Polaris SPORTSMAN ACE Owner'S Manual Download Page 134

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SPECIFICATIONS

SPORTSMAN ACE / SPORTSMAN ACE 570

Gross Vehicle Weight

1455 lbs. (660 kg)

Dry Weight

835 lbs. (378.7 kg) (325)
865 lbs. (392.4 kg) (+/- 5%) (570)

Test GVW - Rollover Protection
System (ROPS)

1505 lbs. (682.7 kg) per OSHA 29 CFR 1928.53

Front Rack/Box Capacity

120 lbs. (54 kg)

Rear Rack/Box Capacity

240 lbs. (108 kg)

Maximum Weight Capacity
(Payload)

575 lbs. (260 kg) (operator/cargo/accessories/
trailer tongue weight)

Receiver Hitch Tongue Capacity

150 lbs. (68 kg)

Receiver Hitch Towing Capacity

1500 lbs. (680 kg

Fuel Capacity

5.25 gal. (19.9 l)

Engine Oil Capacity

1.75 qts. (1.65 l) (325)
2 qts. (1.9 l) (570)

Coolant System Capacity

86 oz. (2.5 l) (325) excluding coolant bottle
96 oz. (2.8 l) (570) 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

Dual overhead cam, 4 valve 4 stroke single
cylinder

Displacement

325 cc (325) / 567 cc (570)

Bore x Stroke

78 mm x 68 mm (325)
99 mm x 73.6 mm (570)

Alternator Output

450 W @ 7000 RPM (325)
650 W @ 7000 RPM (570)

Compression Ratio

11.5:1 (325) / 10:1 (570)

Starting System

Electric

Fuel System

Electronic fuel injection

Throttle Body Size

36 mm (325) / 42 mm (570)

Ignition System

Digital CDI

Ignition Timing

32° +/- 2° @ 5000 RPM (325)
10° +/- 1° @ 1200 RPM (570) (non-adjustable)

Spark Plug / Gap

NGK MR7F

/ 0.8 +/- 0.1 mm

Front Suspension

MacPherson strut with 8.2 in. (20.8 cm) travel

Rear Suspension

Dual A-arm, anti-sway bar with 9.5 in. (24.1 cm)
travel

Summary of Contents for SPORTSMAN ACE

Page 1: ...e to heed the warnings and safety precautions contained in this manual can result in severe injury or death Read this manual carefully Owner s Manual for Maintenance and Safety SPORTSMAN ACE 570 SPORTSMAN ACE ...

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: ...ience have gone into the engineering design and development of your POLARIS vehicle For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Review the safety DVD that came with your vehicle POLARIS also recommends that all drivers take the ROHVA safety e course and a ROHVA hands on safety training course Visit www rohva org or ...

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 49 Winch Guide 69 Emission Control Systems 80 Maintenance 81 Specifications 132 POLARIS Products 134 Troubleshooting 135 Warranty 139 Maintenance Log 146 Index 147 ...

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 56 57 Never allow a guest to operate this vehicle until the guest has completed t...

Page 8: ... 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: ...of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label General Warning ...

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: ...ter 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 7180636 Maximum Payload Warning WARNING Never exceed 43 MPH 70 km h if total payload exceeds 335 lbs 152 kg 7181835 SPORTSMAN ACE MAXIMUM CARGO BOX LOAD 240 lbs 108 kg TIRE PRESSURE IN PSI KPa FRONT 7 48 REAR ...

Page 15: ...EVERE 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 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 PVT System Warning ...

Page 16: ...perator Driving Procedures outlined on pages 56 57 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 56 57 Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone...

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

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: ...se the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt an...

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 60 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: ...esigned 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 i...

Page 26: ...OLS Component Locations Hip Bars Cargo Box Shifter Cab Nets Steering Wheel Throttle Pedal Brake Pedal ROPS Frame Front Box Cover Headlights Taillights Engine Intake Pre Filter Radiator Single Rider Seat Brush Guard Fuel Cap ...

Page 27: ...ough the engine access panel behind the seat Remove the seat and release the access panel latches to remove the access panel Remove rear access panel to access the air box and spark plug 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 radia...

Page 28: ... the steering wheel position does not impede proper operation of the brake pedal throttle pedal and all other controls Front Box Cover Remove the front box cover and 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 remove the t...

Page 29: ...nets and latches with new cab nets and latches Please see your authorized POLARIS dealer 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 please see your POLARIS dealer Ask your dealer to provide any installa...

Page 30: ...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 slide the sea...

Page 31: ... 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 c...

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

Page 33: ...age 35 for 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 are o...

Page 34: ...Park R Reverse N Neutral L Low 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 Towi...

Page 35: ...ays check that the throttle pedal returns normally before starting the engine Make sure there s adequate throttle pedal freeplay See page 109 This vehicle is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle pedal engine speed will be limited and p...

Page 36: ...s damaged in any way No device can assure occupant protection in the event of a rollover When used with seat belts and cab nets 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 could resu...

Page 37: ...main in AWD Engaging AWD The AWD switch may be turned on or off 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 the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage th...

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: ...s in the ON 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 Seriou...

Page 40: ...ter may have shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for 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 Rever...

Page 41: ...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 Indicator A flashing wrench symbo...

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: ...When 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 Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warnin...

Page 45: ...des 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 MODE button to exit the...

Page 46: ...e Level 51 1 Data Erratic Intermittent Or Incorrect 51 2 Voltage Above Normal Or Shorted To High Source 51 3 Voltage Below Normal Or Shorted To Low Source 51 4 Abnormal Rate Of Change 51 10 Out Of Calibration 51 13 Vehicle Speed Sensor Data Valid But Above Normal Operational Range Most Severe Level 84 0 Data Valid But Below Normal Operational Range Most Severe Level 84 1 Data Erratic Intermittent ...

Page 47: ...nge Most Severe Level 168 1 Voltage Above Normal Or Shorted To High Source 168 3 Voltage Below Normal Or Shorted To Low Source 168 4 Data Valid But Above Normal Operating Range Moderately Severe Level 168 16 Data Valid But Below Normal Operating Range Moderately Severe Level 168 18 Engine Speed Data Valid But Above Normal Operational Range Most Severe Level 190 0 Data Valid But Below Normal Operat...

Page 48: ...ere Level 3597 1 Voltage Above Normal Or Shorted To High Source 3597 3 Voltage Below Normal Or Shorted To Low Source 3597 4 Data Valid But Above Normal Operating Range Moderately Severe Level 3597 16 Data Valid But Below Normal Operating Range Moderately Severe Level 3597 18 ECU Output Supply Voltage 2 Data Valid But Above Normal Operational Range Most Severe Level 3598 0 Data Valid But Below Norm...

Page 49: ...Sensor Heater 1 Data Erratic Intermittent Or Incorrect 520209 2 Voltage Above Normal Or Shorted To High Source 520209 3 Voltage Below Normal Or Shorted To Low Source 520209 4 Current Below Normal Or Open Circuit 520209 5 Accelerator Position Brake Position Interaction Condition Exists 520275 31 Throttle Position Sensor 1 or 2 Indeterminable Data Erratic Intermittent Or Incorrect 520276 2 Bad Intel...

Page 50: ...quested Throttle Angle Not Plausible Condition Exists 520305 31 ECU ADC Fault No Load Condition Exists 520306 31 ECU ADC Fault Voltage Condition Exists 520307 31 Accelerator Sensor Sync Fault Sensor Diff Exceeds Limit Condition Exists 520308 31 ECU Fault ICO Condition Exists 520309 31 ECU Fault Hardware Disruption Condition Exists 520311 31 Idle Fuel Correction Bank 1 Data Valid But Above Normal O...

Page 51: ...ion 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 throttl...

Page 52: ...in period 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 Bel...

Page 53: ...ct ensure fastener tightness 115 Frame nuts bolts fas teners Inspect ensure tightness Fuel and oil Ensure proper levels 39 88 91 Coolant level Ensure proper level 101 102 Coolant hoses Inspect for leaks Throttle Ensure proper operation 109 Indicator lights switches Ensure proper operation 31 Air filter pre filter Inspect clean 106 Intake pre filters Inspect clean 107 Headlamps Check operation appl...

Page 54: ...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 55: ...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 56: ... 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 57: ...ne 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 li...

Page 58: ... training is also available through ROHVA 3 Perform the pre ride inspection See page 51 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...

Page 59: ...right turns at a slow speed WARNING Operating in TURF mode if equipped when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again 15 Increase speed only after mastering all maneuvers at a slow speed 16 After you become skilled at making turns and begin to...

Page 60: ...st travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn the vehicle rotate the steering wheel in the direction of the turn Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle rollover Never turn abruptly or at sharp angles Never turn at high speeds ...

Page 61: ...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 62: ...hills If 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 I...

Page 63: ...n a hill or other irregular terrain Always move the AWD 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 do...

Page 64: ...g a hill 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 si...

Page 65: ...duced 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 81 Give special attention to engine oil transmission oil demand drive fluid r...

Page 66: ... 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 67: ...nly 3 Back slowly 4 Apply the brakes lightly for stopping 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 Block the rear wheels on the downhill side or park the vehicle in a sidehill position instead ...

Page 68: ...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 69: ...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 132 Belt Life To extend belt life use low gear when hauling or ...

Page 70: ...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 71: ...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 78 7 Always keep the area around the vehicle winch winch cable and ...

Page 72: ... 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 76 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 73: ...ter Take your winch to your dealer for service 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 will ...

Page 74: ...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 75: ...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 76: ... 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 77: ...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 78: ...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 79: ... 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 80: ...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 81: ...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 82: ... 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 loca...

Page 83: ...If you re not familiar with safe service and adjustment procedures have a qualified dealer 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 Racing or race style high RPM use Prolonged low speed heavy load opera...

Page 84: ...st Remarks Hours Calendar Miles Km Steering Pre Ride Inspect and make adjustments as need ed See Pre Ride Checklist on page 51 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 69 79 Coolant Daily Check level Power steering unit if equipped Daily Inspect daily cle...

Page 85: ...teners 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 D Steering 50 H 6 M 500 800 Lubricate 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 oil a...

Page 86: ...ctric grease to connectors subjected to water mud etc D Clutches drive and driven 100 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 300 H 36 M 3000 4800 Clean out Ź Coolant 60 M Replace coolant Ź...

Page 87: ...ge 88 325 or page 91 570 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 112 Transmission Oil Main Gearcase AGL Gearcase Lubricant Transmission Fluid See page 95 Demand Drive Fluid Front Gearcase Demand Drive Fluid See page 94 Prop Shaft U Joint Grease Locate fittings and grease Rear Control Arm Pivot Bushings Front A Arm Bushings All Season Grease or grease conforming to ...

Page 88: ...86 MAINTENANCE Lubrication Recommendations Rear Control Arm Pivot Bushings Stabilizer Bar Bushings Front A Arm Bushing Tie Rod Bushing Ball Joint Boot ...

Page 89: ...seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart 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 operation See page 134 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious en...

Page 90: ... oil level and to add oil An additional oil fill hole is located at the top of the engine Add oil through either the dipstick hole or the upper fill hole Access the upper fill hole cap through the cargo box access panel 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the di...

Page 91: ...tart the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Install a new sealing washer on the drain plug Tip The sealing surfaces on drain plug and crankcase s...

Page 92: ...o make sure the o ring is in good condition Install the o ring to the filter cover 13 Reinstall the oil filter spring then install the new filter 14 Reinstall the oil filter cover and o ring Torque the screws to 88 in lbs 10 Nm 15 Fill the sump with 1 75 quarts 1 65 l of the recommended oil 16 Reinstall the upper fill cap if removed and tighten the dipstick 17 Make sure the transmission is in PARK...

Page 93: ...ugh the right rear wheel well 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall and tighten the dipstick 5 Remove the dipstick and check the oil level 6 Add the recommended fluid as needed Maintain the oil level in the s...

Page 94: ... PARK Apply the brakes 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Reinstall the sealing washer on the drain plug Tip The sealing surfaces on ...

Page 95: ... hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick and fill the sump with two quarts 1 9 l of recommended oil 13 Reinstall and tighten the dipstick 14 Make sure the transmission is in PARK Apply the brakes 15 Start the engine Allow it to idle fo...

Page 96: ...sition 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 completely 4 C...

Page 97: ...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 98: ... 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 See page 97 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Level Check Plug Torque Transmission Main Gearcase AGL Gearcase Lubrica...

Page 99: ... Condition 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 Wet Fouled 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 ...

Page 100: ...e blown 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 20A Lights Headlights Taillights 20A Drive AWD 20A Accessory Winch Switch 12V Power Receptacle 10A Fuel Pump 20A Electronic Engine Control Starting 30A Engine Control 30A EPS Optional 10A Constant Vehicle Power 15A Fan Circuit Braker Auto Reset Fuse Box ...

Page 101: ...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 102: ...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 134 for the part num...

Page 103: ...re system 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 pres...

Page 104: ...ed 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 completely dry there may b...

Page 105: ...onal loads on 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 as out...

Page 106: ...efore performing 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 See your POLARIS dealer promptly for service if any seals appear to be damaged Tip Belt slip is responsible for creating exces...

Page 107: ...from the 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 transmi...

Page 108: ...he air filter clamp and remove the filter NOTICE Dirt or debris in the air box could result in severe engine damage Always clean all dirt and debris from the air box before installing the filter 5 Inspect the air box for dirt debris oil or water Compress the edges of the air box drain to drain any water Clean the air box thoroughly and wipe it well with a clean dry cloth 6 Reinstall the filter Ins...

Page 109: ...er end of the hose firmly into the airbox fitting NOTICE Operation of the vehicle without breather hoses can cause engine damage Always reinstall a breather hose after removing it for service Intake Pre Filters The engine intake pre filter is located on the right side of the cargo box The PVT intake pre filter is located on the left side of the cargo box Inspect both pre filters before each use of...

Page 110: ...d carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly press and release the throttle pedal several times to purge carbon from the system 5 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet ...

Page 111: ...essive play due to cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 81 Adjust the freep...

Page 112: ... the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 5 3 mm 4 Remove the seat Remove the engine access panel See page 28 5 Locate the in line throttle cable adjuster near the engine valve cover 6 Slide the cable adjuster boot off the cable adjuster 7 Loosen the adjustment jam nut 8 Rotate the cable adjuster until 1 16 to 1 8 1 5 3 mm of freepl...

Page 113: ...te a possible fluid leak or low brake fluid level which must be corrected before riding See page 112 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 114: ...sibility 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 Remove the front box cover and access panel See page 26 4 View the brake fluid level in the reserv...

Page 115: ...for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may 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...

Page 116: ...ring 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 autho rized POLARIS dealer Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory spr...

Page 117: ...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 118: ...e the 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 See your POLARIS dealer 3 ...

Page 119: ...t be replaced 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 Do not operate the vehicle at night or in low light conditions without properly working headlights Headlight Lamp Replacement Do not service the headlamps until they ve cooled sufficiently 1 Unplug the headlamp from the wiring harne...

Page 120: ...t 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 necessary turn the headlight adjustment screw to adjust the beam 6 Repeat steps 4 5 ...

Page 121: ...o your POLARIS dealer before starting the engine 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 3 Remove the spark plug 4 Turn the engine over several times 5 Dry the spark plug and reinstall it or install a new plug...

Page 122: ...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 123: ...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 124: ...Place 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 resultin...

Page 125: ...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 134 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the b...

Page 126: ... 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 127: ...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 128: ...d 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 Washi...

Page 129: ...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 130: ...ent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the pro...

Page 131: ...m 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 90 325 or page 92 570 Air Filter Air Box Inspect and clean or replace the pre filter and air filter Clean the air box See pag...

Page 132: ...to the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plug Torque to specification See page 97 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 o...

Page 133: ... beginning on page 81 WARNING Engine 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 Remove the key to prevent loss during transporting 3 Secure the fuel cap and seat Ensure that the seat is...

Page 134: ... 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 Dual overhead cam 4 valve 4 stroke single cylinder Displacement 325 cc 325 567 cc 570 Bore x Stroke 78 mm x 68 mm 325 99 mm x 73 6 mm 5...

Page 135: ...2 989 1 Tire Size Front 25x8 12 Tire Size Rear 25x10 12 Tire Pressure Front 7 psi 48 KPa Rear 7 psi 48 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 Instrument Cluster LCD Auxiliary DC Outlet 12V Altitude Shift Weight Drive Clutch Spring Driven Clutch Sprin...

Page 136: ...and 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 Starter Grease 2871515 U Joint Grease 3 oz 89 ml cartridge 287155...

Page 137: ...se fast 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 s...

Page 138: ...d or 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 Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your POLARIS dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap ...

Page 139: ... 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 Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Low fuel pressure See your POLARIS dealer Other mechanical failure See y...

Page 140: ...ctive spark plug wires See your POLARIS dealer 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 Other mechanical failure See your POLARIS dealer Overheated engine C...

Page 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 if it is inconsistent with the controlling state law This limited warranty excludes failures not caus...

Page 147: ...pplied by an 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 ...

Page 148: ...146 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 149: ...5 Burning Belts 135 C Cab Frame ROPS 34 Cab Nets 27 Cap Fuel 28 Cargo 66 67 Changing Coolant 100 Changing Gears 32 Chart Periodic Maintenance 81 84 Check Engine Indicator 43 Chrome Wheel Care 128 Cleaning and Storage 126 131 Cleaning the Air Filter 106 Clothing 9 Clutching 133 Component Locations 24 Condition Spark Plugs 97 Coolant Level 102 Coolant Level Radiator 101 Coolant Adding or Changing 10...

Page 150: ...ations Gearcase 96 Fluid Battery 123 Fluid Brake 112 Fogging the Engine 130 Fouled Plugs 97 Freeplay Adjustment Throttle 110 Freeplay Steering Wheel 114 Freeplay Throttle 109 F Front Box Cover 26 Fuel Cap 28 Fuel Safety 22 Fuel Stabilizer 129 Fuel Tank Filler Cap 28 Fuse Box 99 Fuses 98 99 G Gap Spark Plug 96 Gasoline Handling 22 Gear Selector 32 Gearcase Capacities 96 Gearcase Oil Demand Drive 94...

Page 151: ...arcase 95 Transmission 95 O Oil Recommendations 87 Operation on Public Lands 80 Operation Cooling System 100 Operation Transmission 103 105 Operator Restrictions 14 P Parking on an Incline 65 Parking the Vehicle 55 Periodic Maintenance Chart 81 84 Plug Condition 97 Plug Gap 96 Plug Torque 96 Plug Accessory 31 Plug Spark 96 97 Plugs Fouled 97 Polaris Products 134 Polishing the Vehicle 127 Power Ste...

Page 152: ...123 Storage Covers 130 Storage Fluid Levels 129 Storage Oil and Filter 129 Storage Removal 131 Switches AWD Switch 31 35 Ignition Switch 31 Light Switch 31 Mode Button 36 T Tachometer 41 Throttle Freeplay 109 Throttle Freeplay Adjustment 110 Throttle Freeplay Inspection 109 Throttle Pedal 33 Throttle System 109 Tire Tread Depth 115 Tires 115 116 Torque Axle Nuts 115 Torque Spark Plug 96 Torque Whe...

Page 153: ...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 SPORTSMAN ACE, Owner'S Manual

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