflow bottle 3 If the coolant level is below the safe operating range remove the cap and use a funnel to add coolant through the opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completel...

Page 96: ... components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your POLARIS dealer or other qualified ...

Page 97: ...g this procedure 2 Remove the clutch cover screws and open the clutch cover Remove all debris wrapped in and around the PVT system 3 Remove all debris from the entire clutch air duct passage 4 Check for signs of damage to seals on the transmission and engine If any seals appear to be damaged your vehicle requires prompt service that your POLARIS dealer can provide Tip Belt slip is responsible for ...

Page 98: ...bottom of the clutch box Allow the water to drain Reinstall the drain plug securely 2 Place the transmission in PARK Apply the brakes Start the engine 3 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 Apply the brakes Shift the transmission to ...

Page 99: ...emoved clean the intake tube and air box thoroughly Wipe well with a clean dry cloth NOTICE Dirt or debris in the intake tube could result in severe engine damage Always clean all dirt and debris from the intake tube before installing the filter 7 Reinstall the air filter if clean or install a new air filter if soiled Do not attempt to clean the air filter NOTICE Use of a non POLARIS approved air ...

Page 100: ...box Inspect both pre filters before each use of the vehicle to ensure adequate air flow If necessary remove the pre filters and clean with soapy water Dry with low pressure compressed air NOTICE When washing the vehicle always avoid spraying water directly toward the PVT intake duct See page 115 for recommended washing procedures Engine Intake Pre Filter PVT Intake Pre Filter ...

Page 101: ... land 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Dry the spark plug wells with a clean cloth then remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle in for service as soon as possible...

Page 102: ... gas that can cause loss of consciousness or death in a very short time Periodically clean the spark arrester to remove accumulated carbon A plugged spark arrester will affect engine performance Clean daily when driving in mud and water Replace a cracked or damaged arrester before operating 1 Remove the arrester retaining bolt and nut 2 Remove the arrester from the end of the muffler 3 Use a non s...

Page 103: ...te a possible fluid leak or low brake fluid level which must be corrected before riding See page 102 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your POLARIS 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 ...

Page 104: ...ity 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 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Open the front box cover and remove the access panel See page 26 4 View the brake fluid level in the re...

Page 105: ...ay also reduce the friction between the brake pad and caliper 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 0 030 0 762 mm Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 1 Position the vehicle on level ground 2 Lightly t...

Page 106: ...make suspension adjustments Elevate the vehicle slightly for easier adjustment Always heed the following rules if you make adjustments to this suspension Always return the suspension to the lowest softest setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting ...

Page 107: ...ry 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 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nu...

Page 108: ...he wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 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 POLARIS dealer can assis...

Page 109: ... distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Apply the brakes Turn the ignition switch to the LIGHTS ON position 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall in step 2 Include the weight of a rider on the seat while performing this step 5 If adjustment is...

Page 110: ...nditions without properly working headlights Tip If an LED headlamp has moisture or fogging inside disconnect the wiring harness from the headlamp s for a few days to allow the moisture to clear out Taillight Brake Light Replacement The taillight assembly is not serviceable If the taillight or brake light fails to operate properly replace the entire taillight assembly Wiring Harness ...

Page 111: ...s 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 necess...

Page 112: ...frame Lift the panel to access the battery 3 Remove the battery hold down strap screws and remove the strap 4 On conventional batteries remove the battery vent tube 5 Disconnect the black negative battery cable first 6 Disconnect the red positive battery cable last 7 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If el...

Page 113: ...lace the battery in the battery holder 3 On conventional batteries install the battery vent tube sealed batteries do not have a 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 WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting...

Page 114: ...ttery 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 pre determined point See page 122 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the b...

Page 115: ... 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 ch...

Page 116: ...andard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture 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 least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At l...

Page 117: ...ls 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 A...

Page 118: ...amaged contact your POLARIS dealer for free replacement 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 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...

Page 119: ...e 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 page 83 Air Filter Air Box Replace the air filter See page 97 Clean the air box...

Page 120: ...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 plugs Torque to specification See page 88 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 cylind...

Page 121: ...ne exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 3 Remove the key to prevent loss during...

Page 122: ...acity 96 oz 2 8 l excluding coolant bottle Coolant Bottle Capacity 8 oz 237 ml Demand Drive Fluid Capacity 9 oz 265 ml Transmission Oil Capacity 44 oz 1300 ml Overall Length Width Height 90 48 68 in 228 6 122 173 cm Wheelbase 61 5 in 156 2 cm Ground Clearance 10 25 in 26 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93mm x 64 4mm Alternator Output 575 W 3000 RPM Compressi...

Page 123: ...Gear Reduction Low 28 84 1 Gear Reduction Reverse 25 83 1 Gear Reduction High 9 65 1 Drive Ratio Front 2 989 1 Tire Size Front 25x8 12 Tire Size Rear 25x10 12 Tire Pressure Front 10 psi 69 kPa Rear 10 psi 69 kPa Brakes Park Park in Transmission Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 single beam 55W halogen Taillights 2 single beam 6W Brake Lights 2 single beam 27W Ins...

Page 124: ...on Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug 2877922 Demand Drive Fluid qt 95 l 2877923 Demand Drive Fluid gal 3 8 l Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2871460 Premium S...

Page 125: ...t aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Belt slippage from water or snow in...

Page 126: ...defective spark plug Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your POLARIS dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure Your POLARIS dealer can assist Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or ...

Page 127: ...ce spark plug 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 connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace C...

Page 128: ... assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Your POLAR...

Page 129: ...ginal registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage And...

Page 130: ...ES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE ...

Page 131: ...es vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue...

Page 132: ...chased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void bec...

Page 133: ...dar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related p...

Page 134: ...ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply i...

Page 135: ...n aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS Off Road Vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the lett...

Page 136: ...134 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 137: ... Cab Frame ROPS 34 Cap Fuel 28 Cargo 60 61 Changing Coolant 91 Changing Gears 32 Chart Periodic Maintenance 75 78 Check Engine Indicator 43 Cleaning and Storage 115 119 Cleaning the Air Filter 97 Clothing 9 Clutching 121 Component Locations 24 Coolant Level 93 Coolant Level Radiator 92 Coolant Adding or Changing 91 Cooling Fan 92 Cooling System 92 93 Cooling System Operation 91 Cover for Storage 1...

Page 138: ... Storage 117 Fluid Recommendations Gearcase 87 Fluid Battery 112 Fluid Brake 102 Fogging the Engine 118 Fouled Plugs 88 Freeplay Steering Wheel 103 Front Box Cover 26 F Fuel Cap 28 Fuel Safety 22 Fuel Stabilizer 117 Fuel Tank Filler Cap 28 Fuse Box 90 Fuses 89 90 G Gap Spark Plug 87 Gasoline Handling 22 Gear Selector 32 Gearcase Capacities 87 Gearcase Oil Demand Drive 85 Front 85 Main 86 Gearcase ...

Page 139: ...ansmission 86 O Oil Recommendations 81 Operation on Public Lands 74 Operation Cooling System 91 Operation Transmission 94 96 Operator Restrictions 14 P Parking on an Incline 59 Parking the Vehicle 50 Periodic Maintenance Chart 75 78 Plug Gap 87 Plug Torque 87 Plug Accessory 31 Plugs Fouled 88 Plugs Spark 87 88 Polaris Products 122 Polishing the Vehicle 116 Power Steering 27 Power Steering Unit Cle...

Page 140: ...ubrication 118 Storage Area 118 Storage Battery 112 Storage Covers 118 Storage Fluid Levels 117 Storage Oil and Filter 117 Storage Removal 119 Suspension Settings 104 Switches Drive Mode AWD Switch 31 Ignition Switch 31 Light Switch 31 Mode Button 36 T Tachometer 41 Taillight 108 Throttle Pedal 33 Tire Tread Depth 105 Tires 105 106 Torque Axle Nuts 105 Torque Spark Plug 87 Torque Wheel Nut 105 Tow...

Page 141: ...eat belt Vehicle rollover can cause severe injury or death Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polari...

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Polaris ACE 900 SP, Owner'S Manual

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