2019
Owner’s MAnual
POLARIS ACE® 500
WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road
vehicle can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of California
to cause cancer and birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the engine expect as
necessary, service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
!
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.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
!
2019 Owner’s Manual
ACE 500
IMPORTANT SAFETY INFORMATION
Scan this QR code with your smartphone to see an
important Safety Video regarding your Polaris ACE vehicle.
This safety video can also be found at
http://www.polaris.com/en-us/rider-support/safety. If you are
on the homepage of the Polaris website, click on the Rider
Community heading and select “Product Safety and Training
Information” from the dropdown menu to access this page.
POLARIS® and ACE™ are trademarks of POLARIS Industries Inc.
Copyright 2018 Polaris Industries Inc. All information contained within this
publication is based on the latest product information at the time of
publication. Due to constant improvements in the design and quality of
production components, some minor discrepancies may result between the
actual vehicle and the information presented in this publication. Depictions
and/or procedures in this publication are intended for reference use only. No
liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or
in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are
provided as translations of the original instructions.
Printed in U.S.A.
2019 ACE Owner’s Manual
9929035
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide
family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for
the latest news, new product introductions, upcoming events, career
opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational
products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
• BRUTUS® work vehicles
• SLINGSHOT® three wheel
motorcycles
• RZR® sport vehicles
• GEM® vehicles
• INDIAN® motorcycles
• POLARIS POWER® generators
• POLARIS DEFENSE® combat
vehicles
• Timbersled® Snow Bikes
We believe POLARIS sets a standard of excellence for all utility and recreational
vehicles manufactured in the world today. Many years of experience have gone
into the engineering, design, and development of your POLARIS vehicle,
making it the finest machine we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Review the safety
DVD that came with your vehicle. POLARIS also recommends that all drivers
take the ROHVA safety e-course and a ROHVA hands-on safety training course.
Visit www.rohva.org or call 866-267-2751.
Your manual contains instructions for minor maintenance, but information about
major repairs is outlined in the POLARIS Service Manual and can be performed
by a factory certified Master Service Dealer® (MSD) Technician.
Your POLARIS dealer knows your vehicle best and is interested in your total
satisfaction. Your POLARIS dealership can perform all of your service needs
during, and after, the warranty period.
3
WELCOME
Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . 9
Features and Controls . . . . . . . . . . . . . . 29
Operation . . . . . . . . . . . . . . . . . . . . 53
Winch Guide. . . . . . . . . . . . . . . . . . . 73
Emission Control Systems . . . . . . . . . . . . . 85
Maintenance . . . . . . . . . . . . . . . . . . 87
Specifications . . . . . . . . . . . . . . . . . . 135
Troubleshooting ACE Problems . . . . . . . . . . 137
POLARIS Products . . . . . . . . . . . . . . . . 141
Warranty . . . . . . . . . . . . . . . . . . . . 143
Maintenance Log . . . . . . . . . . . . . . . . 151
5
6
INTRODUCTION
WARNING
WARNING indicates a hazardous situation that, if not avoided, may result in
death to the operator, bystanders or person(s) inspecting or servicing the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle
damage or property damage.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in
minor personal injury or damage to the vehicle.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
NOTICE
NOTICE provides key information by clarifying instructions.
The Prohibition Safety Sign indicates an action NOT to take in
order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to
be taken to avoid a hazard.
7
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.
q
Vehicle Identification Number
(VIN)
w
Engine Serial Number
Vehicle Model Number:
Vehicle Identification Number (VIN):
Engine Serial Number:
Key Number
8
INTRODUCTION
SAFETY
SAFETY TRAINING
Safety training is a top priority for POLARIS. POLARIS strongly encourages you
and any family members who will be riding this vehicle to take a training course.
ROHVA (Recreational Off-Highway Vehicle Association) provides both an online
safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-
267-2751.
Your POLARIS vehicle is considered an off-road vehicle. Familiarize yourself
with all laws and regulations concerning the operation of this vehicle in your
area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance program
is designed to ensure that all critical components on your vehicle are thoroughly
inspected at specific intervals.
For more information about recreational off-road vehicle safety in the
United States, visit www.rohva.org, call 866-267-2751 or call POLARIS at
800-342-3764.
9
SAFETY
SAFE RIDING GEAR
Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-
the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces
the chance of injury.
RIDER COMFORT
Under certain operating conditions, heat generated by the engine and exhaust
system can elevate temperatures in the rider cab area. The condition occurs
most frequently when a vehicle is being operated in high ambient temperatures
at low speeds and/or high load conditions for an extended period of time. The
use of certain windshield, roof and/or cab systems may contribute to this
condition by restricting airflow. Any discomfort due to heat buildup in this area
can be minimized by wearing proper riding apparel and by varying speeds to
increase airflow.
q
Helmet
w
Eye Protection
e
Long Sleeves
r
Gloves
t
Long Pants
y
Over-the-Ankle Boots
10
SAFETY
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds established
safety standards.
Parents should verify that the young operator has a helmet that fits, and should
obtain one of proper size if it does not fit before allowing operation.
Approved helmets in the USA and Canada
bear a U.S. Department of Transportation
(DOT) label.
Approved helmets in Europe, Asia and
Oceania bear the ECE 22.05 label. The ECE
mark consists of a circle surrounding the
letter E, followed by the distinguishing
number of the country which has granted
approval. The approval number and serial
number will also be displayed on the label.
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding
this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof
helmet face shield. POLARIS recommends wearing approved Personal
Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or
CE. Make sure protective eye wear is kept clean.
GLOVES
Wear gloves for comfort and for protection from sun, cold weather and other
elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a
POLARIS vehicle with bare feet or sandals.
11
SAFETY
SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and
follow the instructions of the labels on the vehicle carefully. If any of the labels
depicted in this manual differ from the labels on your vehicle, always read and
follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your
POLARIS dealer to purchase a replacement. Replacement safety labels are
provided by POLARIS at no charge. The part number is printed on the label.
q
Seat Belt / Driver Warning
e
Maximum Payload Warning
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Proper Use Warning
12
SAFETY
SEAT BELT / DRIVER WARNING (7185102)
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
Be Prepared
• Fasten seat belt.
• Wear an approved helmet and protective gear.
• ALWAYS use vehicle cab nets and/or doors.
• Driver must be able to sit with back against seat, feet flat on the floor, and
hands on steering wheel. Stay completely inside the vehicle.
Drive Responsibly
Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways sliding,
skidding or fishtailing, and never do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when turning, even from
a stop.
• Plan for hills, rough terrain, ruts and other
changes in traction and terrain.
• Avoid paved surfaces.
• Avoid sidehilling (riding across slopes).
Rollovers have caused
severe injuries and
death, even on flat, open
areas.
Be Sure to Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
• Keep a firm grip on the steering wheel and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
13
SAFETY
PROPER USE WARNING (7185101)
WARNING
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid
driver’s license.
• Do not let people drive after using alcohol or
drugs.
• Do not allow operation on public roads (unless
designated for off-highway vehicle access) -
collisions with cars and trucks can occur.
• Do not exceed seating capacity: 1 occupant.
MAXIMUM PAYLOAD WARNING (7186123)
WARNING
Never exceed 35 mph (56 kph) if total payload exceeds 245 lbs (111 kg).
14
SAFETY
LOAD/PASSENGER/TIRE PRESSURE WARNING
(7186083)
WARNING
• Never carry passengers in cargo box.
• Passengers can be thrown off. This can cause serious injury or death.
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
• Reduce speed and allow greater distance for braking when carrying cargo.
• Overloading or carrying tall, off-center, or unsecured loads will increase your
risk of losing control. Loads should be centered and carried as low as possible
in box.
• For stability on rough or hilly terrain, reduce speed and cargo.
ACE
MAXIMUM CARGO BOX LOAD
240 lbs.
(108 kg)
TIRE PRESSURE IN PSI (KPa)
FRONT 7 (48)
REAR 7(48)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF
OPERATOR, CARGO AND
ACCESSORIES
575 lbs.
(260 kg)
Read Operation and Maintenance Manual for more detailed loading
information.
HITCH CAPACITY LABEL (7170509)
TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15 DEGREES
850 LBS. (386 KG) UP TO 15 DEGREES
15
SAFETY
FUEL TRANSPORT WARNING
WARNING
NEVER carry fuel or other flammable liquids on this
vehicle
Failure to follow this instruction could lead to serious
burn injuries or death.
PVT SYSTEM WARNING (7177469)
WARNING
Improper service or maintenance of this PVT
system can result in vehicle damage,
SEVERE INJURY or DEATH.
Always look for and remove debris inside
and around clutch and vent system when
replacing belt.
Read owner's manual or see authorized
Polaris dealer.
q
PVT System Warning
AIR BOX CAUTION (7181728)
CAUTION
Use a Polaris approved air filter. The use of
a non-Polaris approved air filter may cause
engine damage. Before installing filter,
ensure there is no dirt or debris in the clean
side of the intake tube. The air filter must be
properly seated before the lid is reinstalled.
Please reference your owner’s manual for
additional information regarding air filter
service.
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Air Box Caution
16
SAFETY
SAFETY WARNINGS
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. See the OPERATION section of the owner’s
manual for proper operating procedures.
OPERATING WITHOUT INSTRUCTION
Operating this vehicle without proper instruction
increases the risk of an accident. The operator must
understand how to operate the vehicle properly in
different situations and on different types of terrain.
All operators must read and understand the owner's
manual and all warning and instruction labels before
operating the vehicle.
All operators should review the safety DVD provided
with this vehicle and take a ROHVA training course
(www.rohva.org).
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY. Operation
is prohibited for anyone under 16 years of age or
anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and both
hands on the steering wheel (if equipped) or
handlebars.
USING ALCOHOL OR DRUGS
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
17
SAFETY
FAILURE TO INSPECT BEFORE OPERATING
WARNING
Failure to inspect and verify that the vehicle is in
safe operating condition before operating
increases the risk of an accident.
Always perform the pre-ride inspection before each
use of your vehicle to make sure it's in safe
operating condition.
Always follow the inspection and maintenance
procedures and schedules described in this
manual and your Vehicle Manual.
PROTECTIVE APPAREL
Riding in this vehicle without wearing an approved
helmet and protective eye wear increases the risk of
a serious injuries in the event of an accident.
Always wear a helmet, eye protection, gloves, long-
sleeve shirt, long pants and over-the-ankle boots.
SEAT BELTS
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of rollover, loss of control, other accident or sudden stop. Seat
belts may reduce the severity of injury in these circumstances.
The operator MUST wear the seat belt at all times.
18
SAFETY
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.
CARRYING A PASSENGER
This POLARIS vehicle is a single-rider vehicle.
Carrying a passenger greatly reduces the operator's
ability to control the vehicle, which may result in an
accident or rollover. Carrying a passenger in the
cargo box could result in a fall from the vehicle or
contact with moving components. Never carry a
passenger on this vehicle.
19
SAFETY
OPERATING WITH A LOAD ON THE VEHICLE
The weight of both cargo and operator impacts vehicle operation and stability.
For your safety and the safety of others, carefully consider how your vehicle is
loaded and how to safely operate the vehicle. Follow the instructions in this
manual for loading, tire pressure, gear selection and speed.
• Do not exceed vehicle weight capacities. The vehicle’s maximum weight
capacity is listed in the specifications section of this manual and on a label on
the vehicle. When determining the weight you are adding to the vehicle,
include the weight of the operator, accessories, loads in the rack or box and
the load on the trailer tongue. The combined weight of these items must not
exceed the maximum weight capacity.
• The recommended tire pressures are listed in the specifications section of this
manual and on a label on the vehicle.
Always follow these guidelines:
UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS:
Operator and/or cargo exceeds half the
maximum weight capacity
1. Slow down.
2. Verify tire pressure.
3. Use extra caution when operating.
Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing
IMPROPER TIRE MAINTENANCE
Operating this vehicle with improper tires or with
improper or uneven tire pressure could cause loss of
control or accident.
Always use the size and type of tires specified for your
vehicle.
Always maintain proper tire pressure as described in
the owner's manual and on safety labels.
20
SAFETY
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).
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.
21
SAFETY
TURNING IMPROPERLY
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this owner’s
manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
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.
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 58.
22
SAFETY
DESCENDING HILLS IMPROPERLY
Improperly descending a hill could cause loss of
control or rollover. Always follow proper procedures
for traveling down hills as described in this owner’s
manual. See page 58.
CROSSING HILLSIDES
Driving on a sidehill is not recommended. Improper
procedure could cause loss of control or rollover.
Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow
proper procedures as described in this owner's
manual.
STALLING WHILE CLIMBING A HILL
Stalling or rolling backwards while climbing a hill
could cause a rollover. Maintain a steady speed
when climbing a hill.
If you lose all forward speed:
Apply the brakes gradually until the vehicle is fully
stopped. Place the transmission in reverse and
slowly allow the vehicle to roll straight downhill while
applying light brake pressure to control speed.
23
SAFETY
OPERATING IN UNFAMILIAR TERRAIN
Failure to use extra caution when operating on
unfamiliar terrain could result in an accident or
rollover.
Unfamiliar terrain may contain hidden rocks, bumps,
or holes that could cause loss of control or rollover.
Travel slowly and use extra caution when operating
on unfamiliar terrain. Always be alert to changing
terrain conditions.
OPERATING IMPROPERLY IN REVERSE
Improperly operating in reverse could result in a
collision with an obstacle or person. Always follow
proper operating procedures as outlined in this
manual.
Before shifting into reverse gear, always check for
obstacles or people behind the vehicle. When it's
safe to proceed, back slowly.
SKIDDING OR SLIDING
Failure to use extra caution when operating on
excessively rough, slippery or loose terrain could
cause loss of traction, loss of control, accident or
rollover. Do not operate on excessively slippery
surfaces. Always slow down and use additional
caution when operating on slippery surfaces.
Skidding or sliding due to loss of traction can cause
loss of control or rollover (if tires regain traction
unexpectedly). Always follow proper procedures for
operating on slippery surfaces as described in this
owner's manual. See page 58.
24
SAFETY
OPERATING OVER OBSTACLES
Improperly operating over obstacles could cause
loss of control or rollover.
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as large
rocks and fallen trees. Always follow the proper
procedures outlined in this manual when operating
over obstacles.
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 of the vehicle.
Always follow proper procedures for operating in
water as described in this owner’s manual. See
page 58.
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.
OPERATING ON FROZEN BODIES OF WATER
Severe injury or death can result if the vehicle and/
or the operator fall through the ice. Never operate
the vehicle on a frozen body of water unless you
have first verified that the ice is sufficiently thick to
support the weight and moving force of the vehicle,
you and your cargo, together with any other vehicles
in your party.
Always check with local authorities and residents to
confirm ice conditions and thickness over your
entire route. Vehicle operators assume all risk
associated with ice conditions on frozen bodies of
water.
25
SAFETY
OPERATING A DAMAGED VEHICLE
Operating a damaged vehicle can result in an accident. After any rollover or
other accident, have a qualified service dealer inspect the entire machine for
possible damage, including (but not limited to) seat belts, rollover protection
devices, brakes, throttle and steering systems.
IMPROPER CARGO LOADING
Overloading the vehicle or carrying/towing cargo improperly may cause changes
in stability and handling, which could cause loss of control or an accident.
• Always follow the instructions in this owner’s manual for carrying cargo. See
the Hauling Cargo section for details.
Never exceed the stated load capacity for this vehicle. See the Load /
Passenger / Tire Pressure Warning section for details.
• Cargo should be properly distributed and securely attached. See the Hauling
Cargo section for details.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater
distance for braking.
POOR VISIBILITY
Operating this vehicle in darkness or inclement weather could result in a
collision or accident, especially if operating on a road or street. This vehicle is
not equipped with highway-approved lights. Operate this vehicle off-road only.
Use caution and drive at reduced speeds in conditions of reduced visibility such
as fog, rain and darkness. Clean headlights frequently and replace burned out
headlamps promptly.
REFUELING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always turn off the engine when refueling.
• Always refuel outdoors or in a well ventilated area free of any source of flame
or sparks.
• Never carry fuel or other flammable liquids on this vehicle. Failure to follow
this instruction could lead to serious burn injuries or death.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
26
SAFETY
EXPOSURE TO EXHAUST
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
HOT EXHAUST SYSTEMS
WARNING
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system.
Use caution when traveling through tall grass, especially dry grass. Always
inspect the underside of the vehicle and areas near the exhaust system after
driving through tall grass, weeds, brush, and other tall ground cover. Promptly
remove any grass or debris clinging to the vehicle.
UNAUTHORIZED USE OF THE VEHICLE
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 16, without a drivers license, or without proper
training. This could result in an accident or rollover. Always remove the ignition
key when the vehicle is not in use.
HEAT SHIELDING
WARNING
Your vehicle is equipped with heat shielding. Do not remove heat shielding. If
heat shields become loose, or are removed, see your dealer to have shielding
re-installed properly.
27
SAFETY
EQUIPMENT MODIFICATIONS
Your POLARIS vehicle is designed to provide safe operation when used as
directed. Modifications to your vehicle may negatively impact vehicle stability.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. This vehicle may
become less stable at speeds higher than those for which it is designed. Loss of
control may occur at higher speeds.
Do not install any non-POLARIS-approved accessory or modify the vehicle for
the purpose of increasing speed or power. Any modifications or installation of
non-POLARIS-approved accessories could create a substantial safety hazard
and increase the risk of bodily injury.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if
any non-POLARIS approved equipment and/or modifications have been added
to the vehicle that increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers, or large racks, may change the handling characteristics
of the vehicle. Use only POLARIS-approved accessories, and familiarize
yourself with their function and effect on the vehicle.
FOR MORE INFORMATION ABOUT SAFETY
call POLARIS at 1-800-342-3764.
28
SAFETY
TRAILER RECEIVER HITCH BRACKET
This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer
towing equipment is not supplied with this vehicle.
To avoid injury and property damage, always heed the warnings and towing
capacities outlined in the Hauling Cargo section of this manual.
SERVICE ACCESS PANELS
Access serviceable engine components through the engine access panel
q
behind the seat. Remove the seat and release the access panel latches to
remove the access panel.
Remove the rear access panel
w
to access the air box, oil fill cap and spark
plugs. The rear access panel is located in the bed of the cargo box. Pull the rear
edge of the access panel upward to remove it.
RADIATOR ACCESS/BUMPER REMOVAL
The front bumper can be removed to clean debris from the radiator.
1. Remove the two (2) plastic rivets
q
and four (4) torx screws
w
.
2. Lift the front bumper to remove it
from the vehicle.
30
FEATURES AND CONTROLS
STEERING WHEEL
Always make sure the steering wheel position does not impede proper operation
of the brake pedal, throttle pedal and all other controls.
The steering wheel can be tilted
upward or downward for rider
preference.
Lift and hold the steering wheel
adjustment lever
q
while moving the
steering wheel upward or downward.
Release the lever when the steering
wheel is at the desired position.
FRONT BOX COVER
Open the front box cover and remove
the access panel to access the
radiator cap, coolant overflow bottle
and brake master cylinder reservoir.
1. Turn the box cover fasteners
q
1/4 turn.
2. Lift the rear edge of the box cover.
3. Using the pliers provided in the tool
kit, remove the 8 push darts
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from the access panel.
4. Remove the panel.
31
FEATURES AND CONTROLS
CAB NETS
This vehicle is equipped with 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. Cab nets (or doors) must be used at all
times. Make sure all latches on both sides of the vehicle are secure before
operating the vehicle.
Always inspect cab nets and latches 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 and latches with new cab nets and
latches. Your POLARIS dealer can assist.
EXTREME USE BATTERY
An optional extreme use battery may be available for your model. If the
performance of the factory-installed battery is inadequate due to operation in
extreme cold or due to extended use of multiple electrical accessories, your
POLARIS dealer can assist. Your dealer can provide any installation procedures
that may differ for an extreme use battery.
FUEL CAP
NOTICE
Never use fuel blends with more than 10% ethanol. Engine damage could
occur.
The fuel tank filler cap
q
is located on
the right side of the vehicle near the
seat. Use only unleaded gasoline with
a minimum pump octane number of 87
R+M/2 octane. Unleaded fuel blends
with up to 10% ethanol can be used.
32
FEATURES AND CONTROLS
SEAT
SEAT ADJUSTMENTS
Always make sure the seat position
allows for proper access and operation
of the brake pedal, throttle pedal and
all other controls.
The seat release lever
q
is located at
the left side of the seat. Push the
release lever downward and slide the
seat forward or rearward to the desired
position. Release the lever. The seat
will lock into the new position.
SEAT REMOVAL
1. Push the seat release lever downward and slide the seat forward until it
slides off the frame.
2. Lift the seat away from the vehicle.
3. Reverse the procedure to reinstall the seat.
SEAT BELT
This POLARIS vehicle is equipped with three-point lap and diagonal seat belts.
Always secure the seat belt 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.
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.
33
FEATURES AND CONTROLS
SEAT BELT INSPECTION
Inspect all seat belts for proper operation before each use of the vehicle.
1. Push the latch plate
q
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
w
in the
middle of the buckle to make sure it
releases freely.
3. Pull each seat belt completely out
and inspect the full length for any
damage, including cuts, wear,
fraying or stiffness. If any damage
is found, or if the seat belt does not
operate properly, have the seat belt
system checked and/or replaced
by an authorized POLARIS dealer.
4. To clean dirt or debris from the seat
belts, sponge the straps with mild
soap and water. Do not use bleach,
dye or household detergents. Use
a garden hose to flush out the
retractor
e
and latch housing
w
regularly.
34
FEATURES AND CONTROLS
SWITCHES
q
Instrument Cluster
e
Drive Mode (AWD) Switch
w
Ignition Switch/Light Switch
r
12V Accessory Outlet
IGNITION SWITCH/LIGHT SWITCH
Use the ignition switch to start the engine and to turn
the lights on or off. The key can be removed from the
switch when it is in the OFF position.
OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off.
LIGHTS ON The lights are on. Electrical circuits are on. Electrical equipment can be used.
LIGHTS OFF The lights are off. Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter. See the
Starting the Engine section for starting procedures.
35
FEATURES AND CONTROLS
DRIVE MODE (AWD) SWITCH
The drive mode switch controls the All Wheel
Drive (AWD/4X4) system. Use this switch to
engage AWD (4X4) or 2X4. The vehicle
automatically engages 4X4 when operating in
reverse if the drive mode is set to AWD (4X4).
See page 37 for drive mode (AWD) operating
instructions.
AWD
2WD
AUXILIARY OUTLET
The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the
outlet to power an auxiliary light or other optional accessories or lights. For
service, the dash outlet connection is under the dash.
36
FEATURES AND CONTROLS
ALL WHEEL DRIVE (AWD) SYSTEM
The drive mode switch controls the All
Wheel Drive (AWD/4X4) system.
• Press and release the top of the switch to
toggle through the drive mode options,
which display in the information center of
the gauge for several seconds.
• Press and release the bottom of the
switch to toggle to a previous option.
• When the switch is released, the drive
mode displayed in the information center
is the active drive mode.
When in AWD, the demand drive unit will
automatically engage any time the rear
wheels lose traction. When the rear wheels
regain traction, the demand drive unit will
automatically disengage.
There is no limit to the length of time the
vehicle may remain in AWD.
AWD
2WD
ENGAGING AWD
AWD can be engaged or disengaged while the vehicle is moving. Initially, the
vehicle’s electronic system will not enable the AWD until the engine RPM is
below 3100. Once enabled, the AWD remains enabled until disabled with the
drive mode switch.
Engage AWD before getting into conditions where front wheel drive may be
needed. If the rear wheels are spinning, release the throttle before switching to
AWD.
NOTICE
Switching to AWD while the rear wheels are spinning or slipping may cause
severe drive shaft and gearcase damage. Always switch to AWD while the rear
wheels have traction or are at rest.
37
FEATURES AND CONTROLS
GEAR SELECTOR
To change gears, stop the vehicle, and with the engine idling, move the lever
q
to the desired gear. Do not attempt to shift gears with engine speed above idle or
while the vehicle is moving.
P: Park
R: Reverse
N: Neutral
L: Low Gear
H: High Gear
NOTICE
Do not attempt to shift the transmission while the vehicle is moving or damage
to the transmission could result. Always shift when the vehicle is stationary and
the engine is at idle.
USING LOW RANGE
Always shift into low gear for any of the following conditions.
• Operating in rough terrain or over obstacles
• Loading the vehicle onto a trailer
• Towing heavy loads
• Operating consistently at speeds below 15 MPH (24 kmph)
BRAKE PEDAL
Depress the brake pedal
q
to slow or
stop the vehicle. Apply the brakes
while starting the engine.
When the brake pedal is depressed,
the brake light comes on. Check the
brake light before each ride.
1. Turn the ignition switch to the
LIGHTS ON position.
2. Apply the brakes. The brake light
should come on after about 10 mm
(0.4 in.) of pedal travel.
38
FEATURES AND CONTROLS
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
w
returns normally before starting the engine.
TIP
If the throttle pedal and brake pedal are applied simultaneously, engine power
may be limited.
WARNING
Never start or operate this vehicle if it has a sticking or improperly operating
throttle pedal. Immediately contact your POLARIS dealer or other qualified
person for service if throttle problems arise.
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
The Rollover Protective Structure
(ROPS) on this vehicle meets OSHA
1928.53 rollover performance
requirements. Always have your
authorized POLARIS dealer
thoroughly inspect the ROPS if it ever
becomes damaged in any way.
No device can assure occupant
protection in the event of a rollover.
When used with seat belts and cab
nets (or doors), the ROPS helps
prevent occupants from being ejected
from the vehicle. Always follow all safe
operating practices outlined in this
manual to avoid vehicle rollover.
ROPS label
q
located on ROPS
behind cab.
WARNING
Vehicle rollover could cause severe injury or death. Always avoid operating in
a manner that could result in vehicle rollover.
39
FEATURES AND CONTROLS
INSTRUMENT CLUSTER
OVERVIEW
NOTE
The use of a high pressure washer may damage the instrument cluster. Wash
the vehicle by hand or with a garden hose using mild soap. Do not use alcohol
to clean the instrument cluster. Do not allow insect sprays to contact the lens.
Immediately clean off any gasoline that splashes on the instrument cluster.
q
Gear Indicator
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
– = Gear Signal Error (or shifter between gears)
w
Display Area 2
This area displays odometer, trip meter, trip meter 2, voltage, engine
temperature, engine hour meter, programmable service hour interval,
ground speed, or engine RPM.
e
Display Area 1
This area displays engine RPM, ground speed, or coolant temperature.
r
Fuel Gauge
The segments of the fuel gauge show the level of fuel in the fuel tank.
When the last segment clears, a low fuel warning is activated. All
segments including the fuel icon will flash. Refuel immediately.
t
Service Indicator
A flashing wrench symbol alerts the operator that the preset service
interval has been reached. Your POLARIS dealer can provide scheduled
maintenance. See page 50 for more information.
y
Clock
The clock displays time in a 12-hour or 24-hour format. See page 47 for
more information.
u
AWD Indicator
Segments of the indicator illuminate based on drive mode engaged.
41
FEATURES AND CONTROLS
INDICATOR LAMPS
q
Check Engine
This indicator appears if an EFI-related fault occurs. Do not
operate the vehicle if this warning appears. Serious engine
damage could result. Your authorized POLARIS dealer can
assist.
w
EPS Warning (if
equipped)
This indicator illuminates when a fault has occurred in the
EPS system. Your authorized POLARIS dealer can assist.
EPS operation is possible with key on/engine off for up to 5
minutes.
e
Engine Hot
This lamp illuminates to indicate an overheated engine. If the
indicator flashes, a severe overheating condition exists.
r
Neutral
This lamp illuminates when the transmission is in neutral and
the ignition key is in the ON position.
t
Helmet/Seat Belt
This lamp flashes for several seconds when the key is turned
to the ON position. The lamp is a reminder to wear helmet and
seat belt (if equipped) before operating.
y
High Beam
This lamp illuminates when the headlamp switch is set to high
beam.
u
Chassis Fault
If applicable.
i
Performance
Limited
On models equipped with a low speed limiter, indicator light
will remain on when low speed limiter is active.
42
FEATURES AND CONTROLS
OPTIONS MENU
Press and hold the MODE button to enter the Options Menu.
OPTIONS MENU NOTES
Diagnostic Codes Only displays if fault codes are
present or stored
Units - Distance Select MPH or KPH
Units - Temp Select between °F and °C
Clock Select between 12H or 24H, and set
time
Backlight Color Select between Blue or Red
Backlight Level Set backlight brightness level
Service Hours View/Set Service hours
Exit Menu Exit
45
FEATURES AND CONTROLS
UNIT SELECTION DISTANCE
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
2. Select “Units-Distance” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (MPH or KPH)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
UNIT SELECTION TEMPERATURE
46
FEATURES AND CONTROLS
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
2. Select “Units - Temp” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (°F or °C)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
CLOCK
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
47
FEATURES AND CONTROLS
2. Select “Clock” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (12H or 24H)
e
With the correct unit displayed, Press the mode button which will set
the unit.
r
Toggle the Up/Down Buttons to change the units (Cycles Hours)
t
With the correct unit displayed, Press the mode button which will set
the unit.
y
Toggle the Up/Down Buttons to change the units (Cycles 10s of
Minutes)
u
With the correct unit displayed, Press the mode button which will set
the unit.
i
Toggle the Up/Down Buttons to change the units (Cycles 1s of
Minutes)
o
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
BACK LIGHT COLOR
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
48
FEATURES AND CONTROLS
2. Select “Backlight Color” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (Blue or Red)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
BACK LIGHT LEVEL
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
2. Select “Backlight Level” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (Increase or De-
crease Level)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
49
FEATURES AND CONTROLS
SERVICE HOURS
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
2. Select “Service Hours” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (0, 5, 10, - 95,100)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
NOTE
To reset service hours after they have counted down to "0.0" reselect the
existing setpoint or select a new service hour value.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
50
FEATURES AND CONTROLS
DIAGNOSTIC CODE
NOTE
Diagnostic Code Screen will show available MIL that has come on during that
ignition cycle.
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item
2. Select “Diagnostic Codes” from the Options Menu by pressing the MODE
button.
Toggle the Up/Down Buttons to cycle through Code(s).
NOTE
This option will only be available if a fault code was set or is active during the
current ignition key 'on' cycle. Turning off the ignition will clear any save fault
codes from the gauge.
Reference the image shown above:
q
Area A will Display FMI (XX)
w
Area B will Display SPN (XXXXXX)
e
Clock Area will Display Count (XXX)
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
51
FEATURES AND CONTROLS
52
OPERATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
VEHICLE BREAK-IN PERIOD
The break-in period for your new POLARIS vehicle is the first 25 hours of
operation, or the time it takes to use the first two tanks full 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.
Use of any improper oils may cause serious engine damage. POLARIS PS-4
Full Synthetic 5W-50 4-Cycle Oil is specifically formulated for your 4-cycle
engine.
53
OPERATION
ENGINE AND DRIVETRAIN BREAK-IN
1. Fill the fuel tank with gasoline. Use only unleaded gasoline with a minimum
pump octane number of 87 R+M/2 octane. Unleaded fuel blends with up to
10% ethanol can be used. See the Fuel Cap section of your Vehicle Manual
for the fuel tank’s location. Always exercise extreme caution whenever
handling gasoline.
2. Check the oil level. See the Engine Oil section of your Vehicle Manual for
more information about this procedure. Add the recommended oil as needed
to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined in the Ace Safety
Manual.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained idle.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls and areas outlined on the
daily pre-ride inspection checklist. See page 55.
8. During the break-in period, change both the oil and the filter at 25 hours or
one month.
9. Check fluid levels of transmission and all gearcases after the first 25 hours of
operation and every 100 hours thereafter.
BRAKE SYSTEM BREAK-IN
Apply only moderate braking force for the first 50 stops. Aggressive or overly
forceful braking when the brake system is new could damage brake pads and
rotors.
PVT BREAK-IN (CLUTCHES/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. Pull only light loads. Avoid
aggressive acceleration and high speed operation during the break-in period.
If a belt fails, always clean any debris from the PVT intake and outlet duct and
from the clutch and engine compartments when replacing the belt.
54
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
Brake system/pedal travel Ensure proper operation
Brake fluid Ensure proper level
Front suspension Inspect, lubricate if necessary
Rear suspension Inspect, lubricate if necessary
Steering Ensure free operation
Tires Inspect condition and pressure
Wheels/fasteners Inspect, ensure fastener tightness
Frame nuts, bolts, fasteners Inspect, ensure tightness
Fuel and oil Ensure proper levels
Coolant level Ensure proper level
Coolant hoses Inspect for leaks
Throttle Ensure proper operation
Indicator lights/switches Ensure proper operation
Intake pre-filters Inspect, clean
Headlamps Check operation, apply POLARIS dielectric grease
when lamp is replaced
Brake light/tail lamps Check operation
Seat Latch Push down on the seat back to ensure the latch is
secure
Seat Belt Check length of belt for damage, check latches for
proper operation
Cab Doors (if equipped) Check doors and latches for wear or damage.
Cab Nets (if equipped Check for wear or damage, ensure proper
installation
Grass and Leaves Remove grass, leaves, and other flammable
material or debris, especially near the HOT exhaust
system.
55
OPERATION
STARTING THE ENGINE
1. Position the vehicle on a level surface outdoors
or in a well ventilated area.
2. Sit in the driver's seat and fasten the seat belt.
Secure the cab nets.
3. Place the transmission in PARK.
4. Apply the brakes. Do not press the throttle pedal
while starting the engine.
5. Turn the ignition key to the START position.
Engage the starter for a maximum of five
seconds. Release the key when the engine
starts. Turn the key to either LIGHTS ON or
LIGHTS OFF.
6. If the engine does not start within five seconds,
return the ignition switch to the OFF position and
wait five seconds. Repeat steps 5 and 6 until the
engine starts.
7. Vary the engine RPM slightly with the throttle to
aid in warm up until the engine idles smoothly.
NOTICE
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.
COLD WEATHER OPERATION
If the vehicle is used year-round, check the oil level frequently. A rising oil level
could indicate the accumulation of contaminates such as water or excess fuel in
the bottom of the crankcase. Water in the bottom of the crankcase can lead to
engine damage and must be drained. Water accumulation increases as outside
temperature decreases.
56
OPERATION
STOPPING THE ENGINE
1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
WARNING
A rolling vehicle can cause serious injury. Always place the transmission in
PARK when stopping 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 PARK.
3. Turn the engine off.
4. Engage the parking brake (if equipped).
5. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
6. Remove the ignition key to prevent unauthorized use.
57
OPERATION
TURNING THE VEHICLE
Your vehicle is equipped with a solid rear axle, which drives both rear wheels
equally at all times. This means that the wheel on the outside of the turn must
travel a greater distance than the inside wheel when turning and the inside tire
must slip traction slightly.
To turn the vehicle, rotate the steering wheel in the direction of the turn.
Practice making turns at slow speeds before attempting to turn at faster speeds.
WARNING
Turning improperly can result in vehicle rollover. Never turn abruptly or at sharp
angles. Never turn at high speeds.
DRIVING PROCEDURES
NOTE
Depictions of the vehicle shown in the “Driving Procedures” section represent
the entire ACE product line. The vehicle shown may not the depict the model
you purchased and are intended for reference use only.
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
SAFE OPERATION PRACTICES
1. Visit the Recreational Off-Highway Vehicle Association web site and take the
free on-line training course. Complete the recommended safety training
before operating this vehicle. Visit www.rohva.org or call 866-267-2751.
2. Do not allow anyone under 16 years of age or without a valid driver’s license
to operate this vehicle.
3. Never carry a passenger on this vehicle.
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in
an enclosed area.
5. Never operate with accessories not approved by POLARIS for use on this
vehicle.
58
OPERATION
6. Operate this vehicle off-road only. Never operate this vehicle on any public
street, road or highway, including dirt and gravel roads (unless designated for
off-highway use).
7. Use caution and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness. Clean headlights frequently and replace
burned out headlamps promptly.
8. Always operate at a speed that's appropriate for the terrain, the visibility and
operating conditions and your skills and experience. Never operate at
excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep
both hands on the steering wheel or handlebars during operation.
9. Never consume alcohol or drugs before or while operating this vehicle.
10.Always use the size and type of tires specified for your vehicle. Always
maintain proper tire pressure.
11. Never operate a damaged vehicle. After any rollover or accident, have a
qualified service dealer inspect the entire machine for possible damage.
12.Never operate the vehicle on a frozen body of water unless you have first
verified that the ice is sufficiently thick to support the weight and moving force
of the vehicle, you and your cargo, together with any other vehicles in your
party.
13.Do not touch hot exhaust system components. Always keep combustible
materials away from the exhaust system.
14.Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use.
KNOW YOUR RIDING AREA/TREAD LIGHTLY
Familiarize yourself with all laws and regulations concerning the operation of this
vehicle in your area. Respect the environment in which you ride your vehicle.
Find out where the designated riding areas are by contacting your POLARIS
dealer, a local riding club, or local officials.
Help keep our trails open for recreational vehicle use. As an off-road enthusiast,
you represent the sport and can set a good example (or a poor example) for
others to follow. Tread lightly. Operate with respect for the terrain, avoid littering,
and always stay on the designated trails.
TRAIL ETIQUETTE
Always practice good etiquette when riding. Allow a safe distance between your
vehicle and other vehicles operating in the same area. Communicate to
oncoming operators by signaling the number of vehicles in your group. When
stopping, move your vehicle to the edge of the trail as far as possible to allow
others to pass safely.
59
OPERATION
NEW OPERATOR DRIVING PROCEDURES
1. Read and understand the owner's manual and all warning and instruction
labels before operating this vehicle.
2. Visit the Recreational Off-Highway Vehicle Association web site and take the
free on-line training course. Visit www.rohva.org or call 866-267-2751.
Hands-on training is also available through ROHVA.
3. Perform the pre-ride inspection. See page 55.
4. Do not tow or carry cargo during this period.
5. Select an open area that allows room to familiarize yourself with vehicle
operation and handling.
6. The driver must wear helmet, eye protection, gloves, long-sleeve shirt, long
pants, over-the-ankle boots and seat belt at all times.
7. Sit in the driver's seat and fasten the seat belt.
8. Always make sure all cab doors are closed and latched when riding in this
vehicle.
9. Place the transmission in PARK.
10.Start the engine.
11. Apply the brakes and shift into low gear.
12.Check your surroundings and determine your path of travel.
13.Keeping both hands on the steering wheel, slowly release the brakes and
depress the throttle with your right foot to begin driving.
60
OPERATION
14.Drive slowly at first. On level surfaces, practice starting, stopping, turning,
maneuvering, 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.
WARNING
Operating in TURF mode (if equipped) when on sloped, uneven, or loose
terrain could cause loss of control and result in serious injury or death. One
rear wheel may slip and lose traction or may lift up and grab when it touches
the ground again.
15.Increase speed only after mastering all maneuvers at a slow speed.
16.After you become skilled at making turns and begin to operate at faster
speeds, follow these precautions:
• Avoid sharp turns.
• Never turn while applying heavy throttle.
• Never make abrupt steering maneuvers.
• Operate at speeds appropriate for your skills, the conditions and the
terrain.
• DO NOT do power slides, “donuts”, jumps or other driving stunts.
61
OPERATION
DRIVING ON SLIPPERY SURFACES
When driving on slippery surfaces such as wet trails, loose gravel, or ice, be
alert for the possibility of skidding and sliding. Follow these precautions when
encountering slippery conditions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down before entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp
turns, which can cause skids.
4. Engage all-wheel drive before wheels begin to lose traction.
NOTICE
Severe damage to the drive train may occur if the AWD is engaged while the
wheels are spinning. Always allow the wheels to stop spinning before engaging
AWD.
5. Correct a skid by turning the steering wheel in the direction of the skid. Never
apply the brakes during a skid.
62
OPERATION
DRIVING UPHILL
Whenever traveling uphill, follow these precautions:
1. Always check the terrain carefully before ascending any hill. Never drive on
hills with excessively slippery or loose surfaces.
2. Never operate in TURF mode (if equipped) while operating on a hill or other
irregular terrain. Always switch to AWD before ascending or descending a
hill.
3. Avoid excessively steep hills. If ascending a steeper grade is unavoidable,
engage all-wheel drive before ascending.
4. Drive straight uphill.
5. Proceed at a steady rate of speed and throttle opening. Never open the
throttle suddenly.
6. Avoid unnecessary changes in speed or direction.
7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or
another vehicle or person could be on the other side of the hill.
8. 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 light brake pressure to control speed.
63
OPERATION
DRIVING ON A SIDEHILL (SIDEHILLING)
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 hill is unavoidable, follow these precautions:
1. Engage all-wheel drive.
2. Never operate in TURF mode (if equipped) while operating on a hill or other
irregular terrain. Always switch to AWD before ascending or descending a
hill.
3. Drive slowly and use extreme caution.
4. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately
turn downhill.
5. Avoid obstacles and changes in terrain that may lower or raise one side of
the vehicle or cause the vehicle to slide.
6. If the vehicle begins to slide downhill, immediately turn downhill to stop the
slide, or stop the vehicle and maneuver slowly and carefully until the vehicle
can be driven straight downhill.
64
OPERATION
DRIVING DOWNHILL
Whenever descending a hill, follow these precautions:
1. Avoid excessively steep hills.
2. Never operate in TURF mode (if equipped) while operating on a hill or other
irregular terrain. Always switch to AWD before ascending or descending a
hill.
3. Slow down. Never travel down a hill at high speed.
4. Always check the terrain carefully before descending a hill. Never drive on
hills with excessively slippery or loose surfaces.
5. Always descend a hill with the transmission in forward gear. Never descend
a hill with the transmission in neutral.
6. Avoid traveling down a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight downhill.
7. Apply the brakes lightly to aid in slowing.
65
OPERATION
DRIVING OVER OBSTACLES
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for hazards
such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not
all obstacles are immediately visible.
4. Avoid operating over large obstacles such as large rocks and fallen trees. If
unavoidable, use extreme caution and operate slowly.
66
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 PARK.
2. Turn the engine off.
3. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
4. Block the rear wheels on the downhill side, or park the vehicle in a sidehill
position instead.
68
OPERATION
DRIVING THROUGH WATER
Your vehicle can operate through water with a maximum recommended depth
equal to floor level. Follow these precautions when operating through water:
1. Determine water depth and current before entering water.
2. Choose a crossing where the water level is lowest and where both banks
have gradual inclines. Never operate in water that exceeds the maximum
recommended depth.
WARNING
The large tires on your vehicle may cause the vehicle to float in deep or fast-
flowing water, which could result in loss of traction, loss of control, rollover or
accident.
69
OPERATION
3. 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.
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,
located in your Vehicle Manual. Give special attention to engine oil,
transmission oil, demand drive fluid, rear gearcase oil (if equipped) and all
grease fittings.
If your vehicle becomes immersed or is operated in water that exceeds the
floor level, service is required before starting the engine. Your POLARIS dealer
can provide this service. If it's impossible to bring the vehicle in before starting
the engine, perform the service outlined in the Vehicle Immersion section of
your Vehicle Manual, and take the vehicle in for service at the first opportunity.
70
OPERATION
HAULING CARGO
Your POLARIS vehicle has been designed to carry or tow specific capacities.
Reduce speed and allow a greater distance for braking when carrying cargo.
Loads should be centered and carried as low as possible in the box. For stability
on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the
cargo load extends over the side of the box.
Always read and understand the load distribution warnings listed on warning
labels and in this manual. Never exceed the maximum capacities specified for
your vehicle. See the Specifications chapter of your Vehicle Manual.
TIP
To extend belt life, use low gear when hauling or towing heavy cargo.
WARNING
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:
Never exceed the stated load capacity for this vehicle.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN
HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.
Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.
Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
71
OPERATION
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing vehicle
rollover.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 MPH (16 km/h) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads
in rough terrain, while cornering, or while ascending or descending a hill.
Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg).
Carrying a passenger in the cargo box could result
in a fall from the vehicle or contact with moving
components. Never allow a passenger to ride in the
cargo box.
72
OPERATION
WINCH GUIDE
These safety warnings and instructions apply if your vehicle came equipped with
a winch or if you choose to add an accessory winch to your vehicle.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow
all winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed
synthetic rope. The term “winch cable” will be used for either unless noted
otherwise.
73
WINCH GUIDE
WINCH SAFETY PRECAUTIONS
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the winch.
5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead
and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving vehicle.
See the Shock Loading section on page 82.
7. Always keep the area around the vehicle, winch, winch cable, and load clear
of people (especially children) and distractions while operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch are not
being used.
9. Always be sure that at least five (5) full turns of winch cable are wrapped
around the winch drum at all times. The friction provided by this wrapped
cable allows the drum to pull on the winch cable and move the load.
10.Always apply your vehicle’s park brake and/or park mechanism to hold the
vehicle in place during winching. Use wheel chocks if needed.
11. Always align the vehicle and winch with the load directly in front of the
vehicle as much as possible. Avoid winching with the winch cable at an angle
to the winching vehicle’s centerline whenever possible.
12.If winching at an angle is unavoidable, follow these precautions:
a. Look at the winch drum occasionally. Never let the winch cable “stack” or
accumulate at one end of the winch drum. Too much winch cable at one
end of the winch drum can damage the winch and the winch cable.
b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to
feed and rewind the cable evenly before continuing the winch operation.
13.Never winch up or down at sharp angles. This can destabilize the winching
vehicle and possibly cause it to move without warning.
14.Never attempt to winch loads that weigh more than the winch’s rated
capacity.
15.The winch motor may become hot during winch use. If you winch for more
than 45 seconds, or if the winch stalls during operation, stop winching and
permit the winch to cool down for 10 minutes before using it again.
16.Never touch, push, pull or straddle the winch cable while winching a load.
74
WINCH GUIDE
17.Never let the winch cable run through your hands, even if wearing heavy
gloves.
18.Never release the clutch on the winch when the winch cable is under load.
19.Never use the winch for lifting or transporting people.
20.Never use the winch to hoist or suspend a vertical load.
21.Never immerse or submerse your winch in water. Your dealer can provide
service on your winch if this occurs.
22.Always inspect your winch and winch cable before each use.
23.Never winch the hook fully into the winch. This can cause damage to winch
components.
24.Unplug the remote control from the vehicle when the winch is not in use to
prevent inadvertent activation and use by unauthorized persons.
25.Never grease or oil the winch cable. This will cause the winch cable to collect
debris that will shorten the life of the cable.
75
WINCH GUIDE
WINCH OPERATION
Read the Winch Safety Precautions in the preceding pages before using your
winch.
TIP
Consider practicing the operation and use of your winch before you actually
need to use it in the field.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow
all winch instructions and warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able to
deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any
signs of damage or parts in need of repair or replacement before each use.
Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch
is being used (or has been used) for lifting an accessory plow assembly.
Promptly replace any worn or damaged cable.
2. Never operate a winch or a vehicle in need of repair or service.
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WINCH GUIDE
3. Always apply your vehicle’s park brake and/ or park mechanism to hold the
vehicle in place during winching. Use wheel chocks if needed.
4. Always use the hook strap when handling the hook.
WARNING
Never put your fingers into the hook. This could lead to SEVERE INJURY.
• Attach the hook itself onto the load or use a tow strap or chain to secure
the load to the winch cable.
TIP
A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to
stretch.
77
WINCH GUIDE
WARNING
Never use a recovery strap when winching due to the excessive energy that
can be released if the winch cable breaks. This can result in SEVERE INJURY
or DEATH. See the Shock Loading section on page 82.
• Never hook the winch cable back onto itself. This will damage the winch
cable and may result in winch cable failure.
WARNING
Replace the winch cable at the first sign of damage to prevent SEVERE
INJURY or DEATH in the event of failure. For your safety, always replace
POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer.
• If possible, keep the winch cable aligned with the centerline of the
winching vehicle. This will help the spooling of the winch cable and reduce
the load on the fairlead.
• If freeing a stuck vehicle by attaching to a tree, use an item such as a tow
strap to avoid damaging the tree during winch operation. Sharp cables and
chains can damage and even kill trees. Please remember to
TreadLightly® (treadlightly.org).
• Before operating the winch, be sure that the safety latch on the winch
cable hook is fully seated when the load is attached.
• Never operate your winch with a damaged hook or latch. Always replace
damaged parts before using the winch.
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
78
WINCH GUIDE
7. Pulling out as much cable as possible maximizes the winch’s pulling
capacity. Always be sure that at least five (5) full turns of winch cable are
wrapped around the winch drum at all times. The friction provided by this
wrapped cable allows the drum to pull on the winch cable and move the load.
8. Read and adhere to the following information for winch damping to ensure
safe winch use.
a. In order to absorb energy that could be released by a winch cable failure,
always place a “damper” on the winch cable. A damper can be heavy
jacket, tarp, or other soft, dense object. A damper can absorb much of the
energy released if a winch cable breaks when winching. Even a tree limb
can help as a damper if no other items are available to you.
b. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
c. On a long pull, it may be necessary to stop winching so that the damper
can be repositioned to the new mid-point of the winch cable. Always
release the tension on the winch cable before repositioning the damper.
d. Avoid being directly in line with the winch cable whenever possible. Also,
never permit others to stand near or in line with the winch cable during
winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch
cable and may result in winch cable failure.
10.Never use straps, chains or other rigging items that are damaged or worn.
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WINCH GUIDE
11. The ONLY time a winch-equipped vehicle should be moving when using the
winch is when that vehicle itself is stuck. The winch equipped vehicle should
NEVER be in motion to “shock” load the winch cable in an attempt to move a
second stuck vehicle. See the Shock Loading section on page 82. For your
safety, always follow these guidelines when winching a vehicle free:
a. Release the winch clutch and spool out the necessary length of winch
cable.
b. Align the winch cable as close as possible to the winching vehicle’s
centerline.
c. Attach the winch cable hook to the anchor point or the stuck vehicle’s
frame following instructions in this manual.
d. Re-engage the clutch on the winch.
e. Slowly winch in the slack in the winch cable.
f. Select the proper vehicle gear to propel the stuck vehicle in the direction
of winching.
g. Shift to the lowest gear available on the stuck vehicle.
h. Slowly and carefully apply vehicle throttle and winch together to free the
vehicle.
i. Stop winching as soon as the stuck vehicle is able to propel itself without
the help of the winch.
j. Detach the winch cable hook.
k. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12.Never attempt to winch another stuck vehicle by attaching the winch cable to
a suspension component, brush guard, bumper or cargo rack. Vehicle
damage may result. Instead, attach the winch to a strong portion of the
vehicle frame or hitch.
13.Extensive winching will run down the battery on the winching vehicle. Let the
winching vehicle’s engine run while operating the winch to prevent the
battery from running low if winching for long periods.
14.The winch motor may become hot during winch use. If you winch for more
than 45 seconds, or if the winch stalls during operation, stop winching and
permit the winch to cool down for 10 minutes before using it again.
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WINCH GUIDE
15.After winching is complete, especially if winching at an angle, it may be
necessary to re-distribute the winch cable across the winch drum. You will
need an assistant to perform this task.
a. Release the clutch on the winch.
b. Feed out the winch cable that is unevenly bunched up in one area.
c. Re-engage the winch clutch.
d. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg)
of tension using the hook strap.
e. Slowly winch the cable in while your assistant moves the end of the winch
cable back and forth horizontally to evenly distribute the winch cable on
the drum.
f. Doing this reduces the chances of the winch cable “wedging” itself
between lower layers of winch cable.
WINCH CABLE CARE
For your safety, always replace POLARIS winch parts (including the cable) with
genuine POLARIS replacement parts available at your authorized POLARIS
dealer.
WARNING
Use of worn or damaged cable could lead to sudden failure and SEVERE
INJURY.
1. Always inspect your winch before each use. Inspect for worn or loose parts
including mounting hardware. Never use the winch if any part needs repair or
replacement.
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WINCH GUIDE
2. Always inspect your winch cable before each use. Inspect for worn or kinked
winch cable.
A kinked winch cable made of wire rope is shown at
right. Even after being “straightened out,” this cable
has already been permanently and severely damaged.
Promptly discontinue use of a winch cable in this
condition.
A kinked winch cable made of wire rope that has been
“straightened out” is shown at right. Even though it
may look usable, the cable has been permanently and
severely damaged. It can no longer transmit the load
that it could prior to kinking. Promptly discontinue use
of a winch cable in this condition.
A winch cable made of synthetic rope should be
inspected for signs of fraying. Replace the cable if
fraying is observed (shown at right). Promptly
discontinue use of a winch cable in this condition.
Also replace the winch cable if there are fused or melted fibers. Such an area
of the synthetic rope will be stiff and appear smooth or glazed. Promptly
discontinue use of a winch cable in this condition.
SHOCK LOADING
WARNING
Your winch cable is very strong but it is NOT designed for dynamic, or “shock”
loading. Shock loading may tension a winch cable beyond its strength and
cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope
and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never take up
slack in the winch cable by moving the winching vehicle in an attempt to
move an object. This is a dangerous practice. It generates high winch cable
loads that may exceed the strength of the cable. Even a slowly moving
vehicle can create large shock loads in a winch cable.
WARNING
SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts
extra load on the winch, winch cable, and generates excessive heat from the
motor. This is a form of shock loading.
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WINCH GUIDE
3. Never tow a vehicle or other object with your winch. Towing an object with a
winch produces shock loading of the cable even when towing at slow
speeds. Towing from a winch also positions the towing force high on the
vehicle. This can cause instability of the vehicle and possibly lead to an
accident.
4. Never use recovery straps with your winch. Recovery straps are designed to
stretch and can store energy. This stored energy in the recovery strap is
released if a winch cable fails making the event even more hazardous.
Similarly, never use elastic “bungie” cords for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation
vehicle. This type of use also causes shock loading that can cause damage
to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads produced
by the winch motor when operated from a stationary vehicle. Always
remember that the winch and winch cable are NOT designed for shock
loading.
83
WINCH GUIDE
WINCH MAINTENANCE AND SERVICE SAFETY
WARNING
Improper or lack of winch maintenance and service could lead to SEVERE
INJURY or DEATH. Always follow all winch instructions and warnings in this
manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch
cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections
to prevent accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including the cable)
with genuine POLARIS replacement parts available at your authorized
POLARIS dealer.
5. Some winch models use wire rope as the winch cable. Other winches use a
specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer
rope such as can be purchased in a hardware store. Although they may look
similar, they are NOT alike. A polymer rope not designed for winch use will
stretch and store excessive energy when winching.
WARNING
Failure of a stretched rope under winching conditions will release all of the
stored energy. This will increase the chances of SEVERE INJURY or DEATH.
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WINCH GUIDE
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 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 inside of the lower left frame tube (below
driver’s foot area).
ELECTROMAGNETIC INTERFERENCE
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of UN ECE Regulation 10.
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.
85
EMISSION CONTROL SYSTEMS
86
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 dealer can perform
any service that may be necessary for your vehicle. POLARIS also recommends
POLARIS parts for emissions-related service, however equivalent parts can be
used.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket
parts manufacturer reduces the effectiveness of the vehicle’s emission controls.
Tampering with emission controls is prohibited by federal law.
Owners are responsible for performing the scheduled maintenance identified in
this owner’s manual.
Careful periodic maintenance will help keep your vehicle in the safest, most
reliable condition. Inspection, adjustment and lubrication of important
components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, genuine POLARIS parts are
available from your POLARIS dealer. Equivalent parts may be used for
emissions-related service.
Service and adjustments are important for proper vehicle operation. If you’re not
familiar with safe service and adjustment procedures, a qualified dealer can
perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected and
serviced more frequently.
SEVERE USE DEFINITION
• Frequent immersion in mud, water or sand
• Frequent or prolonged operation in dusty environments
• Short trip cold weather operation
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
Pay special attention to the oil level. A rise in oil level during cold weather can
indicate contaminants collecting in the oil sump or crankcase. Change oil
immediately if the oil level begins to rise. Monitor the oil level, and if it continues
to rise, discontinue use and determine the cause. Your dealer can assist.
87
MAINTENANCE
MAINTENANCE CHART KEY
SYMBOL DESCRIPTION
XU Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized Polaris dealer or other qualified person perform these services.
WARNING
Improperly performing the procedures marked with a D could result in
component failure and lead to serious injury or death. Have an authorized
POLARIS dealer or other qualified person perform these services.
Perform all services at whichever maintenance interval is reached first. Record
maintenance and service in the Maintenance Log.
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKSHRS CLNDR
MILES
(KM)
Steering
Pre-Ride
Inspect and make adjustments as
needed.
See the Pre-Ride Inspections section
for details.
Front Suspension
Rear Suspension
Tires
Brake Fluid Level
Brake Lever Travel
Brake System
Wheels / Fasteners
Frame Fasteners
Engine Oil Level
Intake pre-filters
Coolant -
Daily
-
Check level daily, change coolant
every two years
Head Lights / Tail
Lights
-
Daily
-
Check operation; apply dielectric
grease if replacing
Power Steering unit
(If equipped)
-
Daily Inspect daily, clean often
XU
Air Filter (main
element)
-
Weekly
-
Inspect; replace as needed
XU
D
Brake Pad Wear 10 H
Monthly
100
(160)
Inspect periodically
XU
Engine Breather
25 H
Monthly
150
(250)
Inspect, clean, replace if necessary
Battery
25 H
Monthly
250
(400)
Check terminals; clean; test
88
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKSHRS CLNDR
MILES
(KM)
XU
Engine Oil Change
25 H 1 M -
Break-in oil and filter change
XU
Front Gearcase
Fluid
25 H 1 M - Break-in fluid level check
XU Transmission Fluid 25 H 1 M
250
(400)
Break-in fluid level check
Fuel System
25 H 1 M -
Inspect; cycle key to pressurize fuel
pump; check lines and fittings for
leaks and abrasion
XU General Lubrication 50 H 3 M
500
(800)
Lubricate all fittings, pivots, cables,
etc.
Shift Linkage
50 H 3 M
500
(800)
Inspect
D
Steering
50 H 6 M
500
(800)
Lubricate
XU
Front/Rear
Suspension
50 H 6 M
500
(800)
Lubricate
XU Throttle Cable 50 H 6 M
500
(800)
Inspect; adjust; lubricate; replace if
necessary
Throttle Body
Intake Duct
50 H 6 M
500
(800)
Inspect ducts for proper sealing / air
leaks
XU
Engine Oil Change
100 H 6 M
1000
(1600)
Change the oil and filter
XU
Front Gearcase
Fluid
100 H 12 M -
Change fluid
XU Transmission Fluid 100 H 12 M -
Change fluid
XU
D
Fuel System
100 H 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
XU
Engine Mounts
100 H 12 M
1000
(1600)
Inspect
Exhaust Pipe /
Silencer
100 H 12 M
1000
(1600)
Inspect
XU
Spark Plug
100 H 12 M
600
(1000)
Inspect; replace as needed
XU Radiator 100 H 12 M
1000
(1600)
Inspect; clean external surfaces
Cooling System
100 H 12 M
1000
(1600)
Inspect coolant strength seasonally;
pressure test system yearly
XU
Cooling Hoses
100 H 12 M
1000
(1600)
Inspect for leaks
XU
Wiring
100 H 12 M
1000
(1600)
Inspect for wear, routing, security;
apply dielectric grease to connectors
subjected to water, mud, etc.
89
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKSHRS CLNDR
MILES
(KM)
Drive belt 100 H 12 M
1000
(1600)
Inspect; replace as needed
D
Clutches (Drive/
Driven)
100 H 12 M
1000
(1600)
Inspect; clean; replace worn parts
D
Front Wheel
Bearings
100 H 12 M
1000
(1600)
Inspect; replace as needed
D Brake Fluid 200 H 24 M
2000
(3200)
Change every two years
XU Valve Clearance 200 H -
2000
(3200)
Inspect; adjust as needed
Spark Arrestor
300 H 36 M
3000
(4800)
Clean out; or remove clean out plug
XU Coolant - 60 M -
Replace coolant (50/50 Extended Life
Coolant)
D
Toe Adjustment
-
Inspect periodically; adjust as needed
Headlight Aim
-
Adjust as needed
XU Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized Polaris dealer or other qualified person perform these
services.
90
MAINTENANCE
LUBRICATION RECOMMENDATIONS
Check and lubricate all components at the intervals outlined in the Periodic
Maintenance Chart, or more often under severe use, such as wet or dusty
conditions. Items not listed in the chart should be lubricated at the general
lubrication interval.
ITEM LUBE METHOD
Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick.
See page 93.
Brake Fluid DOT 4 Brake Fluid Maintain level between fill
lines.
See page 115.
Transmission Oil
(Main Gearcase)
AGL Gearcase Lubricant &
Transmission Fluid
See page 98.
Demand Drive Fluid
(Front Gearcase)
Demand Drive Fluid See page 97.
Prop Shaft
q
U-Joint Grease Locate fittings and grease.
Rear Control Arm Pivot
Bushings
e
All Season Grease or grease
conforming to NLGI No. 2
Locate fittings and grease.
Stabilizer Bar Bushings
w
,
r
,
Tie Rod Bushings, Ball Joint
Boots
All Season Grease or grease
conforming to NLGI No. 2
Locate fittings and grease.
PROP SHAFT LUBRICATION
91
MAINTENANCE
ENGINE OIL
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart section. Always use the recommended engine oil. Always
change the oil filter whenever changing oil.
WARNING
Vehicle operation with insufficient, deteriorated, or contaminated engine oil will
cause accelerated wear and may result in engine seizure, accident and injury.
Always perform the maintenance procedures as outlined in the Periodic
Maintenance Chart.
OIL RECOMMENDATIONS
POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a
similar oil. Refer to the Specifications section for capacities.
Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not
used. Follow the manufacturer's recommendations for ambient temperature
operation. See the Lubricants / Service Products section for the part numbers of
POLARIS products.
NOTICE
Mixing brands or using a non-recommended oil may cause serious engine
damage. Always use the recommended oil. Never substitute or mix oil brands.
93
MAINTENANCE
OIL CHECK
Always check the oil when the engine is cold. If the engine is hot when the oil is
checked, the level will appear to be overfull. Maintain the oil level in the safe
range between the FULL and ADD marks on the dipstick.
The oil dipstick and fill tube
q
is located on the engine, behind the passenger
seat. Access the dipstick through the right rear wheel well.
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Always clean away all dirt and
debris from the dipstick area before
removing the dipstick. Remove the
dipstick. Wipe it dry with a clean
cloth.
4. Reinstall and tighten the dipstick.
5. Remove the dipstick and check the
oil level.
6. Add the recommended fluid as
needed. Maintain the oil level in the
safe range between the FULL and
ADD marks. Do not overfill.
7. Reinstall and tighten the dipstick.
OIL AND FILTER CHANGE
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart. Always change the oil filter whenever changing oil.
The engine drain plug
q
is located on the bottom of the crankcase.
1. Position the vehicle on a level surface. Place the transmission in PARK.
Apply the brakes.
2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.
3. Clean the area around the drain plug.
CAUTION
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
94
MAINTENANCE
4. Place a drain pan under the engine crankcase and remove the drain plug.
Allow the oil to drain completely.
5. Reinstall the sealing washer on the drain plug.
TIP
The sealing surfaces on drain plug and crankcase should be clean and free of
burrs, nicks or scratches.
6. Reinstall the drain plug. Torque to specification.
TORQUE
Drain Plug:
12 ft. lbs. (16 Nm)
7. Using a cap-style oil filter wrench, turn the filter
w
counter-clockwise to
remove it.
8. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
Make sure the old filter o-ring is completely removed.
9. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to
make sure the o-ring is in good condition.
10.Install the new filter and turn by hand until the filter gasket contacts the
sealing surface, then turn an additional 3/4 turn.
95
MAINTENANCE
11. Always clean away all dirt and debris from the dipstick area before removing
the dipstick
e
. Remove the dipstick and fill the sump with two quarts (1.9 l)
of recommended oil.
FLUID CAPACITY
Capacity: 2.0 quarts (1.9 l)
12.Reinstall and tighten the dipstick.
13.Make sure the transmission is in PARK. Apply the brakes.
14.Start the engine. Allow it to idle for one to two minutes.
15.Stop the engine. Inspect for leaks.
16.Re-check the oil level on the dipstick and add oil as necessary to bring the
level to the upper mark on the dipstick.
17.Dispose of used filter and oil properly.
96
MAINTENANCE
DEMAND DRIVE UNIT (FRONT GEARCASE)
Always check and change the fluid at the intervals outlined in the Periodic
Maintenance Chart section. Refer to the Gearcase Specifications Chart section
for recommended lubricants, capacities and torque specifications.
FLUID CHECK
The fill plug
q
is located on the bottom right side of the demand drive unit.
Access the fill plug through the right front wheel well. Maintain the fluid level
even with the bottom thread of the fill plug hole.
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the
fluid level.
3. Add the recommended fluid to the
bottom thread of the fill plug hole.
4. Reinstall the fill plug. Torque to
specification.
FLUID CHANGE
The drain plug
w
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. If the o-ring is damaged, install a new o-ring.
5. Reinstall the drain plug. Torque to specification.
6. Add the recommended fluid to the bottom thread of the fill plug hole.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Discard used fluid properly.
97
MAINTENANCE
TRANSMISSION (MAIN GEARCASE)
Always check and change the fluid at the intervals outlined in the Periodic
Maintenance Chart section. Refer to the Gearcase Specifications Chart section
for recommended lubricants, capacities and torque specifications.
FLUID CHECK
The fill plug
q
is located on the rear of the gearcase. Maintain the fluid level at
the bottom of the fill plug hole.
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the
fluid level.
3. Add the recommended fluid to the
bottom of the fill plug hole. Do not
overfill.
4. Reinstall the fill plug. Torque to
specification.
FLUID CHANGE
The drain plug
w
is located on the bottom of the gearcase between the rear
tires. Access the drain plug through the drain hole in the skid plate.
1. Remove the fill plug.
2. Place a drain pan under the drain plug. Remove the drain plug. Allow the
fluid to drain completely.
3. Clean the drain plug. Reinstall the drain plug with a new o-ring. Torque to
specification.
4. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Discard used fluid properly.
98
MAINTENANCE
GEARCASE SPECIFICATION CHART
Use of other fluids may result in improper operation of components. See page
91 for the part numbers of POLARIS products.
GEAR-
CASE
LUBRI-
CANT
CAPACITY FILL PLUG
TORQUE
DRAIN PLUG/
LEVEL CHECK
PLUG TORQUE
Transmis-
sion
(Main
Gear-
case)
AGL
Gearcase
Lubricant
&
Transmis-
sion Fluid
44 oz.
(1300 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Demand
Drive Unit
(Front
Gear-
case)
Demand
Drive Fluid
9 oz.
(265 ml)
8-10 ft. lbs.
(11-13.6
Nm)
8-10 ft. lbs.
(11-13.6 Nm)
99
MAINTENANCE
SPARK PLUGS
SPARK PLUG RECOMMENDATIONS
Refer to the Specifications section for the recommended spark plug type for your
vehicle. Always torque spark plugs to specification.
NOTICE
Using non-recommended spark plugs can result in serious engine damage.
Always use POLARIS-recommended spark plugs or their equivalent.
SPARK PLUG GAP / TORQUE
MODEL
ELECTRODE
GAP
NEW PLUG
TORQUE
USED PLUG
TORQUE
ACE 500 0.85 +/- 0.08mm
9 ft. lbs. (12 Nm)
without anti-seize
9 ft. lbs. (12 Nm)
without anti-seize
NORMAL PLUG
The normal insulator tip is gray, tan or light brown. There will be few combustion
deposits. The electrodes are not burned or eroded. This indicates the proper
type and heat range for the engine and the service.
The tip should not be white. A white 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. General causes of fouling are excessive oil, use of non-recommended oil
or poor fuel quality.
100
MAINTENANCE
SPARK PLUG INSPECTION
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 plugs for correct color. See page
100.
CAUTION
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Remove the cargo box access
panel.
2. Remove the spark plug cap
q
.
3. Using the spark plug wrench
provided in the tool kit, remove a
plug by rotating it counter-
clockwise.
4. Reverse the procedure for spark
plug installation.
5. Torque to specification. See the
Spark Plug Gap/Torque section for
details.
101
MAINTENANCE
FUSES
If the engine stops or will not start, or if you experience other electrical failures, a
fuse may need replacement. Locate and correct any short circuits that may have
caused the blown fuse, then replace the fuse.
MAIN FUSE FEATURE SUPPORTED
20 A Lights: Headlights, Taillights
20 A Drive: AWD
20 A Accessory: Winch Switch, 12V Power
Receptacle
10 A Fuel Pump
10 A EFI
20 A Electronic Engine Control, Starting
30 A Engine Control
30 A EPS (Optional)
10 A Constant Vehicle Power
15 A Fan Circuit Braker - Auto Reset
The fuse box
q
is located under the
seat. Spare fuses are provided in the
fuse box.
102
MAINTENANCE
FUSE BOX
1. Remove the seat to access the
fuse box.
2. Squeeze the cover release tabs
q
inward and remove the fuse box
cover.
3. Remove the suspect fuse from the
fuse panel. If the fuse is blown,
install a new fuse with the same
amperage rating.
4. Reinstall the fuse box cover.
5. Reinstall the seat.
POWER STEERING UNIT
If your model is equipped with power steering, frequently clean the areas around
and on the power steering unit to allow proper cooling. Clean these areas
q
thoroughly.
103
MAINTENANCE
COOLING SYSTEM
OPERATION
The engine coolant level is controlled or maintained by the recovery system. The
recovery system components are the overflow bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated) excess
coolant is forced out of the radiator, past the pressure cap, and into the overflow
bottle. As engine coolant temperature decreases, the contracting (cooled)
coolant is drawn back up from the tank, past the pressure cap, and into the
radiator.
TIP
Some coolant level drop on new vehicles is normal as the system is purging
itself of trapped air. Observe coolant levels and maintain as recommended by
adding coolant to the overflow bottle.
ADDING OR CHANGING COOLANT
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This
antifreeze is already premixed and ready to use. Do not dilute with water. See
the Lubricants / Service Products section for the part numbers of POLARIS
products.
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every five (5) years and fresh
Antifreeze 50/50 Premix added.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant with fresh Antifreeze 50/50 Premix.
RADIATOR AND COOLING FAN
Always check and clean the screen and radiator fins at the intervals outlined in
the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the
radiator by installing unauthorized accessories in front of the radiator or behind
the cooling fan. Interference with the radiator air flow can lead to overheating
and consequent engine damage.
NOTICE
Washing the vehicle with a high-pressure hose could damage the radiator fins
and impair the radiator's effectiveness. Using a high-pressure system is not
recommended.
104
MAINTENANCE
RADIATOR COOLANT LEVEL
This procedure is required only if the cooling system has been drained for
maintenance and/or repair. But if the overflow bottle
q
has run dry, the level in
the radiator should also be inspected.
CAUTION
Escaping steam can cause burns. Never remove the pressure cap while the
engine is warm or hot. Always allow the engine to cool before removing the
pressure cap.
1. Open the front box cover and remove the storage bin. See the Front Box
Cover section for details.
2. Slowly remove the radiator cap
w
.
3. View the coolant level through the opening.
4. Use a funnel and slowly add coolant as needed.
TIP
Use of a non-standard pressure cap will not allow the recovery system to
function properly. Your authorized dealer can provide the correct replacement
part.
105
MAINTENANCE
COOLANT LEVEL
Always check and change the coolant at the intervals outlined in the Periodic
Maintenance Chart.
Maintain the coolant level between the minimum and maximum marks on the
bottle (when the fluid is cool). The coolant level in the bottle can be viewed
through the left front wheel well or in the compartment in the front box.
1. Position the vehicle on a level surface.
2. View the coolant level in the overflow bottle
q
.
3. If the coolant level is below the safe operating range, remove the cap and
use a funnel to add coolant through the opening. Reinstall the cap.
TIP
If coolant must be added often, or if the overflow bottle runs completely dry,
there may be a leak in the system. Your authorized dealer can inspect the
cooling system.
106
MAINTENANCE
POLARIS VARIABLE TRANSMISSION (PVT) SYSTEM
WARNING
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of
balance, creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. As the owner, you have the following responsibilities for
your own safety and the safety of others:
• Always follow all recommended maintenance procedures. Always look for
and remove debris inside and around the clutch and vent system when
replacing the belt.
• See your dealer, or other qualified person, for service and repair assistance.
• This PVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
107
MAINTENANCE
BELT REPLACEMENT / DEBRIS REMOVAL
If a belt fails, always clean any debris from the PVT intake and outlet duct and
from the clutch and engine compartments when replacing the belt.
WARNING
Failure to remove ALL debris when replacing the belt could result in vehicle
damage, loss of control and severe injury or death.
1. Allow hot components to cool before performing this procedure.
2. Remove the clutch cover screws and open the clutch cover. Remove all
debris wrapped in and around the PVT system.
3. Remove all debris from the entire clutch air duct passage.
4. Check for signs of damage to seals on the transmission and engine. If any
seals appear to be damaged, your vehicle requires prompt service that your
authorized dealer can provide.
TIP
Belt slip is responsible for creating excessive heat that destroys belts, wears
clutch components and causes outer clutch covers to fail. Switch to low range
while operating at slower speeds to extend the life of the PVT components
(belt, cover, etc.).
108
MAINTENANCE
PVT DRYING
There may be some instances when water is accidently ingested into the PVT
system. Use the following instructions to dry it out before operating.
NOTICE
When washing the vehicle, always avoid spraying water directly toward the
PVT intake duct. See the Washing the Vehicle section for recommended
washing procedures.
1. Remove the drain plug
q
from the
bottom of the clutch box. Allow the
water to drain. Reinstall the drain
plug securely.
2. Place the transmission in PARK.
Apply the brakes. Start the engine.
3. Apply varying throttle for seconds
to expel the moisture and air-dry
the belt and clutches. Do not hold
the throttle wide open for more
than 10 seconds.
4. Allow the engine RPM to settle to
idle speed. Apply the brakes. Shift
the transmission to the lowest
available range.
5. Test for belt slippage. If the belt
slips, repeat the process.
6. Your vehicle requires service as
soon as possible, which your
authorized dealer can provide.
AIR FILTER
Always clean all dirt and debris away from the air box area before servicing the
air filter. Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart.
1. Remove the cargo box access panel.
2. Clean all dirt and debris from the air box area.
109
MAINTENANCE
3. Unlatch the cover clips
q
and carefully remove the air box cover.
4. Loosen the air filter clamp
e
and remove the filter
w
.
NOTICE
Dirt or debris in the air box could result in severe engine damage. Always clean
all dirt and debris from the air box before installing the filter.
5. Inspect the air box for dirt, debris, oil or water. Compress the edges of the air
box drain to drain any water. Clean the air box thoroughly and wipe it well
with a clean, dry cloth.
6. Reinstall the filter. Install a new filter if needed. Do not attempt to clean the air
filter. Tighten the clamp.
7. Reinstall the air box cover and secure the cover clips.
8. Reinstall the access panel.
HEAT SHIELDING
WARNING
Your vehicle is equipped with heat shielding. Do not remove heat shielding. If
heat shields become loose, or are removed, see your dealer to have shielding
re-installed properly.
BREATHER HOSE INSPECTION
1. Remove the breather hose clamp at the engine (near the exhaust outlet).
2. Pull the other end of the breather hose assembly away from the airbox.
3. Remove the breather hose assembly from the vehicle.
4. Inspect the hoses for debris. Blow gently through the hoses to check for
clogging. Replace a damaged or clogged hose.
110
MAINTENANCE
5. Check hoses for cracks, deterioration, abrasions or leaks. Replace as
needed.
6. Reinstall the hose assembly and secure the clamp at the engine. Push the
other end of the hose firmly into the airbox fitting.
NOTICE
Operation of the vehicle without breather hoses can cause engine damage.
Always reinstall a breather hose after removing it for service.
INTAKE PRE-FILTERS
The engine intake pre-filter
w
is located on the right side of the cargo box. The
PVT intake pre-filter
q
is located on the left side of the cargo box.
Inspect both pre-filters before each use of the vehicle to ensure adequate air
flow. If necessary, remove the pre-filters and clean with soapy water. Dry with
low pressure compressed air.
NOTICE
When washing the vehicle, always avoid spraying water directly toward the
PVT intake duct. See the Washing the Vehicle section for recommended
washing procedures.
111
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 authorized 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.
3. Dry the spark plug wells with a clean cloth, then remove the spark plugs.
4. Turn the engine over several times.
5. Dry the spark plugs and reinstall them, or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
7. Take the vehicle in for service as soon as possible, whether you succeed in
starting it or not. Your authorized dealer can provide the required service.
8. If water has been ingested into the PVT follow the procedure on page 109 for
drying.
112
MAINTENANCE
SPARK ARRESTER
WARNING
• Never operate the vehicle without the spark arrestor.
• Remove any combustible materials from the area.
Failure to heed the following warnings while servicing the spark arrestor
could result in serious injury or death.
• Never run the engine in an enclosed area. Exhaust contains poisonous
carbon monoxide gas that can cause loss of consciousness or death in a
very short time.
• Do NOT perform service on the spark arrestor while the system is HOT.
Exhaust system temperatures can reach extreme temperatures. Allow
components to cool sufficiently before proceeding.
• Do not stand behind or in front of the vehicle while purging the exhaust
system.
• Never go under the vehicle while it is inclined.
• Wear eye protection and gloves while servicing.
Use the following procedure to
periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrester clean-out plug
q
from the bottom of the muffler.
2. Place the transmission in PARK. Start the engine.
3. Quickly press and release the throttle pedal several times to purge carbon
from the system.
4. If carbon comes out of the exhaust, cover or plug the exhaust outlet
w
. Wear
protective gloves.
5. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4.
113
MAINTENANCE
6. If particles are still suspected to be in the muffler, elevate the rear of the
vehicle one foot (30 cm) higher than the front. Block the wheels.
7. Place the transmission in PARK. Repeat steps 4 to 6 until no more particles
are expelled.
8. Stop the engine. Allow the arrester to cool.
9. Reinstall the arrester plug and remove the exhaust outlet cover or plug.
114
MAINTENANCE
BRAKES
The front and rear brakes are hydraulic disc type brakes activated by the brake
pedal.
Always check brake pedal travel and the brake fluid reservoir level before each
use of the vehicle. When applied, the brake pedal should feel firm. Any
sponginess would indicate a possible fluid leak or low brake fluid level, which
must be corrected before riding. Proceed to the next page 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.
WARNING
Operating the vehicle with a spongy brake pedal can result in loss of braking,
which could cause an accident resulting in severe injury or death. Never
operate the vehicle with a spongy-feeling brake pedal.
115
MAINTENANCE
BRAKE FLUID
Inspect the level of the brake fluid before each operation. If the fluid level is low
add DOT 4 brake fluid only. See the Lubricants / Service Products section for the
part numbers of POLARIS products.
WARNING
After opening a bottle of brake fluid, always discard any unused portion. Never
store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly
absorbs moisture from the air. The moisture causes the boiling temperature of
the brake fluid to drop, which can lead to early brake fade and the possibility of
accident or severe injury.
Change the brake fluid every two
years and any time the fluid becomes
contaminated, the fluid level is below
the minimum, or if the type and brand
of the fluid in the reservoir are
unknown.
1. Position the vehicle on a level
surface.
2. Place the transmission in PARK.
3. Open the front box cover and
remove the access panel. See the
Front Box Cover section for details.
4. View the brake fluid level in the
reservoir
q
. The level should be
between the maximum
w
and
minimum
e
level lines.
5. If the fluid level is lower than the
lower level line, add brake fluid to
the upper line.
6. Apply the brake forcefully for few
seconds and check for fluid
leakage around the fittings.
116
MAINTENANCE
BRAKE INSPECTION
WARNING
Do not apply WD-40 or any petroleum product to brake discs. These types of
products are flammable and may also reduce the friction between the brake
pad and caliper.
1. Check the brake system for fluid
leaks.
2. Check the brake pedal for
excessive travel or a spongy feel.
3. Check the friction pads for wear,
damage and looseness.
4. Check brake discs for signs of
cracks, excessive corrosion,
warping or other damage. Clean
any grease using an approved
brake cleaner or alcohol.
5. Inspect the brake disc spline and
pad wear surface for excessive
wear. Change pads when worn to
0.030" (0.762 mm).
117
MAINTENANCE
STEERING WHEEL INSPECTION
Check the steering wheel for specified freeplay and smooth operation at the
intervals outlined in the Periodic Maintenance Chart section.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8"-1.0" (20-25 mm) of freeplay.
4. If there is excessive freeplay or strange noises, or the steering feels rough or
“catchy,” have the steering system inspected by an authorized dealer.
REAR SPRING
The rear shock absorber spring is
adjusted by rotating the adjuster
q
either clockwise or counter-clockwise
to increase or decrease spring tension.
Accessory springs are available
through your authorized dealer.
118
MAINTENANCE
SUSPENSION SETTINGS
The rear suspension is preload
adjustable. The suspension is set on
the lowest (softest) setting at the
factory. This setting is appropriate for
nearly all riding conditions.
If desired, the suspension may be
adjusted to maintain vehicle
clearance height when carrying
loads. Your authorized dealer can
provide the tool required to make
suspension adjustments. Elevate the
vehicle slightly for easier adjustment.
Always heed the following rules if you make adjustments to this suspension.
• Always return the suspension to the lowest (softest) setting after the load is
removed from the vehicle. The increased suspension height will negatively
impact vehicle stability when operating without a load.
• Always apply the same adjustment setting to both rear wheels.
• Never operate the vehicle on the highest (stiffest) or second highest preload
settings without a total combined payload in the vehicle of 450 lbs. (204 kg) or
more. Payload includes the driver, POLARIS approved accessories and
cargo. Never exceed the stated load capacity for this vehicle. See the
Specifications section for details.
119
MAINTENANCE
TIRES
WARNING
Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8” (3 mm) or less.
Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. Always use POLARIS
approved size and type of tires for this vehicle when replacing tires.
TIRE TREAD DEPTH
Always replace tires when tread depth
is worn to 1/8” (3 mm) or less.
AXLE AND WHEEL NUT TORQUE SPECIFICATIONS
Inspect the following items occasionally for tightness, and if they've been
loosened for maintenance service. Do not lubricate the stud or the lug nut.
Lug Nut
(Aluminum
Wheels)
Front and Rear
30 ft. lbs. (41 Nm)
PLUS 1/4 TURN or
70 degrees
2-Piece Flange Nut
(Steel Wheels)
Front and Rear
30 +/- 2 ft. lbs.
(40.6 Nm)
Hub Retaining Nut
Front
60 ft. lbs. (81 Nm)
Rear
110 ft. lbs. (149
Nm)
120
MAINTENANCE
WHEEL REMOVAL
1. Position the vehicle on a level surface.
2. Place the transmission in PARK. 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 and washers. Remove the wheel.
WHEEL INSTALLATION
1. Place the transmission in PARK.
2. Place the wheel on the hub with the valve stem toward the outside and
rotation arrows on the tire pointing toward forward rotation.
WARNING
Improperly installed wheels can adversely affect tire wear and vehicle
handling, which can result in serious injury or death. Always ensure that all
nuts are torqued to specification. Do not service axle nuts that have a cotter pin
installed. Your dealer can assist.
3. Attach the wheel nuts and washers and finger-tighten.
4. Carefully lower the vehicle to the ground.
5. Torque the wheel nuts to specification.
121
MAINTENANCE
LIGHTS
Headlight and taillight lenses become dirty during normal operation. Clean all
lights frequently to ensure a clear field of vision as well as visibility to other
vehicles.
HEADLIGHT BEAM ADJUSTMENT
1. Place the vehicle on a level surface
with the headlight approximately 25
ft. (7.6 m) from a wall. Place the
transmission in PARK.
2. Measure the distance from the floor
to the center of the headlight and
make a mark on the wall at the
same height.
3. Apply the brakes. Turn the ignition
switch to the LIGHTS ON position.
4. Observe the headlight aim. The
most intense part of the headlight
beam should be aimed 8" (20 cm)
below the mark placed on the wall
in step 2. Include the weight of a
rider on the seat while performing
this step.
5. If adjustment is necessary, turn the
headlight adjustment screw
q
to
adjust the beam.
6. Repeat steps 4-5 until the beam is
properly adjusted.
122
MAINTENANCE
HEADLAMPS
If a headlight becomes damaged or
inoperable, the entire headlight
assembly must be replaced. Do not
operate the vehicle at night or in low
light conditions without properly
working headlights.
If a headlamp has moisture or fogging
inside, disconnect the wiring harness
q
from the headlamp(s) for a few days
to allow the moisture to clear out.
TAILLIGHT / BRAKE LIGHT REPLACEMENT
The taillight assembly is not serviceable. If the taillight or brake light fails to
operate properly, replace the entire taillight assembly.
123
MAINTENANCE
BATTERY
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, which requires little maintenance,
or a conventional battery. A sealed battery can be identified by its flat covers on
the top of the battery. A conventional battery has six filler caps on the top of the
battery.
Always keep battery terminals and connections free of corrosion. If cleaning is
necessary, remove the corrosion with a stiff wire brush. Wash with a solution of
one tablespoon baking soda and one cup water. Rinse well with tap water and
dry off with clean shop towels. Coat the terminals with dielectric grease or
petroleum jelly. Be careful not to allow cleaning solution or tap water into a
conventional battery.
WARNING
Improperly connecting or disconnecting battery cables can result in an
explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.
BATTERY REMOVAL
1. Remove the seat. See page 33.
2. Remove the three (3) bolts
q
securing the cup holder panel to the frame. Lift
the panel to access the battery.
3. Remove the battery hold-down strap screws and remove the strap
w
.
4. On conventional batteries, remove the battery vent tube.
5. Disconnect the black (negative) battery cable first.
6. Disconnect the red (positive) battery cable last.
124
MAINTENANCE
7. Lift the battery
e
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.
NOTE
The battery must be oriented so the battery terminals face toward the left-hand
side of the vehicle.
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 127 before installing the battery.
An optional extreme use battery may be available for your model. If the
performance of the factory-installed battery is inadequate due to operation in
extreme cold or due to extended use of multiple electrical accessories, your
authorized dealer can assist. Your dealer can provide any installation
procedures that may differ for an extreme use battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
125
MAINTENANCE
3. On conventional batteries, install the battery vent tube (sealed batteries do
not have a vent tube). The vent tube must be free of obstructions and
securely installed. Route the tube away from the frame and vehicle body to
prevent contact with electrolyte.
WARNING
Battery gases could accumulate in an improperly installed vent tube and cause
an explosion, resulting 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. Install the battery hold-down strap and tighten the screws.
8. Verify that cables are properly routed.
9. Reinstall the cup holder panel. Tighten the bolts.
10.Reinstall the seat.
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 127.
TIP
Battery charge can be maintained by using a POLARIS Battery Tender charger
or by charging about once a month to make up for normal self discharge.
Battery Tender can be left connected during the storage period, and will
automatically charge the battery if the voltage drops below a predetermined
point. See the Lubricants / Service Products section for the part numbers of
POLARIS products.
126
MAINTENANCE
BATTERY FLUID (CONVENTIONAL BATTERY)
A poorly maintained battery will
deteriorate rapidly. Check the
battery fluid level often. Maintain the
fluid level between the upper
q
and
lower level
w
marks.
Add only distilled water. Tap water
contains minerals that are harmful to
a battery.
BATTERY CHARGING (CONVENTIONAL BATTERY)
1. Remove the battery from the vehicle to prevent damage from leaking or
spilled electrolyte during charging.
2. Charge the battery with a charging output no larger than 1/10 of the battery’s
amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or
greater.
3. Reinstall the battery. Make sure the positive terminal is toward the front of the
vehicle.
BATTERY CHARGING (SEALED BATTERY)
The following battery charging instructions apply only to the installation of a
sealed battery. Read all instructions before proceeding with the installation of
this battery.
The sealed battery is already filled with electrolyte and has been sealed and fully
charged at the factory. Never pry the sealing strip off or add any other fluid to this
battery.
The single most important thing about maintaining a sealed battery is to keep it
fully charged. Since the battery is sealed and the sealing strip cannot be
removed, you must use a voltmeter or multimeter to measure DC voltage.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully charged
battery will register 12.8 V or higher.
127
MAINTENANCE
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less
until battery voltage is 12.8 or greater.
TIP
When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
guidelines below for recharging.
Always verify battery condition before and 1-2 hours after the end of charging.
STATE OF
CHARGE
VOLTAGE ACTION CHARGE TIME*
*(USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON
TOP OF BATTERY)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of
charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
128
MAINTENANCE
GENERAL ACE CARE
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.
NOTICE
Water in the PVT system could cause the drive belt to become wet and slip in
the clutches. Always avoid spraying water directly toward any intake pre-filters
(
q
,
w
).
NOTICE
High water pressure may damage the radiator fins and impair the radiator’s
effectiveness. High pressure may also damage other vehicle components.
Certain products, including insect repellents and chemicals, will damage
plastic surfaces. Do not allow these types of products to contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a garden hose
and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first and the
lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
WASHING TIPS
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
129
MAINTENANCE
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or reused
cloths and pads may contain dirt particles that will scratch the finish.
• Grease all zerk fittings immediately after washing. Allow the engine to run for
a while to evaporate any water that may have entered the engine or exhaust
system.
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the following items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
• Air intake components
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.
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.
130
MAINTENANCE
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 the
Washing the Vehicle section.
STABILIZE THE FUEL
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or
equivalent fuel treatments or stabilizers. Follow the instructions on the
container for the recommended amount. Carbon Clean removes water from
fuel systems, stabilizes fuel and removes carbon deposits from pistons,
rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse
through the entire fuel delivery system.
OIL AND FILTER
Change the oil and filter. See the Engine Oil section of your Vehicle Manual.
AIR FILTER / AIR BOX
Replace the air filter. See Maintenance Chapter. Clean the air box.
FLUID LEVELS
Inspect the fluid levels. Add or change fluids as recommended in the Periodic
Maintenance Chart in your Vehicle Manual.
• Demand drive fluid (front gearcase)
• Rear gearcase fluid (if equipped)
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark or
contaminated)
• Coolant (test strength/fill)
131
MAINTENANCE
INSPECT AND LUBRICATE
Inspect all cables and lubricate all areas of the vehicle as recommended in the
Periodic Maintenance Chart in your Vehicle Manual.
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 plugs and add 2-3 tablespoons of engine oil. To access
the plug holes, use a section of clear 1/4” hose and a small plastic squeeze
bottle filled with the pre-measured amount of oil. Do this carefully! If you miss
the plug holes, oil will drain from the spark plug cavities into the hole at the
front of the cylinder head, and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification. See the Spark Plugs
section of your Vehicle Manual.
4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall
the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around the
piston rings and ring lands, coating the cylinder with a protective film of fresh
oil.
6. Reinstall the spark plug caps.
7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
BATTERY MAINTENANCE
See the Battery Storage and Battery Charging (Conventional Battery) sections
of your Vehicle Manual 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.
REMOVAL FROM STORAGE
1. Check the battery electrolyte level and charge the battery if necessary. Install
it in the vehicle. Make sure the battery vent hose is routed properly and that
it's not pinched or restricted in any way.
2. Make sure spark plugs are tight.
3. Fill the fuel tank with fuel.
132
MAINTENANCE
4. Check all the points listed in the Daily Pre-Ride Inspection outlined in your
vehicle’s owner’s manual. 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 in your
Vehicle Manual.
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness or death. Never run an engine in an enclosed area.
TRANSPORTING THE VEHICLE
Follow these procedures when transporting the vehicle.
1. Apply the brakes.
2. Place the transmission in PARK. Stop the engine.
3. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle. Engage the park brake.
4. Remove the key to prevent loss during transporting.
5. Secure the fuel cap (if equipped) and seat. Ensure that the seat is attached
correctly and is not loose.
WARNING
Cargo and other loose vehicle parts may fly off while transporting this vehicle.
Secure or remove all cargo, and inspect the unit for loose parts prior to
transport.
6. Always tie the frame of the vehicle to the transporting unit securely with
suitable straps or rope. Do not attach tie straps to the front control arm bolt
pockets.
133
MAINTENANCE
134
SPECIFICATIONS
ACE 500
POLARIS ACE 500
Gross Vehicle Weight 1479 lbs. (670 kg)
Dry Weight 842 lbs. (382 kg) (+/- 5%)
Test GVW - Rollover Protection System (ROPS) 1505 lbs. (682.7 kg) per OSHA 29 CFR 1928.53
Front Rack/Box Capacity 120 lbs. (54 kg)
Rear Rack/Box Capacity 240 lbs. (108 kg)
Maximum Weight Capacity (Payload) 575 lbs. (260 kg) (operator/cargo/accessories/
trailer tongue weight)
Receiver Hitch Tongue Capacity 150 lbs. (68 kg)
Receiver Hitch Towing Capacity 1500 lbs. (680 kg)
Fuel Capacity 5.25 gal. (19.9 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant System Capacity 96 oz. (2.8 l) excluding coolant bottle
Coolant Bottle Capacity 8 oz. (237 ml)
Demand Drive Fluid Capacity 6.75–7.6 oz. (200–225 ml)
Transmission Oil Capacity 44 oz. (1300 ml)
Overall Length/Width/Height 90/48/75.5 in. (228.6/122/191.8 cm)
Wheelbase 61.5 in. (156.2 cm)
Ground Clearance 10.25 in. (26 cm)
Engine 4-Stroke SOHC Single Cylinder
Displacement 500 cc
Bore x Stroke 93 mm x 73.6 mm
Alternator Output 560 W @ 7000 RPM
Compression Ratio 10:1
Starting System Electric
Fuel System Electronic fuel injection
Throttle Body Size 46 mm
135
SPECIFICATIONS
POLARIS ACE 500
Ignition System ECU
Ignition Timing ECU Controlled
Spark Plug / Gap Autolite 5923 / 0.85 +/– 0.08 mm
Front Suspension MacPherson strut with 8.2 in. (20.8 cm) travel
Rear Suspension Dual A-arm, anti-sway bar with 9.5 in. (24.1 cm)
Lubrication System Wet Sump
Engine Oil PS-4 5W-50
Driving System Type Automatic POLARIS Variable Transmission
Shift Type Side Lever (H/L/N/R/P)
Gear Reduction - Low 18.80:1
Gear Reduction - Reverse 22.92:1
Gear Reduction - High 10.40:1
Drive Ratio - Front 3.818:1
Tire Size - Front 24x8-12
Tire Size - Rear 24x10-12
Tire Pressure Front: 7 psi (48 KPa)
Rear: 7 psi (48 KPa)
Brakes, Park Park in Transmission
Brakes, Front/Rear Foot Activated, 4-wheel hydraulic disc
Headlights 2 single beam, 55W halogen
Taillights 2 single beam, 6W
Brake Lights 2 single beam, 27W
Instrument Cluster LCD
Auxiliary DC Outlet 12V
CLUTCHING
ALTITUDE SHIFT WEIGHT DRIVE SPRING
DRIVEN
SPRING
Meters
(Feet)
0-1500
(0-5000)
25-52
5632409
35-240
7043594
BLK/ALMOND
3235088
1500-3700
(5000 - 12,000)
25-48
5633217
136
SPECIFICATIONS
TROUBLESHOOTING ACE PROBLEMS
DRIVE BELT WEAR/BURN
POSSIBLE CAUSE SOLUTION
Driving onto a pickup or tall
trailer in high range
Use low range during loading.
Starting out going up a steep
incline
Use low range. See warnings on .
Driving at low RPM or ground
speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at low
ambient temperatures
Warm the engine at least 5 minutes. With the transmission in
neutral, advance the throttle to about 1/8 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.
Towing/pushing at low RPM/
low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow
Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and
vehicle rollover.
Climbing over large objects
from a stopped position
Shift the transmission to low range and carefully use fast, brief,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and
vehicle rollover.
Belt slippage from water or
snow ingestion into the PVT
system
Dry out the PVT (see the PVT Drying section of your Vehicle
Manual). Prevent water from entering the PVT intake duct. See
Intake Pre-Filters for more information. 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.
Slippage from failure to warm
up belt
Always warm up the belt by operating below 30 mph for one mile
(5 miles or more when temperature is below freezing).
Wrong or missing belt
Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 53.
137
TROUBLESHOOTING ACE PROBLEMS
ENGINE DOESN'T TURN OVER
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
Loose electronic control box
connections
Inspect, clean, reinstall connectors
ENGINE TURNS OVER, FAILS TO START
POSSIBLE CAUSE SOLUTION
Out of fuel Refuel
Water is present in fuel Drain the fuel system and refuel
Old or non-
recommended fuel
Replace with fresh recommended fuel
Fouled or defective
spark plug
Inspect plug and replace if necessary
No spark to spark plug Inspect plug and replace if necessary
Water or fuel in
crankcase
Your authorized dealer can assist
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure Your authorized dealer can assist
ENGINE BACKFIRES
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 or non-
recommended fuel
Replace with fresh recommended fuel
Incorrectly installed
spark plug wires
Your dealer can assist
138
TROUBLESHOOTING ACE PROBLEMS
POSSIBLE CAUSE SOLUTION
Mechanical failure Your dealer can assist
Loose ignition
connections
Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
ENGINE PINGS OR KNOCKS
POSSIBLE CAUSE SOLUTION
Poor quality or low octane fuel Replace with recommended fuel
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES
POSSIBLE CAUSE SOLUTION
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug
wires
Your dealer can assist
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Clogged intake pre-filter Inspect and clean (with soapy water) or replace
Other mechanical failure Your dealer can assist
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
139
TROUBLESHOOTING ACE PROBLEMS
POSSIBLE CAUSE SOLUTION
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug
wires
Your 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
Clogged intake pre-filter Inspect and clean (with soapy water) or replace
Other mechanical failure Your dealer can assist
Overheated engine Clean radiator screen and core, clean engine exterior. Your
dealer can assist.
140
TROUBLESHOOTING ACE PROBLEMS
POLARIS PRODUCTS
LUBRICANTS / SERVICE PRODUCTS
PRODUCT
SIZE (QUANTITY)
PART NUMBER
Fogging Oil
12 oz aerosol (12)
2870791
1 qt (12)
2871517
PS-4
1 qt (12)
2876244
2 qt (8)
2877490
1 gal (4)
2876245
PS-4 Extreme Duty
1 qt (12)
2878920
2 qt (8)
2878922
1 gal (4)
2878919
AGL
1 qt (12)
2878068
1 gal (4)
2878069
Pump for Gallon Jug
3.8 l 2870465
Demand Drive
1 qt (12)
2877922
2.5 gal (2)
2877923
Antifreeze / Coolant
1 qt (12)
2880514
1 gal (6)
2880513
Grease Gun Kit, Premium All
Season
— 2871312
All Season Grease
Four 3 oz packs (6)
2871322
14 oz cartridge
2871423
Premium Starter Grease — 2871460
U-Joint Grease
3 oz tube (24)
2871515
14 oz cartridge
2871551
Dielectric Grease (Nyogel™)
— 2871329
Carbon Clean
12 oz bottle (12)
2871326
Fuel Stabilizer
16 oz (12)
2870652
2.5 gal (2)
2872280
DOT 4 Brake Fluid — 2872189
Loctite™ 565 Thread Sealant — 2871956
POLARIS Battery Tender™
Charger
— 2859044
141
POLARIS PRODUCTS
142
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.
143
WARRANTY
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; use of unapproved software or
calibration; unauthorized repairs; or repairs made after the warranty period
expires or by an unauthorized repair center.
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
• Suspension components
• Brake components
• Seat components
• Clutches and components
• Steering components
• Batteries
• Light bulbs/Sealed beam lamps
• Filters
• Lubricants
• Bushings
• Finished and unfinished surfaces
• Carburetor/Throttle body
components
• Engine components
• Drive belts
• Hydraulic components and fluids
• Circuit breakers/Fuses
• Electronic components
• Spark plugs
• Sealants
• Coolants
• Bearings
144
WARRANTY
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.
145
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.
146
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
147
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:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for
exhaust emissions:
• Aftertreatment devices
• Crankcase ventilation valves
• Sensors
• Electronic control units
148
WARRANTY
The following parts are considered emission-related components for evaporative
emissions:
• Fuel Tank
• Fuel Cap
• Fuel Line
• Fuel Line Fittings
• Clamps*
• Pressure Relief Valves*
• Control Valves*
• Control Solenoids*
• Electronic Controls*
• Vacuum Control Diaphragms*
• Control Cables*
• Control Linkages*
• Purge Valves
• Vapor Hoses
• Liquid/Vapor Separator
• Carbon Canister
• Canister Mounting Brackets
• Carburetor Purge Port Connector
*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
149
WARRANTY
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.
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
150
WARRANTY
152
A
ACE 500................................ 135
ACE 500 Clutching .................. 136
Adding or Changing Coolant ...... 104
Age Restrictions ........................ 17
Air Box Caution ......................... 16
Air Filter................................. 109
Air Filter / Air Box..................... 131
All Wheel Drive (AWD) System ..... 37
Auxiliary Outlet.......................... 36
Axle and Wheel Nut Torque
Specifications........................ 120
B
Battery .................................. 124
Charging ............................ 127
Battery Charging (Conventional
Battery)................................ 127
Battery Fluid (Conventional
Battery)................................ 127
Battery Installation ................... 125
Battery Maintenance ................ 132
Battery Removal...................... 124
Battery Storage ....................... 126
Belt Replacement/Debris
Removal .............................. 108
Boots ...................................... 11
Brake Fluid..............................116
Brake Inspection ......................117
Brake Pedal ............................. 38
Brake System Break-in ............... 54
Brakes ...................................115
Braking ................................... 57
Breather Hose Inspection ...........110
C
Cab Nets ............................ 19, 32
Carrying a Passenger................. 19
Clean the Exterior.................... 131
Clothing................................... 11
Cold Weather Operation.............. 56
Component Locations................. 29
Coolant Level ......................... 106
Crankcase Emission Control
System .................................. 85
Crossing Hillsides ...................... 23
D
Demand Drive Unit (Front
Gearcase) .............................. 97
Descending Hills Improperly ........ 23
Drive Belt Wear/Burn................ 137
Drive Mode (AWD) Switch ........... 36
Driving Downhill ........................ 65
Driving in Reverse ..................... 67
Driving on a Sidehill (Sidehilling) ... 64
Driving on Slippery Surfaces ........ 62
Driving Over Obstacles ............... 66
Driving Through Water................ 69
Driving Uphill ............................ 63
E
Electromagnetic Interference ....... 85
Emissions Limited Warranty....... 148
Engaging AWD ......................... 37
Engine and Drivetrain Break-In ..... 54
Engine Backfires ..................... 138
Engine Doesn't Turn Over ......... 138
Engine Oil ................................ 93
Engine Pings or Knocks ............ 139
Engine Runs Irregularly, Stalls
or Misfires ............................ 139
Engine Stopping........................ 57
Engine Stops or Loses Power .... 139
Engine Turns Over, Fails to
Start.................................... 138
Exhaust Emission Control
System .................................. 85
Exported Products ................... 147
Exposure to Exhaust .................. 27
Extreme Use Battery .................. 32
Eye Protection .......................... 11
153
F
Failure to Inspect Before
Operating ............................... 18
Fluid Change ....................... 97–98
Fluid Check ......................... 97–98
Fluid Levels............................ 131
Fluid Part Numbers .................. 141
Fog the Engine ....................... 132
Front Box Cover ........................ 31
Fuel Cap.................................. 32
Fuel Safety............................... 26
Fuel Stabilizer......................... 131
Fuel Transport Warning............... 16
Fuse Box ............................... 103
Fuses ................................... 102
G
Gasoline Handling ..................... 26
Gear Selector ........................... 38
Gearcase Specification Chart....... 99
Gloves .................................... 11
H
Hauling Cargo........................... 71
Headlamps ............................ 123
Headlight Beam Adjustment....... 122
Heat Shielding .................... 27, 110
Helmet .................................... 11
Hitch Capacity Label .................. 15
Hot Exhaust Systems ................. 27
How To Obtain Warranty
Service ................................ 146
I
Ignition Switch/Light Switch ......... 35
Improper Cargo Loading ............. 26
Improper Hill Climbing ................ 22
Inspect and Lubricate ............... 132
Instrument Cluster
Back Light Color ..................... 48
Back Light Level ..................... 49
Clock ................................... 47
Diagnostic Code..................... 51
Display Area 1 ....................... 43
Display Area 2 ....................... 44
Indicator Lamps ..................... 42
Options Menu ........................ 45
Overview .............................. 41
Service Hours ........................ 50
Unit Selection Distance............ 46
Unit Selection Temperature....... 46
Intake Pre-Filters ...................... 111
J
Jumps and Stunts ...................... 22
K
Know Your Riding Area/Tread
Lightly ................................... 59
L
Lights.................................... 122
Limited Warranty ..................... 143
Load/Passenger/Tire Pressure
Warning ................................. 15
Lubricants / Service Products ..... 141
Lubrication Recommendations ..... 91
Front Suspension Lubrication.... 92
Prop Shaft Lubrication ............. 91
Rear Suspension Lubrication .... 92
M
Maintenance Chart Key .............. 88
Maintenance Log..................... 151
Maintenance, Periodic ................ 87
Maximum Payload Warning ......... 14
Modifications to Vehicle .............. 28
Mud Guards ............................. 40
154
N
New Operator Driving
Procedures............................. 60
Noise Emission Control System .... 85
O
Oil and Filter........................... 131
Oil and Filter Change.................. 94
Oil Check................................. 94
Oil Recommendations ................ 93
Operating at Excessive Speeds .... 21
Operating Improperly in Reverse... 24
Operating in Unfamiliar Terrain ..... 24
Operating on Frozen Bodies of
Water .................................... 25
Operating on Pavement .............. 21
Operating on Public Roads .......... 21
Operating Over Obstacles ........... 25
Operating Through Water ............ 25
Operating With a Load on the
Vehicle .................................. 20
Operation .............................. 104
Operation on Public Lands in
the U.S.A................................ 85
P
Parking on an Incline .................. 68
Parking the Vehicle .................... 57
Part Numbers ......................... 141
Periodic Maintenance Chart......... 87
Plugs, Spark........................... 100
Polaris Products ...................... 141
Polishing the Vehicle ................ 130
Poor Visibility............................ 26
Power Steering Unit (Cleaning)... 103
Pre-Ride Inspection ................... 55
Proper Use Warning................... 14
Protective Apparel ..................... 18
PVT Break-in (Clutches/Belt) ....... 54
PVT Drying ............................ 109
PVT System ........................... 107
PVT System Warning ................. 16
R
Radiator Access/Bumper
Removal ................................ 30
Radiator and Cooling Fan.......... 104
Radiator Coolant Level ............. 105
Rear Spring.............................118
Registration, Warranty .............. 143
Removal from Storage.............. 132
Rollover Protective Structure
(ROPS).................................. 39
S
Safe Operation Practices ............ 58
Safe Riding Gear....................... 10
Safety Labels and Locations ........ 12
Safety Symbols ...........................7
Safety Training............................ 9
Safety Warnings........................ 17
Safety, Winch Maintenance.......... 84
Seat Adjustments ...................... 33
Seat Belt.................................. 33
Seat Belt / Driver Warning ........... 13
Seat Belt Inspection ................... 34
Seat Removal ........................... 33
Service Access Panels ............... 30
Shock Loading the Winch ............ 82
Signal Words .............................. 7
Skidding or Sliding ..................... 24
Spark Arrester .........................113
Spark Plug Gap / Torque ........... 100
Spark Plug Inspection............... 101
Spark Plug Recommendations ... 100
Stabilize the Fuel..................... 131
Stalling While Climbing a Hill........ 23
Starting the Engine .................... 56
Steering Wheel ......................... 31
Steering Wheel Inspection..........118
Stopping the Engine................... 57
Storage ................................. 131
Storage Area .......................... 132
Suspension Settings .................119
Switches.................................. 35
155
T
Taillight / Brake Light
Replacement ........................ 123
Throttle Pedal ........................... 39
Tire Tread Depth ..................... 120
Tires ..................................... 120
Trail Etiquette ........................... 59
Trailer Receiver Hitch Bracket ...... 30
Transmission
Operation ........................... 107
System............................... 107
Warning.............................. 107
Transmission (Main Gearcase) ..... 98
Transporting the Vehicle............ 133
Turning Improperly..................... 22
Turning the Vehicle .................... 58
U
Unauthorized Use of the Vehicle ... 27
Using Low Range ...................... 38
V
Vehicle Break-in Period............... 53
Vehicle Identification Numbers ....... 8
Vehicle Immersion ....................112
W
Warning Symbols ........................ 7
Washing the Vehicle................. 129
Wet Fouled Plug...................... 100
Wheel Installation .................... 121
Wheel Removal....................... 121
Winch Cable Care ..................... 81
Winch Maintenance and
Service Safety ......................... 84
Winch Operation ....................... 76
Winch Safety Precautions ........... 74
Winch Shock Loading................. 82
156
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. 9929035 Rev 01
Printed in USA
