2020 ACE 150

We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We encourage you to teach your children to ride safely, and to help ensure the future of recreational sports, please teach them to show respect for our environment and for the rights of others while operating the vehicle.

This vehicle is not a toy and can be hazardous to operate. We've provided this owner’s manual and an instructional video to help you and your children learn about the safe operation and care of your new POLARIS vehicle. Before your children drive or ride in the vehicle, please read and make sure they read this owner’s manual. Watch the instructional video with them. Make sure all operators and passengers understand and follow all of the instructions and warnings contained in this owner’s manual and video. Make sure they understand that the vehicle must be used under adult supervision at all times.

After reading this owner’s manual and watching the video, help your child practice the steps in the New Operator Driving Procedures section.

Never allow a child under age 10 to operate or ride as a passenger in this vehicle. Children differ in skills, physical abilities and judgement. Please supervise the use of the vehicle at all times. Permit continued use only if you determine that your child has the ability and maturity to operate safely.

For your child’s safety, be sure your child can reach and operate all ACE 150 controls, including steering wheel, accelerator and brake pedals, and ignition switch. Make sure your child is not too tall to ride safely in this vehicle. See the Age Restrictions section.

The vehicle’s speed control system allows adults to limit vehicle speed for new and inexperienced operators. Please see the Speed Control System section for more information.

The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's vehicle are thoroughly inspected at specific intervals. Always follow all of the instructions and recommendations in this manual to ensure the vehicle remains in safe operating condition at all times.

This POLARIS vehicle is not designed for adult use. Serious damage may occur if the maximum weight capacity is exceeded. Refer to vehicle labels and to the Specifications section for the maximum weight capacity.

Before you ride your new POLARIS vehicle, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you're riding.

Your parents and POLARIS want you to be safe while you enjoy riding your new vehicle, and that's why it’s very important that you read this owner’s manual and watch the instructional video. Make sure you understand and follow all of the instructions and warnings in this owner’s manual and video. Ask your parents to explain anything you don't understand.

Your safety and the safety of others is the most important thing to think about at all times. Pay attention when you see this symbol:

After reading this owner’s manual and watching the video, complete the steps in the New Operator Driving Procedures section. Show your parent that you understand how to drive safely.

Enjoy riding your new POLARIS vehicle!

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The 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.

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.

1 Vehicle Identification Number
(LH rear wheel well)

2 Engine Serial Number

3 Key Number

Always wear a 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.

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

• 1 Dash Warning Label

• 2 Rear Warning Label

• 3 Fuel Transport Warning Label

Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by the operator at all times. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized POLARIS dealer. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets.

The steering wheel can be adjusted upward or downward for rider preference.

1. Loosen and remove the steering wheel adjustment bolt 1.

2. Move steering wheel upward or downward to the desired position by aligning the mounting holes.

3. Tighten bolt to 13.5 Nm (10 ft-lbs).

This POLARIS vehicle is equipped with three-point lap and diagonal seat belt for the operator. Always make sure the seat belt are secured for the operator before riding. The driver’s seat belt is equipped with an interlock. Vehicle speed will be limited if the seat belt is not secured.

• 1 Screws

• 2 Adjusters / Latches

Riding in this vehicle without using the cab nets (or doors) increases the risk of serious injury or death in the event of an accident or rollover.

Cab nets must be used by the operator at all times. Make sure all latches are secure before operating the vehicle.

Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.

Promptly replace worn or damaged cab nets with new cab nets, available from your authorized dealer.

The fuel tank filler cap 1 is located on the left-hand side of the vehicle.

Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See the POLARIS Products chapter for part numbers.

When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Non-ethanol fuel is recommended. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

• The ignition switch 1 is a three-position, key-operated switch. Use the ignition switch to start the engine. See the Starting the Engine section for starting procedures.

• The key can be removed from the switch when it is in the OFF position.

F: Forward

N: Neutral

R: Reverse

The gear selector is located on the side of the seat. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

Depress the brake pedal 1 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.

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 2 returns normally before starting the engine.

1. Apply the brakes.

2. When the vehicle is fully stopped, pull the parking brake lever rearward as far as possible to set the parking brake.

3. Stop the engine.

4. To release the parking brake, apply the brakes and push the lever toward the right side of the vehicle.

5. See Parking Brake Adjustment section for details on adjustment.

This vehicle has an adjustable speed control system that controls the speed of the vehicle. The speed of this vehicle is restricted to 16 km/h (10 MPH) at manufacture. The speed limiting device may be adjusted by supervising adults when they determine that their child is capable of safely handling additional speed.

Electronic Speed Control System

Adjust speed modes by moving the jumper fuse between the assigned speed slots inside the fuse box.

1. Slide the driver’s seat forward to access the fuse box.

   

2. Remove the two push rivets from the retention bracket. Remove bracket.

   

3. Remove the fuse box cover.

   

4. Move the fuse jumper to desired speed mode slot.

   

5. Replace fuse box cover.

6. Replace fuse box bracket and replace push rivets.

7. Reposition the seat.

The break-in period for your new POLARIS vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.

No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.

1. Complete the steps in the New Operator Driving Procedures section.

2. Do not ride at night or when visibility is poor (rain, fog, dusk). Your vehicle doesn't have lights that are designed for driving in these conditions.

3. Never tow objects or carry loads with this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. Never allow a child to handle gasoline.

5. Never install accessories not approved by POLARIS for use on this vehicle.

6. Ride this vehicle only in areas permitted by a supervising adult. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. DO NOT attempt to do power slides, “donuts”, jumps or other driving stunts. Keep both hands on the steering wheel at all times.

8. Never consume alcohol or drugs before or while operating this vehicle.

9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

10. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

11. Never operate the vehicle on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

1. Sit in the driver’s seat and fasten the seat belt.

2. Secure the cab nets.

3. Place the transmission in neutral. Set the parking brake.

4. Apply the brakes.

5. Do not press the throttle pedal while starting the engine.

6. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

   NOTICE

   Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

7. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 6 and 7 until the engine starts.

8. Vary the engine RPM slightly with the throttle to aid in warm-up until the engine idles smoothly.

9. Release the parking brake before driving.

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in NEUTRAL.

3. Set the parking brake.

4. Stop the engine.

1. Release the throttle pedal completely.

   NOTICE

   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.

1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

2. Place the transmission in NEUTRAL.

3. Set the parking brake.

4. Stop the engine.

5. Remove the ignition key to prevent unauthorized use.

When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding.

Follow these precautions when driving in slippery conditions:

1. Slow down before entering slippery areas.

2. Be alert, watch the path ahead and avoid quick turns, which can cause skids.

3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

1. Read and understand this owner's manual and all warning and instruction labels before operating this vehicle.

2. Watch the instructional video with the supervising adult.

3. Review the previous sections of this owner’s manual about starting the engine, stopping the engine, braking, and parking.

4. Perform the steps noted in the Pre-Ride Inspection section.

5. The driver must wear a helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times.

6. Do not operate or ride in this vehicle if the clearance between the top of your helmet and the overhead cab frame is less than 2 inches (5 cm).

7. Select a level open area to practice driving. Make sure you have adult supervision and permission to drive in this area.

8. Sit in the driver's seat and fasten the seat belt.

9. Make sure all cab nets are properly secured.

10. Set the parking brake.

11. Place the transmission in neutral.

12. Start the engine.

13. Apply the brakes and shift into gear.

14. Release the parking brake.

15. Check your surroundings. Make sure the area is clear of people and obstacles.

16. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your right foot to begin driving.

17. Drive slowly at first. Practice starting, stopping, turning, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

18. Increase speed only after mastering all maneuvers at a slow speed.

19. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

    • Avoid sharp turns. Make turns gradually.

    • Never turn while applying heavy throttle.

    • Never turn the steering wheel abruptly.

    • Operate at speeds appropriate for your skills, the conditions and the terrain.

    • DO NOT attempt to do power slides, “donuts”, jumps or other driving stunts.

Whenever traveling uphill, follow these precautions:

1. Always check the terrain carefully before ascending a hill. Never drive on hills with excessively slippery or loose surfaces.

2. Avoid excessively steep hills (15° maximum).

1. Drive straight uphill.

2. Drive at a steady rate of speed. Never press the throttle suddenly.

3. Avoid unnecessary changes in speed or direction.

4. Never go over the crest of a hill at a high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

5. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to reverse straight downhill while applying the brakes lightly to control speed.

Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or rollover.

If crossing a hill is unavoidable, follow these precautions:

1. Drive slowly and use extreme caution.

2. If the vehicle begins to roll over, or if it feels as if it may roll over, immediately turn downhill.

3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.

4. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.

Whenever driving down a hill, follow these precautions:

1. Avoid excessively steep hills (15° maximum).

2. Slow down. Never travel down a hill at high speed.

3. Always check the terrain carefully before driving down a hill. Never drive on hills with excessively slippery or loose surfaces.

4. Always drive down a hill with the transmission in forward gear. Never “coast” or drive down a hill with the transmission in neutral.

5. Avoid driving down a hill at an angle, which would cause the vehicle to lean sharply to one side. Always drive straight downhill.

6. Apply the brakes lightly to keep speed slow.

Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water:

1. Check water depth. Never drive through water that is deeper than the floor level 1.

2. After driving through water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

Follow these precautions when driving over obstacles:

1. Always check for obstacles before driving in a new area.

2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches.

3. Drive slowly and use extra caution when driving on unfamiliar terrain. Obstacles are not always clearly visible.

4. Do not drive over large obstacles such as large rocks and fallen trees. If it’s unavoidable, use extreme caution and drive slowly.

Follow these precautions when driving in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Apply the throttle lightly. Never apply the throttle suddenly.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions:

1. Place the transmission in neutral.

2. Set the parking brake.

3. Stop the engine.

4. Always block the rear wheels on the downhill side.

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

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 emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

The emissions label is located on the frame behind the left front wheel.

This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.

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.

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997.

The operating conditions of the machinery during testing:

• Vehicles were in like-new condition.

• Environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s manual.

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

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.

Maintenance Chart Key

Symbol	Description
XU	Perform these procedures more often for vehicles subjected to severe use.
D	Have an authorized 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 dealer or other qualified person perform these services.

5 Hour / Break-in Service

Item		Remarks
XU	Engine Oil Change (Break-in)	Perform a break-in oil change at one month
	Drive Chain (Break-in)	Adjust and lubricate
XU D	Brake pad wear (Break-in)	Inspect periodically

10 Hour / 160 km (100 mile) Service

Item		Remarks
D	Valve Clearance (Break-in)	Valve lash adjustment: Every 50 hours after first 10–hour adjustment

25 Hour / 400 km (250 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Engine Oil Change

50 Hour / 800 km (500 mile) Service

Item		Remarks
XU	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment: Every 40 hours after first 10-hour adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
XU	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks

75 Hour / 1200 km (750 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

100 Hour / 1600 km (1000 mile) Service

Item		Remarks
	Battery	Check terminals; clean; test
XU	Transmission (Main Gearcase)	Replace transmission fluid
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks
D	Fuel System / Filter	Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years
XU	Spark Plug	Inspect; replace as needed
XU	Engine Mounts	Inspect
	Exhaust Muffler / Pipe	Inspect
XU	Wiring	Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
D	Clutches (Drive and Driven)	Inspect; clean; replace worn parts
	Drive belt	Inspect; replace as needed
D	Front wheel bearings	Inspect; replace as needed

125 Hour / 2000 km (1250 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

150 Hour / 1500 mile (2400 km) Service

Item		Remarks
XU	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks

175 Hour / 2800 km (1750 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

200 Hour / 3200 km (2000 mile) Service

Item		Remarks
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks
D	Fuel System / Filter	Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years
XU	Spark Plug	Inspect; replace as needed
XU	Engine Mounts	Inspect
	Exhaust Muffler / Pipe	Inspect
XU	Wiring	Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
XU	Clutches (Drive and Driven)	Inspect; clean; replace worn parts
	Drive belt	Inspect; replace as needed
D	Front wheel bearings	Inspect; replace as needed
D	Brake fluid	Change every two years

225 Hour / 3600 km (2250 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

250 Hour / 4000 km (2500 mile) Service

Item		Remarks
XU	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks

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.

1 A-Arm Pivot Greasing Points (8 total)

Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the interval specified in the Periodic Maintenance Chart. Lubricate more often under severe use, such as in dirty or wet conditions.

1. Loosen upper nut 1 on the chain tensioner bracket.

2. Turn lower nut 2 clockwise in 1/2 turn increments, then turn upper nut until tight. Follow this procedure until chain is at proper tension. To check for proper tension, press the down on the middle of the chain with thumb using 100N (22 lbs) of force. Chain deflection 3 should be within specification.

   MEASUREMENT

   Chain Deflection:

   Using 100N (22 lbs) of force

   New Chain: 5 - 10 mm (3/16 - 13/32”)

   Broken In Chain: 10 - 15 mm (13/32 - 19/32”)

   NOTE

   A new chain will stretch after the vehicle is used for a period of time.

3. Repeat these steps until chain is adjusted to desired deflection.

Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often. Access the air box near the right rear wheel.

1. Disengage the two cover latches 1.

2. Unlatch the cover and carefully remove it from the air box.

3. Remove the filter 2.

4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean shop towel.

1. Inspect the air filter and replace if necessary.

   NOTE

   DO NOT attempt to clean the air filter with compressed air.

2. Place the air filter into the air box and reinstall the air box cover.

3. Engage the cover latches.

To prevent dirt intrusion,

1. Ensure the O-ring 4 is installed properly within the rim of the air intake box 3.

2. Align the tabs 5 of the intake cover within the hinges 1 and snap the hinges closed securely.

To remove accumulated carbon, clean the spark arrester at the intervals recommended in the Periodic Maintenance Chart beginning on Maintenance Intervals.

1. Remove the 3 bolts and remove the arrester 1 from the end of the muffler.

2. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air.

3. Inspect the screen for wear and damage. Replace the arrester if damage is found.

4. Reinstall the arrester.

5. Torque the bolts to 7 ft. lbs. (9.5 Nm).

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.

If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs.

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart.

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 POLARIS dealer or other qualified service facility before operating the vehicle.

The front and rear shock absorber springs are adjustable to increase or decrease spring tension. Rotate the adjuster 1 either clockwise or counter-clockwise to make adjustments.

Always apply the same adjustment setting to all four wheels.

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires approximately 25.4 cm (10″) from the floor or as close to the hub/axle center line as possible 1.

   NOTE

   It is important the height of both marks be equally positioned to get an accurate measurement.

3. Measure the distance between the marks and record the measurement. Call this measurement “2”.

1. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

1. Again measure the distance between the marks and record. Call this measurement “3”. Subtract measurement “3” from measurement “2”. The difference between measurements “2” and “3” is the vehicle toe alignment. The recommended vehicle toe tolerance is 0 to 3.2 mm (0 to 1/8”) toe out. This means the measurement at the front of the tire 3 is 0 to 3.2 mm (0 to 1/8”) wider than the measurement at the rear 2.

If you discover improper alignment, see your authorized dealer for service.

If it’s impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land.

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. Thoroughly dry the air pre-filter..

3. Remove the air box drain plug to drain any water. Reinstall the drain plug securely.

4. Remove the spark plug.

5. Turn the engine over several times using the electric start.

6. Dry the spark plug and reinstall it, or install a new plug.

7. Attempt to start the engine. If necessary, repeat the drying procedure.

8. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service.

9. If water has been ingested into the transmission follow the procedure in the Constant Variable Transmission (CVT) System section for details on drying.

Your vehicle uses a sealed battery, which requires little maintenance. A sealed battery can be identified by its flat covers 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. Never pry the sealing strip off or add any other fluid to a sealed battery.

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. Laws and regulations in your jurisdiction may give extra protection. 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, or other qualified person, 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.

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.

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.

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.

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. Dealership contacts can be found via this website, if needed:

www.polaris.com/en-us/contact

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

Use the following chart to record periodic maintenance.