Owner's Manual
for Maintenance and Safety
ACE™ 150 EFI
WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
1
Visit us at www.polaris.com
2
POLARIS® is a trademark of POLARIS Industries Inc.
Copyright 2016 POLARIS Industries Inc. All information contained within this
publication is based on the latest product information at the time of publication. Due
to constant improvements in the design and quality of production components, some
minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained
within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided
as translations of the original instructions.
Printed in China
2017 ACE 150 EFI Owner’s Manual
P/N 9927517
3
WELCOME
Dear Parents:
We believe your children should have the opportunity to enjoy the
POLARIS riding experience along with you. We encourage you to
teach your children to ride safely, and to help ensure the future of
recreational sports, please teach them to show respect for our
environment and for the rights of others while operating the vehicle.
This vehicle is not a toy and can be hazardous to operate. We've
provided this owner’s manual and an instructional video to help you
and your children learn about the safe operation and care of your new
POLARIS vehicle. Before your children drive in the vehicle, please
read and make sure they read this owner’s manual. Watch the
instructional video with them. Make sure all operators understand
and follow all of the instructions and warnings contained in this
owner’s manual and video. Make sure they understand that the vehicle
must be used under adult supervision at all times.
After reading this owner’s manual and watching the video, help your
child practice the New Operator Driving Procedures on pages 47-48.
Never allow a child under age 10 to operate this vehicle. Children
differ in skills, physical abilities and judgement. Please supervise the
use of the vehicle at all times. Permit continued use only if you
determine that your child has the ability and maturity to operate safely.
4
WELCOME
For your child’s safety, be sure your child can reach and operate all
ACE 150 controls, including steering wheel, accelerator and brake
pedals, and ignition switch. Make sure your child is not too tall to ride
safely in this vehicle. See page 14.
The vehicle’s speed control system allows adults to limit vehicle speed
for new and inexperienced operators. Please see page 39 for more
information.
The preventive maintenance program outlined in this manual is
designed to ensure that all critical components on your child's vehicle
are thoroughly inspected at specific intervals. Always follow all of the
instructions and recommendations in this manual to ensure the vehicle
remains in safe operating condition at all times.
This POLARIS vehicle is not designed for adult use. Serious damage
may occur if the maximum weight capacity is exceeded. Refer to
vehicle labels and to the specifications section beginning on page 100
for the maximum weight capacity.
5
WELCOME
Dear Young Operators:
Before you ride your new POLARIS vehicle, there are some important
things that you need to know. You must learn how to keep yourself
and those around you safe while you're riding.
Your parents and POLARIS want you to be safe while you enjoy
riding your new vehicle, and that's why it’s very important that you
read this owner’s manual and watch the instructional video. Make sure
you understand and follow all of the instructions and warnings in this
owner’s manual and video. Ask your parents to explain anything you
don't understand.
Your safety and the safety of others is the most important thing to
think about at all times. Pay attention when you see this symbol:
This is the safety alert symbol. When you see this symbol on your
vehicle or in this manual it means PAY ATTENTION because you could
die or be seriously injured if you don't follow the instructions.
After reading this owner’s manual and watching the video, complete
the New Operator Driving Procedures on pages 47-48. Show your
parent that you understand how to drive safely.
Enjoy riding your new POLARIS vehicle!
6
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Features and Controls . . . . . . . . . . . . . . . . 27
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Emission Control Systems . . . . . . . . . . . . 56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 57
Specifications . . . . . . . . . . . . . . . . . . . . . . 100
POLARIS Products . . . . . . . . . . . . . . . . . . 102
Troubleshooting . . . . . . . . . . . . . . . . . . . . 103
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance Log. . . . . . . . . . . . . . . . . . . . 115
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7
INTRODUCTION
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result
in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
8
INTRODUCTION
Failure to follow the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and
can be hazardous to operate. This vehicle handles differently than cars, trucks
or other off-road vehicles. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail
to take proper precautions.
• Never operate this vehicle without proper instruction. All operators and
supervising adults must watch the instructional video that was provided with
the vehicle. Read this owner’s manual and review the safety DVD that came
with your vehicle. A free extra copy of the DVD can be obtained by
contacting your local POLARIS dealer. Understand all safety warnings,
precautions and operating procedures before operating the vehicle. Keep
this manual with the vehicle.
• For your child’s safety, be sure your child can reach and operate all ACE 150
controls, including steering wheel, accelerator and brake pedals, and ignition
switch. All operators must be able to sit with backs against the seat, both feet
flat on the floor and both hands on the steering wheel.
• Always follow the age guidelines for your vehicle. Operation is prohibited for
anyone under age 10.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Complete the New Operator Driving Procedures outlined on pages 47-3.
Never allow a guest to operate this vehicle until the guest has watched the
instructional video and has completed the New Operator Driving Procedures.
• Passengers are prohibited at all times. Never allow someone other than the
current driver to occupy this vehicle.
WARNING
9
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number:
Vehicle Identification Number:
Engine Serial Number:
Key Number:
Engine Serial Number
(on top of engine)
Key
Number
Vehicle
Identification
Number
(left rear wheel well)
####
10
SAFETY
Equipment Modifications
Your POLARIS vehicle is designed to provide safe operation when used as
directed.
WARNING! Modifying this vehicle in any way can change the top speed,
stability and handling performance of this vehicle. Modifications that increase
speed, decrease stability or change performance may present a greater risk to
inexperienced or younger operators and could result in loss of control and
serious injury or death. Use only POLARIS-approved accessories to modify
this vehicle. Review all vehicle changes with your child prior to operating.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if
any non-POLARIS-approved equipment and/or modifications have been
added to the vehicle that increase speed, ride height, handling characteristics,
or power.
11
SAFETY
Safe Riding Gear
The driver must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times. Protective
gear reduces the chance of injury.
Helmet
Wearing a helmet can prevent a severe head
injury. Whenever riding this POLARIS vehicle,
always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada bear a
U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05
label. The ECE mark consists of a circle surrounding the letter E,
followed by the distinguishing number of the country which has
granted approval. The approval number and serial number will also be
displayed on the label.
Helmet
Eye
Protection
Gloves
Long
Sleeves
E
4
051039
0006.31
12
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this POLARIS vehicle, always wear shatterproof
goggles or use a shatterproof helmet face shield. POLARIS
recommends wearing approved Personal Protective Equipment (PPE)
bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure
protective eye wear is kept clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and
other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never
ride a POLARIS vehicle with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the driver cab area. The
condition occurs most frequently when a vehicle is being operated in
high ambient temperatures at low speeds and/or high load conditions
for an extended period of time. The use of certain windshield, roof
and/or cab systems may contribute to this condition by restricting
airflow. Any discomfort due to heat buildup in this area can be
minimized by wearing proper riding apparel and by varying speeds to
increase airflow.
13
SAFETY
Safety Warnings
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all
safety warnings outlined in this section of the owner’s manual and in the
safety DVD provided with your vehicle.
Be sure to read all of the following warnings about driving hazards and how to
avoid them. These warnings are provided for your child's safety. Be sure to
explain to your young driver that the hazards outlined in this section of this
owner’s manual MUST be avoided at all times. See the OPERATION section
of this owner’s manual for proper operating procedures.
Operating Without Instruction
Operating this vehicle without proper
instruction increases the risk of an accident.
The operator and the supervising adult must
understand how to operate the vehicle
properly in different situations and on
different types of terrain. Complete the New
Operator Driving Procedures outlined on
pages 47-8.
All operators must read and understand this
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 read this manual
and all product labels and has completed the New Operator Driving
Procedures outlined on pages 47-48.
WARNING
14
SAFETY
Age Restrictions
This vehicle is for recreational use by young
operators under adult supervision ONLY.
Operation is prohibited for anyone under age
10. Operators must be able to sit with backs
against the seat, both feet flat on the floor and
both hands on the steering wheel.
Rider Height
Some riders may be too tall to ride safely in
this vehicle. Do not operate in this vehicle if
the clearance between the top of your
helmet and the overhead cab frame is less
than 2 inches (5 cm).
Seat Belts
Riding in this vehicle without wearing the
seat belt increases the risk of serious injury
in the event of rollover, loss of control, other
accident or sudden stop. Seat belts may
reduce the severity of injury in these
circumstances. Operators must wear seat
belts at all times. Always make sure the seat
belt is secured for the operator before riding.
Passengers
Passengers are prohibited on this vehicle. Never carry passengers in the
vehicle cab or in the cargo box. Passengers can be thrown off. This can cause
serious injury or death.
Minimum
2 inches
(5
cm)
15
SAFETY
Safety Warnings
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is
in safe operating condition before operating
increases the risk of an accident.
Always inspect the vehicle before each use to
make sure it's in safe operating condition. See
page 43.
Always follow the inspection and maintenance
procedures and schedules described in this
owner’s manual. See page 57.
Protective Apparel
Riding in this vehicle without wearing an
approved helmet and protective eye-wear
increases the risk of serious injury in the
event of an accident.
Operator must always wear an approved
helmet that fits properly and eye protection
(goggles or face shield).
Cab Nets
Riding in this vehicle without using the cab nets (or doors, if equipped)
increases the risk of serious injury or death in the event of an accident or
rollover. Always use the cab nets (or doors) while riding in this vehicle. Always
keep hands and feet inside the vehicle at all times.
16
SAFETY
Safety Warnings
Using Alcohol or Drugs
Riding in this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating or riding in this vehicle.
Operating on Pavement
This vehicle's tires are designed for off-road use
only, not for use on pavement. Operating this
vehicle on paved surfaces (including sidewalks,
paths, parking lots and driveways) may adversely affect the handling of the
vehicle and may increase the risk of loss of control and accident or rollover.
Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly,
travel short distances and avoid sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets,
roads or highways could result in a
collision with another vehicle. Never
operate this vehicle on any public street,
road or highway, including dirt and gravel
roads (unless designated for off-highway
use).
17
SAFETY
Safety Warnings
Operating at Excessive Speeds
Operating this vehicle at excessive
speeds increases the operator's risk
of losing control.
Always operate at a speed that's
appropriate for the terrain, the
visibility and operating conditions,
and your skills and experience.
Turning Improperly
Turning improperly could cause loss
of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this
owner’s manual.
Never turn abruptly or at sharp angles. Never turn at high speeds. Practice
turning at slow speeds before attempting to turn at faster speeds.
Physical Control of the Vehicle
Removing hands from the steering wheel or removing feet from the floor while
riding increases the risk of loss of control and accident or rollover.
The operator should always keep both hands on the steering wheel during
operation.
Always keep hands and feet inside the vehicle at all times.
Jumps and Stunts
Exhibition driving increases the risk of an
accident or rollover. DO NOT do power
slides, “donuts”, jumps or other driving
stunts. Avoid exhibition driving.
18
SAFETY
Safety Warnings
Driving Downhill Improperly
Driving down a hill improperly could cause
loss of control or rollover. Always follow
proper procedures for driving down a hill as
described in this owner’s manual. See page
51.
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 50. Never
operate the vehicle on hills steeper than 15
degrees.
Crossing Hillsides
Driving on a sidehill is not recommended.
Improper procedure could cause loss of
control or rollover. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow proper procedures as
described in this owner’s manual. See page 51.
+15°
+15°
19
SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill
could cause a rollover. Maintain a steady speed
when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is
fully stopped. Place the transmission in reverse
and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to
control speed.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating
on unfamiliar terrain could result in an
accident or rollover.
Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of
control or rollover.
Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions.
20
SAFETY
Safety Warnings
Operating on Sand or
Slippery Terrain
Operating on sand or on excessively
rough, slippery or loose terrain could
cause loss of traction, loss of control,
accident or rollover.
Always use extra caution when operating
on sand or on rough, slippery or loose
terrain. Do not operate on excessively
rough, slippery or loose terrain.
Operating Improperly in
Reverse
Improperly operating in reverse could
result in a collision with an obstacle or
person. Always follow proper operating
procedures as outlined in this manual.
See page 54.
Before shifting into reverse gear,
always check for obstacles or people
behind the vehicle. When it's safe to
proceed, back slowly.
Improper Tires and Maintenance
Operating this vehicle with improper tires or with improper or uneven tire
pressure could cause loss of control, accident or rollover.
Always use the size and type of tires specified for your vehicle. Always
maintain proper tire pressure as described in this owner's manual and on
safety labels.
21
SAFETY
Safety Warnings
Operating Over Obstacles
Improperly operating over
obstacles could cause loss of
control or rollover.
Before operating in a new area,
check for obstacles. Never attempt
to operate over large obstacles
such as large rocks or fallen trees.
Always follow the proper
procedures outlined in this manual
when operating over obstacles.
See page 53.
Operating Through Water
Operating through deep or fast-flowing
water can cause loss of traction, loss
of control, rollover or accident. Never
operate in fast-flowing water or in
water that exceeds the floor level.
Always follow proper procedures for
operating in water as described in this
owner’s manual. See page 52.
Wet brakes may have reduced
stopping ability. After leaving water,
test the brakes. Apply them lightly
several times while driving slowly. The friction will help dry out the pads.
22
SAFETY
Safety Warnings
Overloading the Vehicle
Overloading the vehicle or carrying/towing loads may cause changes in
stability and handling, which could cause loss of control or an accident.
• Never tow objects.
• Never carry loads over the maximum cargo limit.
• Never exceed the maximum weight capacity for this vehicle. See page 26.
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any rollover or
other accident, have a qualified service dealer inspect the entire machine for
possible damage, including (but not limited to) seat belt, rollover protection
devices, brakes, throttle and steering systems.
Operating on Frozen Bodies of Water
Operating on frozen bodies of water can
result in the vehicle falling through the ice.
Never operate this vehicle on a frozen body
of water.
23
SAFETY
Safety Warnings
Refueling
Gasoline is highly flammable and is explosive under certain conditions.
Always exercise extreme caution whenever handling gasoline.
• Never allow a child to refuel or handle gasoline.
• Always stop the engine when refueling.
• Always refuel outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks in or near the refueling area or
where gasoline is stored.
• Never refuel while a person is in the vehicle.
• Do not over fill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system.
Use caution when traveling through tall grass, especially dry grass. Always
inspect the underside of the vehicle and areas near the exhaust system after
driving through tall grass, weeds, brush and other tall ground cover. Promptly
remove any grass or debris clinging to the vehicle.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 10 or without proper training. This could result in an
accident or rollover. Always remove the ignition key when the vehicle is not in
use.
FOR MORE INFORMATION ABOUT SAFETY
call POLARIS at 1-800-342-3764.
24
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off,
contact your POLARIS dealer to purchase a replacement.
Replacement safety labels are provided by POLARIS at no charge.
The part number is printed on the label.
Rear Warning Label
Dash Warning Label
25
SAFETY
Safety Labels and Locations
Dash Warning Label
WARNING
Improper vehicle use can result in SEVERE INJURY or
DEATH
NEVER allow vehicle to be operated:
• without first viewing and understanding the safety video
and warning labels.
• on hills steeper than 15 degrees 15°.
• on paved surfaces - pavement may seriously affect
handling and control.
• with non-POLARIS approved accessories - they may
seriously affect stability.
• at speeds that are too fast for the operator’s skills, the
conditions and/or the terrain.
ALWAYS require operator to:
• wear seat belt and plant feet firmly on the floor.
• secure cab nets.
• keep hands and feet inside vehicle.
• use an approved helmet and protective gear.
• avoid quick turns of the steering wheel and driving stunts
such as jumps, donuts or power slides.
• watch for branches or other hazards that could enter vehicle.
26
SAFETY
Safety Labels and Locations
Dash Warning Label
WARNING
Operation of this vehicle by children under age 10 increases the risk of severe
injury or death.
Adult supervision required for children under age 16.
NEVER permit children under age 10 to operate in this vehicle.
Rear Warning Label
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 or injury. Loads should be centered and carried as low
as possible in box.
• For stability on rough or hilly terrain, reduce speed and cargo.
ACE 150
MAXIMUM CARGO BOX LOAD 50 lbs (22 kg)
TIRE PRESSURE IN PSI (KPa) FRONT - 3 (20.7)
REAR - 6 (41.4)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF
OPERATOR, CARGO, AND ACCESSORIES
230 lbs (104 kg)
27
FEATURES AND CONTROLS
Component Locations
Your vehicle is equipped with cab nets on both sides of the vehicle.
Cab nets must be used by the operator at all times. Promptly replace
worn or damaged cab nets with new cab nets, available from your
authorized POLARIS dealer. The vehicle illustrated below is shown
without cab nets only to allow component identification. Always use
the cab nets.
Dash
Hip Bar
Fuel Tank
Cap
Seat Belt
Seat
Shifter
Parking
Brake
28
FEATURES AND CONTROLS
Component Locations
Running
Lights
Brush Guard
Steering
Wheel
Cab
Frame
Muffler
(Spark Arrester)
29
FEATURES AND CONTROLS
Seats
Driver’s Seat Adjustment
1. Lift the seat latch lever located under
the right front edge of the driver’s
seat.
2. While holding the lever upward, slide
the seat forward or rearward to the
desired position, then release the
lever.
3. Slide the seat forward and rearward
to ensure the latch is engaged. Before
operating the vehicle, always make
sure the seat is securely installed.
Seat Removal
1. To remove the driver’s seat, lift the
seat latch lever.
2. While holding the lever upward,
slide the seat completely forward,
remove 10mm bolts, and remove
seat from the seat mounting rails.
3. Before operating the vehicle,
always make sure the driver’s seat
is installed and securely latched.
Seat Latch Lever
Slide Seat Forward
30
FEATURES AND CONTROLS
Steering Wheel
The steering wheel can be adjusted
upward or downward for rider
preference.
1. Loosen and remove the steering
wheel adjustment bolt.
2. Move steering wheel upward or
downward to the desired position
by aligning the mounting holes.
3. Tighten bolt to 10 ft-lbs (13.5
Nm).
CAUTION! Ensure bolt is fully tightened
prior to operating the vehicle.
Adjustment Bolt
31
FEATURES AND CONTROLS
Seat Belts
This POLARIS vehicle is equipped with three-point lap and diagonal
seat belt for the operator. Always make sure the seat belt are secured
for the operator before riding.
To wear the seat belt properly, follow this
procedure:
1. Pull the seat belt latch downward and
across your chest toward the buckle at
the inner edge of the seat. The belt
should fit snugly across your hips and
diagonally across your chest. Make
sure the belt is not twisted.
Tip: The position of the shoulder strap can be
adjusted to the height of the operator.
Have an adult relocate the mounting bolt
to a different position, making sure the nut
and bolt are tightened securely. Nut and
bolt should be tightened to 30 ft-lbs (40.6
Nm)
2. Push the latch plate into the buckle
until it clicks.
3. Release the strap, it will self-tighten.
4. Press the red release latch on the
buckle to release the seat belt.
Seat Belt
Latch
Seat Belt
Buckle
Nut and
Bolt
32
FEATURES AND CONTROLS
Seat Belts
Seat Belt Inspection
Inspect seat belt 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 the seat belt completely out and inspect the full length for any
damage, including cuts, wear, fraying or stiffness. If any damage
is found, or if the seat belt does not operate properly, have the seat
belt system checked and/or replaced by an authorized POLARIS
dealer.
4. To clean dirt or debris from the seat belt, sponge the straps with
mild soap and water. Do not use bleach, dye or household
detergents.
33
FEATURES AND CONTROLS
Cab Nets
Riding in this vehicle without using the cab nets increases the risk of
serious injury or death in the event of an accident or rollover.
Cab nets must be used by the operator at all times. Make sure all
latches are secure before operating the vehicle.
Always inspect cab nets for tightness, wear and damage before each
use of the vehicle. Use the strap adjusters to tighten any loose straps.
Promptly replace worn or damaged cab nets with new cab nets,
available from your authorized POLARIS dealer.
Screw
Adjusters/Latches
34
FEATURES AND CONTROLS
Fuel Cap
Never allow a child to refuel or handle
gasoline.
The fuel tank filler cap is located on the
left-hand side of the vehicle.
Use POLARIS Carbon Clean fuel
treatment at each fill. Follow the mixing
directions on the container. See page 102
for the part numbers of POLARIS
products.
When refueling, always use either leaded
or unleaded gasoline with a minimum pump octane number of 87
R+M/2 octane. Non-ethanol fuel is recommended. Do not use fuel
with ethanol content greater than 10 percent, such as E-85 fuel.
Fuel Cap
35
FEATURES AND CONTROLS
Ignition Switch
The ignition switch is a three-position,
key-operated switch. Use the ignition
switch to start the engine. See page 45
for starting procedures.
The key can be removed from the switch
when it is in the OFF position.
OFF The engine is off. Electrical circuits are off, except accessory
12V.
ON Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric
starter. The key returns to the ON position when released.
Ignition Switch
36
FEATURES AND CONTROLS
Gear Selector
F: Forward
N: Neutral
R: Reverse
The gear selector is located to the
right of the seat. To change gears, stop
the vehicle, and with the engine
idling, move the lever to the desired
gear. Do not attempt to shift gears
with engine speed above idle or while
the vehicle is moving.
Tip: Maintaining shift linkage adjustment is important to assure proper
transmission function. Your POLARIS dealer can assist in resolving any
shifting problems.
NOTICE: Do not attempt to shift the transmission while the vehicle is moving
or damage to the transmission could result. Always shift when the
vehicle is stationary and the engine is at idle.
Gear Selector
37
FEATURES AND CONTROLS
Parking Brake
1. Apply the brakes.
2. When the vehicle is fully stopped, pull the parking brake lever
rearward as far as possible to set the parking brake.
3. Stop the engine.
4. To release the parking brake, apply the brakes and push the lever
toward the outside of the vehicle and forward.
5. See page 70 for parking brake adjustment procedures.
Tip: Always set the parking brake whenever the vehicle is left unattended.
Operating the vehicle while the parking brake is engaged could cause
an accident resulting in serious injury or death. It could also result in
driveline or engine damage. Always be sure to disengage the parking
brake before operating the vehicle.
38
FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to slow or
stop the vehicle. Apply the brakes
while starting the engine.
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.
Throttle
Pedal
Brake
Pedal
39
FEATURES AND CONTROLS
Speed Control System
This vehicle has an adjustable speed control system that controls the
speed of the vehicle. The speed of this vehicle is restricted to 10 MPH
(16 km/h) at manufacture. The speed limiting device may be adjusted
by supervising adults when they determine that their child is capable
of safely handling additional speed.
Electronic Speed Control System
Adjust speed modes by moving the jumper fuse between the assigned
speed slots inside the fuse box.
Jumper Condition Restricted
Maximum Speed of Vehicle
Speed 1 29 MPH (47 km/h)
Speed 2 22 MPH (35 km/h)
Speed 3 15 MPH (24 km/h)
Speed 4 10 MPH (16 km/h)
40
FEATURES AND CONTROLS
Electronic Speed Control System
1. Slide the driver’s seat forward to
access the fuse box.
2. Remove the two push rivets from the
retention bracket. Remove bracket.
3. Remove fuse box cover.
4. Move fuse jumper to desired speed
mode slot.
5. Replace fuse box cover.
6. Replace fuse box bracket and replace push rivets.
7. Reposition the seat.
41
OPERATION
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Vehicle Break-in Period
The break-in period for your new POLARIS vehicle is defined as the
first ten hours of operation, or the time it takes to use the first two full
tanks of gasoline.
No single action on your part is as important as a proper break-in
period. Careful treatment of a new engine and drive components will
result in more efficient performance and longer life for these
components. Perform the following procedures carefully.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
WARNING
42
OPERATION
Vehicle Break-in Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. Always exercise extreme caution
whenever handling gasoline. Never allow a child to handle
gasoline.
2. Check the oil level. See page 65. Add the recommended oil as
needed to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined on pages
47-48.
4. Avoid aggressive use of the brakes. See Brake System Break-in
below.
5. Vary throttle position. Don’t idle extensively.
6. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 43.
7. Change the engine oil at 5 hours or one month.
8. Adjust/lubricate drive chain at 5 hours or 1 month.
Brake System Break-in
Apply only moderate braking force for the first 50 stops. Aggressive
or overly forceful braking when the brake system is new could
damage brake pads and rotors.
CVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer
life and better performance. Break in the clutches and belt by
operating at slower speeds during the break-in period as
recommended. Avoid aggressive acceleration and high speed
operation during the break-in period.
43
OPERATION
Pre-Ride Inspection
Failure to inspect and verify that the vehicle is in safe operating
condition before operating increases the risk of an accident. Always
inspect the vehicle before each use to make sure it's in safe operating
condition.
Item Remarks Page
Brake system/pedal
travel
Ensure proper operation 38
77
Brake fluid Ensure proper level 79
Front suspension Inspect, lubricate if necessary 64
Rear suspension Inspect, lubricate if necessary 64
Steering Ensure free operation 80
Tires Inspect condition and pressure 26
82
Wheels/fasteners Inspect, ensure fastener tightness 83
Frame nuts, bolts,
fasteners
Inspect, ensure tightness -
Fuel and oil Ensure proper levels 34
65
Grass and debris Remove grass and debris from the
vehicle, especially on the engine
intake and near the exhaust system
-
Throttle Ensure proper operation 38
Indicator lights/switches Ensure proper operation -
Air filter Inspect and clean or replace 76
Daytime running lights Ensure proper operation 84
Brake light Ensure proper operation -
Seat Latch Move the seat forward and rearward
to ensure correct installation
29
Seat Belt Check length of belt for damage,
check latches for proper operation
31
Cab Nets Check for wear or damage, ensure
proper installation
33
44
OPERATION
Safe Operation Practices
1. Complete the New Operator Driving Procedures outlined on pages
47-6.
2. Do not ride at night or when visibility is poor (rain, fog, dusk).
Your vehicle doesn't have lights that are designed for driving in
these conditions.
3. Never tow objects with this vehicle.
4. Engine exhaust fumes are poisonous. Never start the engine or let
it run in an enclosed area. Never allow a child to handle gasoline.
5. Never install accessories not approved by POLARIS for use on
this vehicle.
6. Ride this vehicle only in areas permitted by a supervising adult.
Never operate the vehicle on pavement or on any public street,
road or highway, including dirt and gravel roads.
7. Drive in a manner appropriate for your skills and operating
conditions. Never operate at excessive speeds. DO NOT attempt
to do power slides, “donuts”, jumps or other driving stunts. Keep
both hands on the steering wheel at all times.
8. Never consume alcohol or drugs before or while operating this
vehicle.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged vehicle. After any rollover or accident,
have a qualified service dealer inspect the entire machine for
possible damage.
11. Never operate the vehicle on a frozen body of water.
12. Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
45
OPERATION
Starting the Engine
1. Sit in the driver’s seat and fasten the seat belt.
2. Secure the cab nets.
3. Place the transmission in neutral. Set the parking brake.
4. Apply the brakes.
5. Do not press the throttle pedal while starting the engine.
6. Turn the ignition key past the ON/RUN position to START.
Engage the starter for a maximum of five seconds. Release the
key when the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
7. If the engine does not start within five seconds, return the ignition
switch to the OFF position and wait five seconds. Repeat steps 6
and 7 until the engine starts.
8. Vary the engine RPM slightly with the throttle to aid in warm-up
until the engine idles smoothly.
9. Release the parking brake before driving.
46
OPERATION
Stopping the Engine
1. Release the throttle pedal completely and brake to a complete
stop.
2. Place the transmission in neutral.
3. Set the parking brake.
4. Stop the engine.
Braking
1. Release the throttle pedal completely. (When the throttle pedal is
released completely and engine speed slows to near idle, the
vehicle has no engine braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and
stopping (using the brakes) until you're familiar with the controls.
Parking the Vehicle
1. Stop the vehicle on a level surface. When parking inside a garage
or other structure, be sure that the structure is well ventilated and
that the vehicle is not close to any source of flame or sparks,
including any appliance with pilot lights.
2. Place the transmission in neutral.
3. Set the parking brake.
4. Stop the engine.
5. Remove the ignition key to prevent unauthorized use.
47
OPERATION
New Operator Driving Procedures
1. Read and understand this owner's manual and all warning and
instruction labels before operating this vehicle.
2. Watch the instructional video with the supervising adult.
3. Review the section of this owner’s manual about starting the
engine, stopping the engine, braking and parking (pages 45-46).
4. Perform the pre-ride inspection (page 43).
5. The driver must wear helmet, eye protection, gloves, long-sleeve
shirt, long pants, over-the-ankle boots and seat belt at all times.
6. Do not operate in this vehicle if the
clearance between the top of your
helmet and the overhead cab frame is
less than 2 inches (5 cm).
7. Select a level open area to practice
driving. Make sure you have adult
supervision and permission to drive in
this area.
8. Sit in the driver's seat and fasten the
seat belt.
9. Make sure all cab nets are properly secured.
10. Set the parking brake.
11. Place the transmission in neutral.
12. Start the engine.
Minimum
2 inches
(5 cm)
48
OPERATION
New Operator Driving Procedures
13. Apply the brakes and shift into gear.
14. Release the parking brake.
15. Check your surroundings. Make sure the area is clear of people
and obstacles.
16. Keeping both hands on the steering wheel, slowly release the
brakes and press the throttle with your right foot to begin driving.
17. Drive slowly at first. Practice starting, stopping, turning, using the
throttle and brakes and driving in reverse. Learn how the vehicle
handles when making both left and right turns at a slow speed.
18. Increase speed only after mastering all maneuvers at a slow speed.
19. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions:
• Avoid sharp turns. Make turns gradually.
• Never turn while applying heavy throttle.
• Never turn the steering wheel abruptly.
• Operate at speeds appropriate for your skills, the conditions and
the terrain.
• DO NOT attempt to do power slides, “donuts”, jumps or other
driving stunts.
49
OPERATION
Driving on Slippery Surfaces
When driving on slippery surfaces such as wet trails, loose gravel,
sand or ice, be alert for the possibility of skidding and sliding.
Follow these precautions when driving in slippery conditions:
1. Slow down before entering slippery areas.
2. Be alert, watch the path ahead and avoid quick turns, which can
cause skids.
3. Correct a skid by turning the steering wheel in the direction of the
skid. Never apply the brakes during a skid.
Sideways
skid
Turn in
direction of
skid
50
OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always check the terrain carefully before ascending a hill. Never
drive on hills with excessively slippery or loose surfaces.
2. Avoid excessively steep hills (15° maximum).
3. Drive straight uphill.
4. Drive at a steady rate of speed. Never press the throttle suddenly.
5. Avoid unnecessary changes in speed or direction.
6. Never go over the crest of a hill at a high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other side
of the hill.
7. If the vehicle stalls while climbing a hill, apply the brakes. Place
the transmission in reverse and slowly allow the vehicle to roll
straight downhill while applying the brakes lightly to control
speed.
15° maximum
51
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Driving on a sidehill
improperly cause loss of control or rollover.
If crossing a hill is unavoidable, follow these precautions:
1. Drive slowly and use extreme caution.
2. If the vehicle begins to roll over, or if it feels as if it may roll over,
immediately turn downhill.
3. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide.
4. If the vehicle begins to slide downhill, immediately turn downhill
to stop the slide, or stop the vehicle and maneuver slowly and
carefully until the vehicle can be driven straight downhill.
Driving Downhill
Whenever driving down a hill, follow these precautions:
1. Avoid excessively steep hills (15° maximum).
2. Slow down. Never travel down a hill at high speed.
3. Always check the terrain carefully before driving down a hill.
Never drive on hills with excessively slippery or loose surfaces.
4. Always drive down a hill with the transmission in forward gear.
Never “coast” or drive down a hill with the transmission in
neutral.
5. Avoid driving down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Always drive straight
downhill.
6. Apply the brakes lightly to keep speed slow.
52
OPERATION
Driving Through Water
Your vehicle can drive through shallow
water. Make sure the water is no deeper
than the floor of the vehicle. Follow
these precautions when driving through
water:
1. Check water depth. Never drive
through water that is deeper than
the floor level.
2. After driving through water, test
the brakes. Apply them lightly
several times while driving slowly.
The friction will help dry out the
pads.
NOTICE: Major engine damage can result if
the vehicle is not thoroughly inspected after operation in water.
Perform the services outlined in the maintenance chart. See page
57. Give special attention to engine oil, transmission oil and all
grease fittings.
If your vehicle becomes immersed or is operated in water that
exceeds the floor level, service is required before starting the
engine. Your POLARIS dealer can provide this service. If it's
impossible to bring the vehicle in before starting the engine, perform
the service outlined on page 86, and take the vehicle in for service
at the first opportunity.
Floor Level
53
OPERATION
Driving Over Obstacles
Follow these precautions when driving over obstacles:
1. Always check for obstacles before driving in a new area.
2. Look ahead and watch the terrain. Always be alert for hazards
such as logs, rocks and low hanging branches.
3. Drive slowly and use extra caution when driving on unfamiliar
terrain. Obstacles are not always clearly visible.
4. Do not drive over large obstacles such as large rocks and fallen
trees. If it’s unavoidable, use extreme caution and drive slowly.
54
OPERATION
Driving in Reverse
Follow these precautions when driving in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Apply the throttle lightly. Never apply the throttle suddenly.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid making sharp turns.
55
OPERATION
Parking on an Incline
A rolling vehicle can result in serious injury. Avoid parking on an
incline. If parking on an incline is unavoidable, follow these
precautions:
1. Place the transmission in neutral.
2. Set the parking brake.
3. Stop the engine.
4. Always block the rear wheels on the downhill side.
56
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements
(40 CFR 205) and local noise level requirements.
Operation on Public Lands
in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and
qualified to be in accordance with the USFS standard 5100-1c. Federal
law requires that this spark arrester be installed and functional when
the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is
regulated by 43 CFR 420. Violations are subject to monetary
penalties. Federal regulations can be viewed online at
www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by
gases are forced back to the combustion chamber by the intake system.
All exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI
components are set at the factory for optimal performance and are not
adjustable.
The emissions label is located on the frame behind the left front wheel.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the
limitations of their device and the applicable electromagnetic
standards and directives that apply to this vehicle.
57
MAINTENANCE
Periodic Maintenance Chart
Any qualified repair shop or person may maintain, replace or repair
the emission control devices or systems on your vehicle. An
authorized POLARIS dealer can perform any service that may be
necessary for your vehicle. POLARIS also recommends POLARIS
parts for emissions-related service, however equivalent parts can be
used.
It is a potential violation of the Clean Air Act if a part supplied by an
aftermarket parts manufacturer reduces the effectiveness of the
vehicle’s emission controls. Tampering with emission controls is
prohibited by federal law.
Owners are responsible for performing the scheduled maintenance
identified in this owner’s manual.
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance
chart.
58
MAINTENANCE
Periodic Maintenance Chart
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, genuine POLARIS
parts are available from your POLARIS dealer. Equivalent parts may
be used for emissions-related service.
Record maintenance and service in the Maintenance Log beginning on
page 115.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, a
qualified dealer can perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected
and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise.
Monitor the oil level, and if it continues to rise, discontinue use and
determine the cause. Your POLARIS dealer can assist.
59
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
WARNING! Improperly performing the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an
authorized POLARIS dealer or other qualified person perform these services.
Symbol Description
Ź Perform these operations more often for vehicles subjected to severe
use.
D Have an authorized POLARIS dealer or other qulaified person perform
these services.
60
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached
first.
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these
services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Daily
-
Check each day before
driving the vehicle.
Make adjustments as
needed.
See the Pre-Ride
Checklist on page 43.
Front suspension - -
Rear suspension - -
Tires - -
Brake fluid level - -
Brake pedal travel - -
Brake system - -
Wheels/fasteners - -
Frame fasteners - -
Engine oil level - -
Ź Air filter - Daily - Inspect; clean often;
replace as needed
Airbox Purge
Valve
Daily Drain when deposits are
visible
61
MAINTENANCE
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these
services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Daytime running
lights/taillight
- Daily - Check operation
Drive chain - Daily - Inspect daily; adjust and
lubricate if needed
CVT housing (if
equipped)
- Weekly - Drain water as needed,
check often if driving in
wet conditions
Ź Engine oil change
(break-in)
5 1 M - Perform a break-in oil
change at one month
Drive chain
(break-in)
5 1 M - Adjust and lubricate
Ź
D
Brake pad wear 10 Monthly 100 (160) Inspect periodically
D Valve Clearance
(Initial)
10 Monthly 100 (160) Valve lash adjustment:
Every 40 hours after first
10-hour adjustment
Fuel System 25 Monthly - Inspect; cycle key to
pressurize fuel pump;
check lines and fittings
for leaks and abrasion
Battery 25 Monthly 250 (400) Check terminals; clean;
test
Ź Main gearcase oil 25 Monthly 250 (400) Inspect level; change
yearly
62
MAINTENANCE
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these
services.
.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Ź Engine oil change 30 6 M 300 (480)
D Valve Clearance 40 6M 500 (800) Valve lash adjustment:
Every 40 hours after
first 10-hour
adjustment.
Ź General
lubrication
50 3 M 500 (800) Lubricate all fittings,
pivots, cables, etc.
Shift Linkage 50 6 M 500 (800) Inspect, lubricate,
adjust
D Steering 50 6 M 500 (800) Lubricate
Ź Front Suspension 50 6 M 500 (800) Lubricate
Ź Rear Suspension 50 6 M 500 (800) Lubricate
Throttle Body
Intake Duct
50 6 M 500 (800) Inspect duct for proper
sealing/air leaks
D Fuel system/filter 100 12 M 600 (1000) Cycle key to pressurize
fuel pump; check for
leaks at fill cap, fuel
lines/rail and fuel
pump; replace lines
every two years
Ź Spark plug 100 12M 600 (1000) Inspect; replace as
needed
63
MAINTENANCE
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these
services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Ź Engine mounts 100 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 12 M 1000 (1600) Inspect
Ź Wiring 100 12 M 1000 (1600) Inspect for wear,
routing, security; apply
dielectric grease to
connectors subjected
to water, mud, etc.
D Clutches (drive
and driven)
100 12 M 1000 (1600) Inspect; clean; replace
worn parts
Drive belt 100 12 M 1000 (1600) Inspect; replace as
needed
D Front wheel
bearings
100 12 M 1000 (1600) Inspect; replace as
needed
D Brake fluid 200 24 M 2000 (3200) Change every two
years
Spark arrester 300 36 M 3000 (4800) Clean out
D Toe adjustment - Inspect periodically;
adjust when parts are
replaced
64
MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 57, or more often
under severe use, such as wet or dusty conditions. Items not listed in
the chart should be lubricated at the general lubrication interval.
ŹPerform these procedures more often for vehicles subjected to severe use.
Item Lube Method
Engine Oil 10w40 Conventional
Engine Oil
See page 65.
Brake Fluid DOT 4 Brake Fluid See page 79.
Transmission Oil
(Main Gearcase)
AGL Gearcase Lubricant
& Transmission Fluid
See page 67.
Drive Chain POLARIS Chain Lube or
SAE 80/90
See page 68.
A-Arm Pivots POLARIS All Season
Grease or grease
conforming to NLGI No.
2
Grease at general
lubrication interval, also
after washing vehicle or
driving in water.
A-Arm Pivots
65
MAINTENANCE
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 57. POLARIS
recommends the use of 10w40 Conventional Engine Oil for this
vehicle. Mixing brands or using a non-recommended oil may cause
serious engine damage. Always use the recommended oil. Never
substitute or mix oil brands.
Oil Check
Maintain the oil level within the safe
range on the dipstick. Do not overfill.
1. Position the vehicle on a level
surface.
2. Remove the dipstick. Wipe it dry with
a clean cloth.
3. Reinstall the dipstick completely.
4. Remove the dipstick and check the oil
level.
Tip: A rising oil level between checks in cool
weather driving can indicate contaminants
such as gas or moisture collecting in the
crankcase. If the oil level is over the full/
safe mark, change the oil immediately.
5. Add the recommended oil as needed.
6. Reinstall the dipstick.
Dipstick
Full
Add Oil
{
Safe Range
66
MAINTENANCE
Engine Oil
Oil Change
1. Position the vehicle on a level surface. Set the parking brake.
2. Clean the area around the pre-filter plug.
3. Start the engine. Allow it to idle for two to three minutes.
4. Stop the engine.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
5. Remove the 4 nuts/bolts holding the lower chain guard in place. Remove
the lower chain guard to avoid collecting oil as it drains.
6. Place a drain pan under the engine crankcase.
7. Remove the pre-filter plug. Allow the oil to drain completely.
8. Wash the oil pre-filter screen with solvent to remove debris. Allow the
screen to air dry.
9. The external oil filter is located behind the seat on the right-hand side of
the rear swingarm. The screw on the oil filter should be replaced when
oil is changed. With the oil drained from the crankcase, unscrew the oil
filter and replace with a new one. Ensure that the oil filter gasket is
properly seated, lubricated with oil and in good condition. Do not over
tighten the oil filter.
10. Clean the pre-filter plug. Install a new sealing washer on the plug. The
sealing surfaces on the plug and crankcase should be clean and free of
burrs, nicks or scratches.
11. Reassemble the pre-filter screen and spring to the pre-filter plug.
12. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm).
13. Reinstall the lower chain guard.
14. Remove the dipstick. Add 35.5 oz. (1050 ml) of the recommended oil.
Do not overfill. See the specifications section beginning on page 100 for
capacities.
15. Reinstall the dipstick.
16. Start the engine. Allow it to idle for one to two minutes.
17. Stop the engine and inspect for leaks.
18. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
19. Dispose of used oil properly.
67
MAINTENANCE
Transmission (Main Gearcase)
Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 57. POLARIS
recommends the use of AGL Gearcase Lubricant & Transmission
Fluid for this vehicle.
Fluid Check
The fill plug is located on the rear of the gearcase.
Access the fill plug on the right-hand side of the
gearcase.
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Check the fluid level.
4. Add the recommended fluid as needed.
5. Reinstall the fill plug.
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. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring. Torque to 14 ft. lbs. (19
Nm).
6. Add 25 oz. (750 ml) of the recommended fluid to the fill hole. Do
not overfill.
7. Reinstall the fill plug.
8. Check for leaks.
9. Discard used fluid properly.
Fill Plug
Drain Plug
68
MAINTENANCE
Drive Chain Lubrication
Lubricate the drive chain with POLARIS chain spray lube or an
approved chain lube at the general lubrication interval specified in the
Periodic Maintenance Chart beginning on page 57. Lubricate more
often under severe use, such as in dirty or wet conditions. See page
102 for the part numbers of POLARIS products.
NOTICE: Washing the drive chain with a high pressure washer or gasoline
can cause premature wear and drive chain failure. Don't use a high
pressure washer or gasoline to clean the drive chain.
Adjusting or operating the vehicle with improper rear drive chain
slack can result in severe damage to the transmission and drive
components. Always make sure the slack is within the stated
specifications.
Drive Chain Slack Adjustment
1. Loosen the upper nut.
2. Turn lower nut clockwise in 1/2-turn
increments, then turn upper nut until
tight. Follow this procedure until
chain is at proper tension. Chain
should have 1/4” deflection.
3. Repeat these steps until chain is
adjusted to desired fit.
Lower Nut
Upper Nut
69
MAINTENANCE
Parking Brake Cable Freeplay Adjustment
1. Inspect and perform any needed service on the brake pads before
adjusting parking brake cable freeplay.
2. Make sure the parking brake is NOT set (lever is DOWN).
3. Pull the brake cable back to inspect freeplay between the cable
end and the caliper bracket. Freeplay should be 1/16" (1.5 mm).
4. To adjust freeplay, loosen the jam nut. Turn the in-line adjuster nut
outward to decrease freeplay. Turn the adjuster nut inward to
increase freeplay.
5. Tighten the jam nut against the adjuster nut.
Adjustment Nut
Jam Nut
70
MAINTENANCE
Parking Brake Adjustment
1. Inspect and perform any needed service on the brake pads before
adjusting the parking brake.
2. Position the vehicle on a level surface. Place the transmission in
neutral.
3. Carefully elevate the rear of the vehicle slightly. Use an
appropriate lift.
4. Loosen the jam nut on the parking
brake adjustment bolt.
5. While rotating the rear wheels by
hand, tighten the adjustment bolt until
significant brake drag is detected.
Then back the adjustment bolt out 1/4
turn, or until the wheel freely spins.
6. Hold the adjustment bolt in place and
tighten the jam nut securely against
the lever arm.
7. Check parking brake lever movement. Verify that the rear wheels
rotate freely with the parking brake off (lever in DOWN position)
and that the vehicle will not move when the parking brake is
applied (lever in UP position).
8. Verify that the park brake lever stays in the UP position when the
brake is fully applied.
Adjustment Bolt
71
MAINTENANCE
Spark Plug
Spark Plug Gap/Torque
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Use POLARIS-recommended spark plugs or their
equivalent. See page 100.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark
plug for correct color. See page 71.
A hot exhaust system and engine can cause burns. Wear protective
gloves when removing a spark plug for inspection.
Spark Plug 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.
Tip: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. See your dealer for throttle body adjustments.
Electrode Gap New Plug Torque Used Plug Torque
0.6-0.7 mm 9-11 ft. lbs.
(12-15 Nm)
17-20 ft. lbs.
(23-27 Nm)
72
MAINTENANCE
Spark Plug
Spark Plug Removal and Replacement
1. Use a spark plug wrench to remove the spark
plug.
2. Inspect the spark plug each time you change
the oil. The electrodes should be kept clean
and free of carbon. The presence of carbon
or excess oil will reduce proper engine
performance. If possible, check the spark
plug gap (area between electrodes) using a
wire feeler gauge.
3. Reverse the procedure for spark plug
installation. Torque to specification. See
page 71.
NOTE: It is advisable to replace the spark plug at
least once a year to insure easy starting and
good engine performance.
73
MAINTENANCE
Valve Adjustment Procedure
NOTE: In order to properly set the valves, the engine must be at TDC on the
compression stroke. To find TDC on the compression stroke, roll the
engine over until the intake valve closes and stops at TDC.
Intake Valve Clearance Adjustment
1. Remove the valve cover.
2. Verify cam lobes are pointed down.
3. Insert correct thickness feeler gauge between end of intake valve
stem and adjuster screw.
4. When clearance is correct, hold adjuster screw and tighten locknut
securely.
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.
MEASUREMENT
Valve Clearance
0.004” (0.10 mm)
74
MAINTENANCE
Valve Adjustment Procedure
Exhaust Valve Clearance Adjustment
1. Remove the valve cover.
2. Verify cam lobes are pointed down.
3. Insert correct thickness feeler gauge between end of exhaust
valave stem and adjuster screw.
4. Loosen locknut and turn adjuster screw until there is a slight drag
on feeler gauge.
5. When clearance is correct, hold adjuster screw and tighten locknut
securely.
6. Re-check the valve clearance.
7. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.
MEASUREMENT
Exhaust Valve Clearance
0.0047” (0.12 mm)
75
MAINTENANCE
Constant Variable Transmission (CVT) System
Failure to comply with the instructions in this warning can result in severe
injury or death.
Do not modify any component of the CVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The CVT system has
been precision balanced. Any modification will cause the system to be out of
balance, creating vibration and additional loads on components.
The CVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the
following responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your
POLARIS dealer, or other qualified person, for service and repair assistance.
• This CVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the CVT housing is securely in place during operation.
CVT Drying
There may be some instances when water is accidently ingested into
the CVT system. Use the following instructions to dry it out before
operating. The drain plug is located on the bottom of the CVT cover.
1. Remove the drain plug. Allow the water to drain. Reinstall the
drain plug.
2. Shift the transmission to neutral. Set the parking brake.
3. Start the engine. Apply varying throttle for 10-15 seconds to expel
the moisture and air-dry the belt and clutches. Do not hold the
throttle wide open for more than 10 seconds.
4. Allow the engine RPM to settle to idle speed.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Your vehicle requires service as soon as possible. Your POLARIS
dealer can assist.
NOTICE: Exposure to salt water will cause corrosion to metal components. If
your vehicle is operated in salt water areas, rinse it off frequently
with fresh water.
WARNING
76
MAINTENANCE
Filter Systems
Air Filter
Always change the air filter at the intervals
outlined in the Periodic Maintenance Chart
beginning on page 57. Access the air box
near the right rear wheel.
1. To remove the air cleaning element,
unlatch each metal clip holding the
cover in place.
2. Remove the air filter element.
3. Clean away any oil or sediments in the
air box.
4. Apply a commercially available chassis
lubricant to the inside lip of the new air filter.
5. Install the new filter.
6. Reinstall the cover and secure the clips.
NOTICE: Never operate the vehicle with the filter element removed. Dirt will
enter the engine, causing rapid wear and severe damage to the
engine.
Metal clips
77
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes activated by
the brake pedal. See page 38.
Always check brake pedal travel and the brake fluid reservoir level
before each use of the vehicle. When applied, the brake pedal should
feel firm. Any sponginess would indicate a possible fluid leak or low
brake fluid level, which must be corrected before riding. See page 79
for brake fluid information.
If you discover any irregularities in brake system operation, including
excessive pedal travel, contact your dealer for proper diagnosis and
repairs.
Operating the vehicle with a spongy brake pedal can result in loss of
braking, which could cause an accident resulting in severe injury or
death. Never operate the vehicle with a spongy-feeling brake pedal.
78
MAINTENANCE
Brakes
Brake Inspection
1. Check the brake system for fluid
leaks.
2. Check the brake pedal for excessive
travel or a spongy feel.
3. Check the brake pads for wear,
damage and looseness.
4. Inspect the brake pad wear surface
for excessive wear.
5. Change pads when the friction
material is worn to .04" (1 mm).
6. Check the surface condition of the
brake discs. Measure the thickness of
the front and rear discs. Replace a
disc if the thickness is less than 0.1” (2.5 mm).
7. Check brake system hoses and fittings for cracks, deterioration,
abrasion and leaks. Tighten any loose fittings and replace any
worn or damaged parts.
Brake Pad
Rear Disc
Front Disc
79
MAINTENANCE
Brakes
Brake Fluid
Inspect the level of the brake fluid before each operation. If the fluid
level is low add DOT 4 brake fluid only. See page 102 for the part
numbers of POLARIS products.
After opening a bottle of brake fluid, always discard any unused portion.
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake
fade and the possibility of accident or severe injury.
Change the brake fluid every two years and
any time the fluid becomes contaminated, the
fluid level is below the minimum, or if the type
and brand of the fluid in the reservoir are
unknown. Access the brake fluid reservoir
through the left front wheel well.
1. Position the vehicle on a level surface.
2. Place the transmission in neutral. Set the
parking brake.
3. View the brake fluid level in the reservoir.
The level should be between the maximum
and minimum level lines. Add brake fluid
as needed.
4. Apply the brake forcefully for a few
seconds and check for fluid leakage around
the fittings.
Brake Fluid
Reservoir
80
MAINTENANCE
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 57.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. If there is excessive freeplay or strange noises, or the steering
feels rough or "catchy," have the steering system inspected by an
authorized POLARIS dealer or other qualified service facility
before operating the vehicle.
Shock Spring Adjustment
The front and rear shock absorber springs are adjustable to increase or
decrease spring tension. There are five (5) adjustable positions on each
shock.
Use a round nut wrench to rotate the
adjuster. The tension of the shock spring
will increase when rotated left and
decrease when rotated right.
WARNING! Uneven adjustment may cause
poor handling of the vehicle, which could
result in an accident. Always adjust both the
left and right spring preloads equally or have
your POLARIS dealer perform the
adjustments.
Adjuster
81
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.
WARNING! Severe injury or death can result from improper toe alignment
and adjustment. Do not attempt to adjust tie rod alignment. All tie rod
adjustments should be performed by an authorized POLARIS dealer or other
qualified service facility.
1. Position the vehicle on a level surface.
2. Set the handlebars in a straight-ahead position and secure them in this
position.
3. Place a chalk mark on the center line of the front tires approximately 10"
(25.4 cm) from the floor, or as close to the hub/axle center line as
possible. Make sure both marks are the same distance from the floor.
4. Measure the distance between the marks and record the measurement
(1).
5. Move the vehicle to rotate the tires 180°. Position the wheels with the
chalk marks at the rear of the tires, even with the hub/axle center line.
6. Measure the distance between the marks and record the measurement
(2).
7. Subtract measurement 2 from measurement 1. The difference is the
vehicle toe-out alignment.
If you discover improper alignment, see your POLARIS dealer for
service.
1
2
82
MAINTENANCE
Tires
Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. Always use POLARIS-
approved size and type of tires for this vehicle when replacing tires.
Tire Tread Depth
Always replace tires when tread depth is
worn to 1/8" (3 mm) or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical
component operations. All service must be performed by your
authorized POLARIS dealer or other qualified service facility.
Front Wheel Replacement
1. Position the vehicle on a level
surface.
2. Place the transmission in neutral. Set
the parking brake. Stop the engine.
3. Loosen the wheel nuts slightly.
4. Elevate the side of the vehicle by
placing a suitable stand under the
frame.
5. Remove the wheel nuts.
6. Remove the wheel.
7. Reverse Steps to install.
WARNING
1/8" (3 mm)
83
MAINTENANCE
Tires
Rear Wheel Replacement
NOTE: Do not disassemble the castle nuts when you replace the rear wheel
and hub assembly.
1. Position the vehicle on a level surface.
2. Place the transmission in neutral. Set
the parking brake. Stop the engine.
Block the front wheel to prevent
rolling.
3. Loosen the four (4) lug nuts slightly.
4. Elevate the side of the vehicle by
placing a suitable stand under the
frame.
5. Remove the lug nuts.
6. Remove the wheel.
7. Reverse steps to install.
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 assist.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been
loosened for service.
Location Nut Torque
Front Wheel 30 ft-lbs (41 Nm)
Rear Wheel 30 ft-lbs (41 Nm)
84
MAINTENANCE
Lights
Daytime Running Lights Replacement
This vehicle’s daytime running lamps operate using LED lights. If
they become inoperable, the entire assembly will need to be replaced
by your authorized POLARIS dealer or other qualified service facility.
85
MAINTENANCE
Lights
Tail Light Lamp Replacement
If the brakelight doesn't work, the light
assembly may need to be replaced.
1. Disconnect the tail light from the
harness.
2. Remove attachment nuts holding light
assembly.
3. Install new light assembly and secure
with attachment nuts.
4. Reconnect the light harness.
5. Start the engine to make sure the lights
come on. If the lights do not operate,
your POLARIS dealer can assist.
86
MAINTENANCE
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result
if the machine is not thoroughly inspected. Take the vehicle in for
service before starting the engine. Your POLARIS dealer can
provide this service.
If it’s impossible to take your vehicle to a dealer before starting it,
follow the steps outlined below.
1. Move the vehicle to dry land.
2. Check the air box. If water is present, dry the air box and replace
the filter with a new filter. Thoroughly dry the air pre-filter. See
page 76.
3. Remove the air box drain plug to drain any water. Reinstall the
drain plug securely.
4. Remove the spark plug.
5. Turn the engine over several times using the electric start.
6. Dry the spark plug and reinstall it, or install a new plug.
7. Attempt to start the engine. If necessary, repeat the drying
procedure.
8. Take the vehicle in for service as soon as possible, whether you
succeed in starting it or not. Your POLARIS dealer can provide
the required service.
9. If water has been ingested into the transmission follow the
procedure on page 75 for drying.
87
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an
explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup
water. Rinse well with tap water and dry off with clean shop towels.
Coat the terminals with dielectric grease or petroleum jelly. Be careful
not to allow cleaning solution or tap water into a conventional battery.
WARNING
WARNING
88
MAINTENANCE
Battery
Battery Removal
1. Access the battery through the left rear
wheel well.
2. On conventional batteries, remove the
battery vent tube (sealed batteries do not
have a vent tube).
3. Disconnect the black (negative) battery
cable first.
4. Disconnect the red (positive) battery cable
last.
5. Lift the battery out of the vehicle. Be
careful not to tip a conventional battery sideways, which could
spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to
the vehicle.
Battery
89
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the
battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging instructions on page 91
before installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. On conventional batteries, install the battery vent tube. The vent
tube must be free of obstructions and securely installed. Route the
tube away from the frame and vehicle body to prevent contact
with electrolyte.
Battery gases could accumulate in an improperly installed vent tube and
cause an explosion, resulting in serious injury or death. Always ensure
that the vent tube is free of obstructions and is securely installed as
recommended.
4. Coat the terminals with dielectric grease or petroleum jelly.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed.
90
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
See page 91.
Tip: Battery charge can be maintained by using a POLARIS Battery Tender
charger or by charging about once a month to make up for normal self-
discharge. Battery Tender can be left connected during the storage
period, and will automatically charge the battery if the voltage drops
below a pre-determined point. See page 102 for the part numbers of
POLARIS products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the battery fluid
level often. Maintain the fluid level
between the upper and lower level marks.
Add only distilled water. Tap water
contains minerals that are harmful to a
battery.
Lower
Mark
Upper
Mark
91
MAINTENANCE
Battery
Battery Charging
The following battery charging instructions apply only to the
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already filled with electrolyte and has been
sealed and fully charged at the factory. Never pry the sealing strip off
or add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is
to keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to
measure DC voltage.
An overheated battery may explode, causing severe injury or death.
Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming
charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2
amps or less until battery voltage is 12.8 or greater.
Tip: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use
the guidelines on the next page for recharging.
92
MAINTENANCE
Battery
Battery Charging
Always verify battery condition before and 1-2 hours after the end of
charging.
*Using constant current charger at standard amps specified on top of
battery.
State of
Charge
Voltage Action Charge Time*
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 least 20 hours
93
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its
appearance but it can also extend the life of various components.
Before washing the vehicle, locate the CVT inlet and outlet ducts and
the air box. The ducts are located under the rear wheel wells. Avoid
spraying water directly toward the ducts or air box when washing the
vehicle from the rear.
NOTICE: Water in the CVT system could cause the drive belt to become wet
and slip in the clutches. Always avoid spraying water directly toward
the CVT inlet and outlet ducts when washing the vehicle from the
rear.
High water pressure may damage components. POLARIS
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
94
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
The best and safest way to clean your POLARIS vehicle is with a
garden hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body
first and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
95
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not
recommended), exercise extreme caution. The water may damage
components and could remove paint and labels. Avoid directing the
water stream at the following items:
• Wheel bearings
• Transmission seals
• CVT inlet and outlet ducts
•Air box
•Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
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.
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.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch
the finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch
the finish.
96
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended.
See page 93.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer or equivalent fuel treatments or stabilizers. Follow the
instructions on the container for recommended amount. Carbon
Clean removes water from fuel systems, stabilizes fuel, and
removes carbon deposits from pistons, rings, valves, and exhaust
systems.
3. Allow engine to run 15-20 minutes to allow stabilizer to disperse
through entire fuel system.
Air Filter / Air Box
Inspect and clean or replace the air filter. See page 76. Clean the air
box. Drain the sediment tube.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 57.
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks
dark or contaminated)
Engine Oil
Change the oil. See page 66.
97
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as
recommended in the Periodic Maintenance Chart beginning on page
57.
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean or other
equivalent fuel treatment. Follow the instructions on the container.
Start the engine. Allow it to idle for several minutes so the Carbon
Clean reaches the injectors. Stop the engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To
access the plug hole, use a section of clear 1/4” hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
3. Reinstall the spark plug. Torque to specification. See page 71.
4. Apply dielectric grease to the inside of the spark plug cap. Do not
reinstall the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and
around the piston rings and ring lands, coating the cylinder with a
protective film of fresh oil.
6. If fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
7. Reinstall the spark plug cap to the spark plug.
98
MAINTENANCE
Cleaning and Storage
Removal from Storage
1. Check the battery and charge if necessary. Install it in the vehicle.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 43. Tightness of the bolts, nuts and other fasteners should
be checked by an authorized POLARIS dealer or other qualified
service facility.
5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 57.
Battery Maintenance
See pages 90-92 for storage and charging procedures.
Storage Area/Covers
Be sure the storage area is well ventilated. Cover the vehicle with a
genuine POLARIS cover. Do not use plastic or coated materials. They
do not allow enough ventilation to prevent condensation, and may
promote corrosion and oxidation.
99
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Place the transmission in neutral. Set the
parking brake.
2. Stop the engine.
3. Remove the key to prevent loss during
transporting.
4. Secure the fuel cap and seat. Ensure that
the seat is attached correctly and is not
loose.
NOTICE: Always tie the frame of the POLARIS
vehicle to the transporting unit securely
with suitable straps or rope. Do not attach
tie straps to the front control arm bolt
pockets.
5. Wrap the front tie strap through the frame
tubes, or attach a tie-down hook around
each of the tubes.
6. Wrap the rear tie strap around the swing
arm.
Step 5
Step 5
Step 6
Tubes
100
SPECIFICATIONS
ACE 150 EFI
Maximum Rider Weight 180 lbs. (81 kg)
Maximum Weight Capacity 230 lbs. (104 kg)
Gross Vehicle Weight 802 lbs. (364 kg)
Dry Weight 572 lbs. (260 kg)
Fuel Capacity 2.5 gal. (9.5 ltr)
Engine Oil Capacity 35.5 oz. (1050 ml)
Transmission Oil Capacity 25 oz. (750 ml)
Overall Length 85 in. (216 cm)
Overall Width 48 in. (122 cm)
Overall Height 58 in. (147.3 cm)
Wheelbase 65 in. (165 cm)
Ground Clearance 9 in. (22.9 cm)
Engine Type 4-Stroke
Displacement 149 cc
Cooling Air + Oil
Bore x Stroke 57.4 mm x 57.8 mm
Alternator Output 180 watts
Compression Ratio 9.5:1
Starting System Electric
Fuel System Electronic fuel injection
101
SPECIFICATIONS
ACE 150 EFI
Throttle Body Size 32 mm
Ignition System Electronic Control Unit
Ignition Timing Timing non-adjustable, ECU controlled
Spark Plug / Gap NGK CR7HSA / 0.6-0.7 mm
Front Suspension Dual A-arm w/5.1 in. (13 cm) travel
Rear Suspension Dual Shock swing A-arm w/6 in. (15.2 cm)
travel
Lubrication System Wet Sump
Driving System Type Automatic Constant Variable Transmission
Final Drive Chain
Shift Type F/N/R
Tire Size - Front 22x7-10
Tire Size - Rear 22x10-10
Tire Pressure - Front 3 psi (20.7 kPa)
Tire Pressure - Rear 6 psi (41.4 kPa)
Brakes, Front/Rear Foot Activated, hydraulic disc
Parking Brake Mechanical, Rear (Lever)
Daytime Running Lights Dual, Standard
Brake Light Standard
102
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
Gearcase / Transmission Lubricants
2878068 AGL Full Synthetic Gearcase Lubricant & Transmission
Fluid (qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission
Fluid (gal./3.8 l)
2872348 Chain Lube, Aerosol
Grease / Specialized Lubricants
2871312 Grease Gun Kit, All Season Grease
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
2871329 Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326 Carbon Clean
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956 Loctite™ 565 Thread Sealant
103
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving at low RPM or
ground speed
Drive at a higher speed.
Insufficient warm-up at
low ambient
temperatures
Warm the engine at least 5 minutes. With the
transmission in neutral, apply small amount of throttle
in short bursts, 5 to 7 times. The belt will become more
flexible and prevent belt burning.
Slow/easy clutch
engagement
Use the throttle quickly and effectively.
Belt slippage from water
or snow ingestion into
the CVT system
Dry out the CVT (see page 75). Prevent water from
entering the CVT inlet and outlet ducts (see page 93).
Inspect clutch seals for damage if repeated leaking
occurs.
Clutch malfunction Your POLARIS dealer can assist.
Poor engine
performance
Check for fouled plug or foreign material in gas tank or
fuel lines. Your POLARIS dealer can assist.
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 41.
104
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel
Water is present in fuel Drain the fuel system and refuel
Old/non-recommended fuel Replace with fresh recommended fuel
Fouled/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.
Clogged fuel filter 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 heat
range
Set gap to specs or replace plug
Old/non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug
wires
Your POLARIS dealer can assist.
Incorrect ignition timing Your POLARIS dealer can assist.
Mechanical failure Your POLARIS dealer can assist.
Loose ignition connection Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
Exhaust system leak Your POLARIS dealer can assist.
105
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing Your POLARIS dealer can assist.
Incorrect spark plug gap/heat range Set gap to specs or replace plug
Possible Cause Solution
Fouled or defective spark plug Inspect/clean/replace spark plug
Worn or defective spark plug wires Your POLARIS dealer can assist.
Incorrect spark plug gap/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
Kinked/plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
ETC malfunction Your POLARIS dealer can assist.
Other mechanical failure Your POLARIS dealer can assist.
Possible Lean Fuel Cause
Solution
Low or contaminated fuel Add/change fuel, clean fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Your POLARIS dealer can assist.
Incorrect fuel Replace with recommended fuel
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Stopping/starting without adequate
warm-up
Allow engine to warm up before
operating and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
106
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Refuel
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug Inspect, clean and/or replace 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
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
Electronic throttle control malfunction Your POLARIS dealer can assist.
Other mechanical failure Your POLARIS dealer can assist.
107
WARRANTY
LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a
SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle
against defects in material or workmanship. POLARIS further warrants that the spark
arrester in this product will meet the efficiency requirements of USFS standard 5100-
1C for at least 1000 hours when subjected to normal use and when maintenance and
installation are in accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective
parts and begins on the date of purchase by the original retail purchaser. This warranty
is transferable to another owner during the warranty period through a POLARIS
dealer, but any such transfer will not extend the original term of the warranty. The
duration of this warranty may vary by international region based upon local laws and
regulations.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days of purchase. Upon receipt of this
registration, POLARIS will record the registration for warranty. No verification of
registration will be sent to the purchaser as the copy of the Warranty Registration
Form will be your proof of warranty coverage. If you have not signed the original
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 Exclusions:
Limitations Of Warranties And Remedies
This POLARIS limited warranty excludes any failures that are not caused by a defect
in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF
DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental
damage, normal wear and tear, abuse or improper handling. This warranty also does
not cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained or used for racing, competition or purposes other
than for which it was designed.
This warranty excludes damages or failures resulting from improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external
stress, heat, cold or contamination; operator error or abuse; improper component
alignment, tension, adjustment or altitude compensation; snow, water, dirt or other
foreign substance ingestion/contamination; improper maintenance; modified
components; use of aftermarket or unapproved components, accessories, or
attachments; unauthorized repairs; or repairs made after the warranty period expires or
by an unauthorized repair center.
108
WARRANTY
Warranty Coverage And Exclusions:
Limitations Of Warranties And Remedies
This warranty excludes damages or failures caused by abuse, accident, fire, or any
other cause other than a defect in materials or workmanship and provides no coverage
for consumable components, general wear items, or any parts exposed to friction
surfaces, stresses, environmental conditions and/or contamination for which they were
not designed or not intended, including but not limited to the following items:
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components and fluids
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps • Spark plugs
• Filters • Sealants
• Lubricants • Coolants
• Bushings • Bearings
109
WARRANTY
Warranty Coverage And Exclusions:
Limitations Of Warranties And Remedies
Lubricants and Fluids
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids
is not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage,
transportation costs, hotels, meals, shipping or handling fees, product pick-up or
delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or
personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,
AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH
IN THIS WARRANTY ARE THE ONLY REMEDIES 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
CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS
INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE
EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL
EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES
DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE
DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY
NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
110
WARRANTY
How To Obtain Warranty Service
If your vehicle requires warranty service, you must take it to a POLARIS Servicing
Dealer. When requesting warranty service you must present your copy of the Warranty
Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you
use your original selling dealer; however, you may use any POLARIS Servicing
Dealer to perform warranty service.
In the Country where your product was purchased:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer.
If you move or are traveling within the country where your product was purchased,
Warranty and Service Bulletin repairs may be requested from any authorized
POLARIS dealer that sells the same line as your product.
Outside the Country where your product was purchased:
If you are traveling temporarily outside the country where your product was
purchased, you should take your product to an authorized POLARIS dealer. You must
show the dealer photo identification from the country of the selling dealer's authorized
location as proof of residence. Upon residence verification, the servicing dealer will
be authorized to perform the warranty repair.
If you move:
If you move to another country, be sure to contact POLARIS Customer Assistance
and the customs department of the destination country before you move. Product
importation rules 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 your warranty coverage and to ensure that you receive information and
notices regarding your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside
of the country in which the product was originally purchased, all warranty coverage
will be denied. You must nonetheless register your product under your name and
address with a local POLARIS dealer in your country to ensure that you receive safety
information and notices regarding your product.
111
WARRANTY
Exported Products
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT
IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S
AUTHORIZED LOCATION. This policy does not apply to products that have
received authorization for export from POLARIS. Dealers may not give authorization
for export. You should consult an authorized dealer to determine this product's
warranty or service coverage if you have any questions. This policy does not apply to
products registered to government officials or military personnel on assignment
outside the country of the selling dealer's authorized location. This policy does not
apply to Safety Bulletins.
Notice
If your product is registered outside of the country where it was purchased and you
have not followed the procedure set above, your product will no longer be eligible for
warranty or service bulletin coverage of any kind, other than safety bulletins. Products
registered to government officials or military personnel on assignment outside of the
country where the product was purchased 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 because of federal, state, local law, all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
112
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first
purchased, this emissions-certified vehicle is designed, built and equipped so it
conforms with applicable U.S. Environmental Protection Agency emission
regulations. POLARIS warrants that the vehicle is free from defects in materials and
workmanship that would cause it to fail to meet these regulations.
The warranty period for off road vehicles 100cc or greater emissions-certified
vehicles starts on the date of purchase by original retail purchaser and continues for a
period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle
travel, or 30 calendar months from the date of purchase, whichever comes first. The
warranty period for ATVs less than 100cc emissions-certified vehicles starts on the
date of purchase by original retail purchaser and continues for a period of 250 hours of
engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar
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 parts may be
covered subject to the terms of any such paid service contract or paid warranty
extension.
This emissions limited warranty covers components whose failure increases the
vehicle's regulated emissions, and it covers components of systems whose only
purpose is to control emissions. Repairing or replacing other components not covered
by this warranty is the responsibility of the vehicle owner. This emissions limited
warranty does not cover components whose failure does not increase the vehicle's
regulated emissions.
For exhaust emissions, emission-related components include any engine parts related
to the following systems:
The following parts are also considered emission-related components for exhaust
emissions:
• Air-induction system • Ignition system
• Fuel system • Exhaust gas recirculation systems
• Aftertreatment devices • Sensors
• Crankcase ventilation valves • Electronic control units
113
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The following parts are considered emission-related components for evaporative
emissions:
*As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is to
reduce emissions or whose failure will increase emissions without significantly
degrading engine/equipment performance. The exclusive remedy for breach of this
limited warranty shall be, at the exclusive option of POLARIS, repair or replacement
of any defective materials, components or products. THE REMEDIES SET FORTH
IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES 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
CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS
INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE
EXCLUSIVE REMEDY FAILED OF 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 if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover damage due to accidents, abuse or
improper handling, maintenance or use. This limited warranty also does not cover any
engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or
defects caused by fire, explosions or other similar causes beyond the control of
POLARIS.
• Fuel Tank • Vacuum Control Diaphragms*
• Fuel Cap • Control Cables*
• Fuel Line • Control Linkages*
• Fuel Line Fittings • Purge Valves
• Clamps* • Vapor Hoses
• Pressure Relief Valves* • Liquid/Vapor Separator
• Control Valves* • Carbon Canister
• Control Solenoids* • Canister Mounting Brackets
• Electronic Controls* • Carburetor Purge Port Connector
114
WARRANTY
U.S.A. EPA Emissions Limited Warranty
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. POLARIS may deny warranty claims for failures that have been
caused by the owner's or operator's improper maintenance or use, by accidents for
which POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission
control devices or systems on your vehicle. An authorized POLARIS dealer can
perform any service that may be necessary for your vehicle. POLARIS also
recommends POLARIS parts, however equivalent parts may be used for such service.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering
with emission controls is prohibited by federal law.
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 letter “B” in the ninth position of
the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed
and built with features such as a reduced cargo box capacity. Any modifications to
these features may be a violation of the applicable California regulations and may
void this limited emissions warranty offered by the manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please
contact POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
115
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED /
COMMENTS
116
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED /
COMMENTS
117
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED /
COMMENTS
118
119
INDEX
A
Adjustment
Steering Wheel . . . . . . . . . . . . . . 30
Air Filter . . . . . . . . . . . . . . . . . . . . . 76
Air Filter Cleaning . . . . . . . . . . . . . 76
B
Battery . . . . . . . 87, 88, 89, 90, 91, 92
Charging (Sealed Battery) . . 91, 92
Battery Fluid Replenishment . . . . . 90
Battery Installation . . . . . . . . . . . . . 89
Battery Removal . . . . . . . . . . . . . . . 88
Battery Storage . . . . . . . . . . . . . . . . 90
Before Riding . . . . . . . . . . . . . . . . . 43
Belt Burning . . . . . . . . . . . . . . . . . 103
Belt Wear . . . . . . . . . . . . . . . . . . . 103
Belts, Seat . . . . . . . . . . . . . . . . . 31, 32
Boots . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Adjustment, Parking . . . . . . . 70
Brake Adjustment, Parking Brake Cable
Freeplay . . . . . . . . . . . . . . . . . . . . . 70
Brake Fluid . . . . . . . . . . . . . . . . . . . 79
Brake Pedal . . . . . . . . . . . . . . . . . . . 38
Brakes . . . . . . . . . . . . . . . . . . . . 77, 79
Braking . . . . . . . . . . . . . . . . . . . . . . 46
Break-In Period . . . . . . . . . . . . . 41, 42
Burning Belts . . . . . . . . . . . . . . . . 103
C
Cab Nets . . . . . . . . . . . . . . . . . . . . . 33
Cap, Fuel . . . . . . . . . . . . . . . . . . . . . 34
Changing Gears . . . . . . . . . . . . . . . 36
Chart, Periodic Maintenance
. . . . . . . . . . . . . . . . . 57, 59, 60, 62, 63
Cleaning and Storage
. . . . . . . . . . . . . . . . . 93, 95, 96, 97, 98
Cleaning the Air Filter . . . . . . . . . . 76
Clothing . . . . . . . . . . . . . . . . . . . . . 12
Clutching Chart . . . . . . . . . . . . . . . 102
Component Locations . . . . . . . . 27, 28
Condition, Spark Plugs . . . . . . . . . . 71
Constant Variable Transmission System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cover for Storage . . . . . . . . . . . . . . 98
Crankcase Emission Control System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CVT Break-In . . . . . . . . . . . . . . . . . 42
CVT Drying . . . . . . . . . . . . . . . . . . 75
CVT System . . . . . . . . . . . . . . . . . . 75
D
Drive Belt Wear . . . . . . . . . . . . . . 103
Drive Chain Lubrication . . . . . . . . . 68
Drive Chain Slack . . . . . . . . . . . . . 69
Drive Chain Slack Adjustment . . . . 70
Drivetrain Break-In . . . . . . . . . . . . 42
Driving Downhill . . . . . . . . . . . . . . 51
Driving in Reverse . . . . . . . . . . . . . 54
Driving on a Sidehill . . . . . . . . . . . 51
Driving on Slippery Surfaces . . . . . 49
Driving Over Obstacles . . . . . . . . . 53
Driving Procedures . . . . . . . . . . . . . 47
Driving Through Water . . . . . . . . . 52
Driving Uphill . . . . . . . . . . . . . . . . 50
E
Electromagnetic Interference . . . . . 56
Emission Control, Crankcase . . . . . 56
Emission Control, Exhaust . . . . . . . 56
Emission Control, Noise . . . . . . . . 56
Emissions Limited Warranty
. . . . . . . . . . . . . . . . . . . . 112, 113, 114
Engine Break-In . . . . . . . . . . . . . . . 42
Engine Fogging . . . . . . . . . . . . . . . 97
Engine Oil . . . . . . . . . . . . . . . . 65, 66
Engine Stopping . . . . . . . . . . . . . . . 46
Equipment Modifications . . . . . . . . 10
Exhaust Emission Control System . 56
Eye Protection . . . . . . . . . . . . . . . . 12
F
Filling the Battery . . . . . . . . . . . . . . 90
Filter Care During Storage . . . . . . . 96
Filter Cleaning, Air . . . . . . . . . . . . 76
Filter Systems . . . . . . . . . . . . . . . . . 76
Filter, Air . . . . . . . . . . . . . . . . . . . . 76
Fluid
Main Gearcase . . . . . . . . . . . . . . 67
Transmission . . . . . . . . . . . . . . . 67
Fluid Check
Main Gearcase . . . . . . . . . . . . . . 67
Transmission . . . . . . . . . . . . . . . 67
Fluid Levels During Storage . . . . . 96
Fluid, Battery . . . . . . . . . . . . . . . . . 90
Fluid, Brake . . . . . . . . . . . . . . . . . . 79
Fogging the Engine . . . . . . . . . . . . 97
Fouled Plugs . . . . . . . . . . . . . . . . . . 71
Freeplay, Steering Wheel . . . . . . . . 80
Fuel Cap . . . . . . . . . . . . . . . . . . . . . 34
Fuel Safety . . . . . . . . . . . . . . . . . . . 23
Fuel Stabilizer . . . . . . . . . . . . . . . . 96
Fuel Tank Filler Cap . . . . . . . . . . . 34
120
INDEX
G
Gap, Spark Plug . . . . . . . . . . . . . . . 71
Gasoline Handling . . . . . . . . . . . . . 23
Gear Selector . . . . . . . . . . . . . . . . . 36
Gearcase Oil
Main . . . . . . . . . . . . . . . . . . . . . . 67
Gearcases
Main Gearcase . . . . . . . . . . . . . . 67
Transmission . . . . . . . . . . . . . . . 67
Gears, shifting . . . . . . . . . . . . . . . . . 36
Gloves . . . . . . . . . . . . . . . . . . . . . . . 12
H
Helmet . . . . . . . . . . . . . . . . . . . . . . . 12
I
Ignition Switch . . . . . . . . . . . . . . . . 35
Inspection, Pre-Ride . . . . . . . . . . . . 43
Inspection, Seat Belts . . . . . . . . . . . 32
Inspection, Steering Wheel . . . . . . . 80
Installation, Battery . . . . . . . . . . . . . 89
Installation, Wheels . . . . . . . . . . . . 83
Interference, Electromagnetic . . . . . 56
K
Key, Periodic Maintenance Chart . . 59
L
Lamp Replacement
Tail Light . . . . . . . . . . . . . . . . . . 85
Lamp Replacement, Daytime Running
Lights . . . . . . . . . . . . . . . . . . . . . . . 84
Lights . . . . . . . . . . . . . . . . . . . . . . . 84
Lubricant Part Numbers . . . . . . . . 102
Lubrication for Storage . . . . . . . . . . 97
Lubrication Recommendations . . . . 64
M
Maintenance Log . . . . . . . . . 115, 116
Maintenance, Periodic
. . . . . . . . . . . . . . . . . 57, 59, 60, 62, 63
N
Nets, Cab . . . . . . . . . . . . . . . . . . . . . 33
New Operator Driving Procedures . 47
Noise Emission Control System . . . 56
O
Obstacles . . . . . . . . . . . . . . . . . . . . 53
Oil
Engine . . . . . . . . . . . . . . . . . 65, 66
Main Gearcase . . . . . . . . . . . . . . 67
Transmission . . . . . . . . . . . . . . . 67
Oil Change
Engine Oil . . . . . . . . . . . . . . . . . 66
Oil Check
Engine Oil . . . . . . . . . . . . . . . . . 65
Main Gearcase . . . . . . . . . . . . . . 67
Transmission . . . . . . . . . . . . . . . 67
Operation on Public Lands . . . . . . . 56
P
Parking Brake Adjustment . . . . . . . 70
Parking Brake Cable Freeplay
Adjustment . . . . . . . . . . . . . . . . . . . 70
Parking on an Incline . . . . . . . . . . . 55
Parking the Vehicle . . . . . . . . . . . . 46
Periodic Maintenance Chart
. . . . . . . . . . . . . . . . . 57, 59, 60, 62, 63
Plug Condition . . . . . . . . . . . . . . . . 71
Plug Gap . . . . . . . . . . . . . . . . . . . . . 71
Plug Torque . . . . . . . . . . . . . . . . . . 71
Plug, Spark . . . . . . . . . . . . . . . . . . . 71
Plugs, Fouled . . . . . . . . . . . . . . . . . 71
Polaris Products . . . . . . . . . . . . . . 102
Pre-Ride Inspection . . . . . . . . . . . . 43
Public Lands . . . . . . . . . . . . . . . . . . 56
R
Refueling Safety . . . . . . . . . . . . . . . 23
Registration, Warranty . . . . . . . . . 107
Removal, Battery . . . . . . . . . . . . . . 88
Removal, Seat . . . . . . . . . . . . . . . . . 29
Removing the Vehicle from Storage 98
Reverse . . . . . . . . . . . . . . . . . . . . . . 54
Riding Gear . . . . . . . . . . . . . . . 11, 12
121
INDEX
S
Safe Operation Practices . . . . . . . . . 44
Safety Labels . . . . . . . . . . . . . . 24, 25
Safety Symbols . . . . . . . . . . . . . . . . . 7
Safety Warnings
13, 15, 16, 17, 18, 19, 20, 21, 22, 23
Age Restrictions . . . . . . . . . . . . . 13
Cab Nets . . . . . . . . . . . . . . . . . . . 15
Crossing Hillsides . . . . . . . . . . . 18
Driving Downhill Improperly . . 18
Excessive Speeds . . . . . . . . . . . . 17
Exposure to Exhaust . . . . . . . . . 23
Failure to Inspect . . . . . . . . . . . . 15
Frozen Bodies of Water . . . . . . . 22
Improper Hill Climbing . . . . . . . 18
Improper Tires and Maintenance 20
Instruction . . . . . . . . . . . . . . . . . 13
Jumps and Stunts . . . . . . . . . . . . 17
Obstacles . . . . . . . . . . . . . . . . . . 21
Operating a Damaged Vehicle . . 22
Operating on Sand . . . . . . . . . . . 20
Operating Through Water . . . . . 21
Overloading . . . . . . . . . . . . . . . . 22
Pavement . . . . . . . . . . . . . . . . . . 16
Physical Control . . . . . . . . . . . . . 17
Protective Apparel . . . . . . . . . . . 15
Public Roads . . . . . . . . . . . . . . . 16
Reverse . . . . . . . . . . . . . . . . . . . . 20
Rider Height . . . . . . . . . . . . . . . . 14
Seat Belts . . . . . . . . . . . . . . . . . . 14
Slippery Terrain . . . . . . . . . . . . . 20
Stalling on a Hill . . . . . . . . . . . . 19
Turning Improperly . . . . . . . . . . 17
Unauthorized Use of the Vehicle 23
Unfamiliar Terrain . . . . . . . . . . . 19
Using Alcohol or Drugs . . . . . . . 16
Seat Adjustment, Driver’s . . . . . . . 29
Seat Belt Cleaning . . . . . . . . . . . . . 32
Seat Belt Inspection . . . . . . . . . . . . 32
Seat Belts . . . . . . . . . . . . . . . . . 31, 32
Seat Removal . . . . . . . . . . . . . . . . . 29
Selector, Gear . . . . . . . . . . . . . . . . . 36
Severe Use Definition . . . . . . . . . . . 58
Shifting Gears . . . . . . . . . . . . . . . . . 36
Shock Spring Adjustment . . . . . . . . 80
Signal Words . . . . . . . . . . . . . . . . . . 7
Spark Plug . . . . . . . . . . . . . . . . . . . . 71
Spark Plug Condition . . . . . . . . . . . 71
Spark Plug Gap . . . . . . . . . . . . . . . . 71
Spark Plug Removal . . . . . . . . . . . . 72
Spark Plug Torque . . . . . . . . . . . . . 71
Spark Plugs, Fouled . . . . . . . . . . . . 71
Speed Control System . . . . . . . . . . . 39
Stabilizing the Fuel . . . . . . . . . . . . . 96
Steering Wheel Adjustment . . . . . . 30
Steering Wheel Inspection . . . . . . . 80
Stopping the Engine . . . . . . . . . . . . 46
Storage . . . . . . . . . . 93, 95, 96, 97, 98
Storage and Inspection . . . . . . . . . . 97
Storage and Lubrication . . . . . . . . . 97
Storage Area . . . . . . . . . . . . . . . . . . 98
Storage, Battery . . . . . . . . . . . . . . . 90
Storage, Covers . . . . . . . . . . . . . . . 98
Storage, Fluid Levels . . . . . . . . . . . 96
Storage, Oil Change . . . . . . . . . . . . 96
Storage, Removal . . . . . . . . . . . . . . 98
T
Tail Light . . . . . . . . . . . . . . . . . . . . 85
Throttle Pedal . . . . . . . . . . . . . . . . . 38
Tire Tread Depth . . . . . . . . . . . . . . 82
Tires 82, 83
Front Wheel Hub Tightening . . . 82
Wheel Nut Torque . . . . . . . . . . . 83
Toe Alignment . . . . . . . . . . . . . . . . 81
Torque, Spark Plug . . . . . . . . . . . . . 71
Transmission Oil . . . . . . . . . . . . . . 67
Transporting the Vehicle . . . . . . . . 99
Tread Depth, Tire . . . . . . . . . . . . . . 82
V
Vehicle Identification Numbers . . . . 9
Vehicle Immersion . . . . . . . . . . . . . 86
Vehicle Transport . . . . . . . . . . . . . . 99
W
Warning Symbols . . . . . . . . . . . . . . . 7
Washing the Vehicle . . . . . . . . 93, 95
Water, Immersion of Vehicle . . . . . 86
Wear, Drive Belt . . . . . . . . . . . . . 103
Wheel Hub Tightening . . . . . . . . . . 82
Wheel Installation . . . . . . . . . . . . . 83
Wheel Nut Torque Specifications . 83
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER Operate:
• On hills steeper than 15 degrees.
• Without first viewing and understanding safety video and warning labels.
• On paved surfaces - pavement may seriously affect handling and control.
• At speeds that are too fast for the operator’s skills, the conditions and/or
the terrain.
ALWAYS:
• Secure cab nets or doors and keep hands and feet inside vehicle at all times.
• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
• Wear your seat 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.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9927517 Rev 03
Printed in USA
ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR.
ALL RIDERS MUST WEAR SEAT BELTS. NEVER USE ON PUBLIC ROADS.
NEVER USE WITH DRUGS OR ALCOHOL.
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
