1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. ACE 150 EFI 2018
  6. Owner's manual

Polaris ACE 150 EFI 2018 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
2018
Owner's MAnual
POLARIS ACE® 150 EFI

Advertisement

Table of Contents
loading

Related Manuals for Polaris ACE 150 EFI 2018

Summary of Contents for Polaris ACE 150 EFI 2018

  • Page 1 2018 Owner’s MAnual POLARIS ACE® 150 EFI...
  • Page 2 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 Visit us at www.polaris.com...
  • Page 4 POLARIS® is a trademark of POLARIS Industries Inc. Copyright 201 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.
  • Page 5 Dear Parents: We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We encourage you to teach your children to ride safely, and to help ensure the future of recreational sports, please teach them to show respect for our environment and for the rights of others while operating the vehicle.
  • Page 6 This POLARIS vehicle is not designed for adult use. Serious damage may occur if the maximum weight capacity is exceeded. Refer to vehicle labels and to the specifications section beginning on page 100 for the maximum weight capacity.
  • Page 7 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.

  • Page 8: Table Of Contents

    Specifications ..... . 100 POLARIS Products ....102 Troubleshooting .

  • Page 9: Introduction

    INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 10 WARNING Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 11 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.

  • Page 12: Safety

    SAFETY Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. WARNING! Modifying this vehicle in any way can change the top speed, stability and handling performance of this vehicle. Modifications that increase speed, decrease stability or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death.
  • Page 13 Helmet Sleeves Gloves 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. 051039 0006.31 Approved helmets in the USA and Canada bear a U.S.
  • Page 14 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.
  • Page 15 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.
  • Page 16 SAFETY Age Restrictions This vehicle is for recreational use by young operators under adult supervision ONLY. Operation is prohibited for anyone under age 10. Operators must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel.
  • Page 17 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. See page 43.
  • Page 18 SAFETY Safety Warnings Using Alcohol or Drugs Riding in this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating or riding in this vehicle. Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement.
  • Page 19 SAFETY Safety Warnings Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your skills and experience. Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or...
  • Page 20 SAFETY Safety Warnings Driving Downhill Improperly Driving down a hill improperly could cause loss of control or rollover. Always follow proper procedures for driving down a hill as described in this owner’s manual. See page +15° Improper Hill Climbing Improper hill climbing could cause loss of control or rollover.
  • Page 21 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped.
  • Page 22 SAFETY Safety Warnings Operating on Sand or Slippery Terrain Operating on sand or on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Always use extra caution when operating on sand or on rough, slippery or loose terrain.
  • Page 23 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Never attempt to operate over large obstacles such as large rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.
  • Page 24 SAFETY Safety Warnings Overloading the Vehicle Overloading the vehicle or carrying/towing loads may cause changes in stability and handling, which could cause loss of control or an accident. • Never tow objects. • Never carry loads over the maximum cargo limit. •...
  • Page 25 Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 10 or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use. FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764.
  • Page 26 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. Dash Warning Label...
  • Page 27 15°. • on paved surfaces - pavement may seriously affect handling and control. • with non-POLARIS approved accessories - they may seriously affect stability. • at speeds that are too fast for the operator’s skills, the conditions and/or the terrain.
  • Page 28 SAFETY Safety Labels and Locations Dash Warning Label WARNING Operation of this vehicle by children under age 10 increases the risk of severe injury or death. Adult supervision required for children under age 16. NEVER permit children under age 10 to operate in this vehicle. Rear Warning Label WARNING •...

  • Page 29: Features And Controls

    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.
  • Page 30 FEATURES AND CONTROLS Component Locations Frame Steering Wheel Running Lights Brush Guard Muffler (Spark Arrester)
  • Page 31 FEATURES AND CONTROLS Seats Driver’s Seat Adjustment 1. Lift the seat latch lever located under Seat Latch Lever the right front edge of the driver’s seat. 2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever.
  • Page 32 FEATURES AND CONTROLS Steering Wheel The steering wheel can be adjusted Adjustment Bolt upward or downward for rider preference. 1. Loosen and remove the steering wheel adjustment bolt. 2. Move steering wheel upward or downward to the desired position by aligning the mounting holes. 3.
  • Page 33 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belt for the operator. Always make sure the seat belt are secured for the operator before riding. To wear the seat belt properly, follow this...
  • Page 34 If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer. 4. To clean dirt or debris from the seat belt, sponge the straps with mild soap and water.
  • Page 35 Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, available from your authorized POLARIS dealer.
  • Page 36 Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See page 102 for the part numbers of POLARIS Fuel Cap products. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane.
  • Page 37 FEATURES AND CONTROLS Ignition Switch The ignition switch is a three-position, key-operated switch. Use the ignition switch to start the engine. See page 45 for starting procedures. The key can be removed from the switch when it is in the OFF position. The engine is off.
  • Page 38 Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer can assist in resolving any shifting problems. NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.
  • Page 39 FEATURES AND CONTROLS Parking Brake 1. Apply the brakes. 2. When the vehicle is fully stopped, pull the parking brake lever rearward as far as possible to set the parking brake. 3. Stop the engine. 4. To release the parking brake, apply the brakes and push the lever toward the outside of the vehicle and forward.
  • Page 40 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released.
  • Page 41 FEATURES AND CONTROLS Speed Control System This vehicle has an adjustable speed control system that controls the speed of the vehicle. The speed of this vehicle is restricted to 10 MPH (16 km/h) at manufacture. The speed limiting device may be adjusted by supervising adults when they determine that their child is capable of safely handling additional speed.
  • Page 42 FEATURES AND CONTROLS Electronic Speed Control System 1. Slide the driver’s seat forward to access the fuse box. 2. Remove the two push rivets from the retention bracket. Remove bracket. 3. Remove fuse box cover. 4. Move fuse jumper to desired speed mode slot.

  • Page 43: Operation

    Vehicle Break-in Period The break-in period for your new POLARIS vehicle is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
  • Page 44 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. Never allow a child to handle gasoline. 2. Check the oil level. See page 65. Add the recommended oil as needed to maintain the oil level in the safe operating range.
  • Page 45 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal...
  • Page 46 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.
  • Page 47 OPERATION Starting the Engine 1. Sit in the driver’s seat and fasten the seat belt. 2. Secure the cab nets. 3. Place the transmission in neutral. Set the parking brake. 4. Apply the brakes. 5. Do not press the throttle pedal while starting the engine. 6.
  • Page 48 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in neutral. 3. Set the parking brake. 4. Stop the engine. Braking 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2.
  • Page 49 OPERATION New Operator Driving Procedures 1. Read and understand this owner's manual and all warning and instruction labels before operating this vehicle. 2. Watch the instructional video with the supervising adult. 3. Review the section of this owner’s manual about starting the engine, stopping the engine, braking and parking (pages 45-46).
  • Page 50 OPERATION New Operator Driving Procedures 13. Apply the brakes and shift into gear. 14. Release the parking brake. 15. Check your surroundings. Make sure the area is clear of people and obstacles. 16. Keeping both hands on the steering wheel, slowly release the brakes and press the throttle with your right foot to begin driving.
  • Page 51 OPERATION Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding. Follow these precautions when driving in slippery conditions: 1. Slow down before entering slippery areas. 2.
  • Page 52 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. Never drive on hills with excessively slippery or loose surfaces. 2. Avoid excessively steep hills (15° maximum). 3. Drive straight uphill. 4.
  • Page 53 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Driving on a sidehill improperly cause loss of control or rollover. If crossing a hill is unavoidable, follow these precautions: 1. Drive slowly and use extreme caution. 2.
  • Page 54 If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 86, and take the vehicle in for service at the first opportunity.
  • Page 55 OPERATION Driving Over Obstacles Follow these precautions when driving over obstacles: 1. Always check for obstacles before driving in a new area. 2. Look ahead and watch the terrain. Always be alert for hazards such as logs, rocks and low hanging branches. 3.
  • Page 56 OPERATION Driving in Reverse Follow these precautions when driving in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply the throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.
  • Page 57 OPERATION Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Place the transmission in neutral. 2. Set the parking brake. 3. Stop the engine. 4.

  • Page 58: Emission Control Systems

    Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 59: Maintenance

    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.
  • Page 60 Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service. Record maintenance and service in the Maintenance Log beginning on page 115.
  • Page 61 Description Perform these operations more often for vehicles subjected to severe use. Have an authorized POLARIS dealer or other qulaified 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...
  • Page 62 Daily Inspect; clean often; replace as needed Airbox Purge Daily Drain when deposits are Valve visible Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services.
  • Page 63 250 (400) Check terminals; clean; test Main gearcase oil Monthly 250 (400) Inspect level; change yearly Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services.
  • Page 64 Spark plug 600 (1000) Inspect; replace as needed Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services.
  • Page 65 36 M 3000 (4800) Clean out D Toe adjustment Inspect periodically; adjust when parts are replaced Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services.
  • Page 66 See page 79. Transmission Oil AGL Gearcase Lubricant See page 67. (Main Gearcase) & Transmission Fluid Drive Chain POLARIS Chain Lube or See page 68. SAE 80/90 A-Arm Pivots POLARIS All Season Grease at general Grease or grease lubrication interval, also conforming to NLGI No.
  • Page 67 Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. POLARIS recommends the use of Engine Oil for this vehicle. Mixing brands or using a non-recommended oil may cause serious engine damage.
  • Page 68 MAINTENANCE Engine Oil Oil Change Position the vehicle on a level surface. Set the parking brake. Clean the area around the pre-filter plug. Start the engine. Allow it to idle for two to three minutes. Stop the engine. Hot oil can cause burns to skin. Do not allow hot oil to contact skin. Remove the 4 nuts/bolts holding the lower chain guard in place.
  • Page 69 MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. POLARIS recommends the use of AGL Gearcase Lubricant & Transmission Fluid for this vehicle. Fluid Check Fill Plug The fill plug is located on the rear of the gearcase.
  • Page 70 MAINTENANCE Drive Chain Lubrication Lubricate the drive chain with POLARIS chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 57. Lubricate more often under severe use, such as in dirty or wet conditions. See page 102 for the part numbers of POLARIS products.
  • Page 71 MAINTENANCE Parking Brake Cable Freeplay Adjustment 1. Inspect and perform any needed service on the brake pads before adjusting parking brake cable freeplay. 2. Make sure the parking brake is NOT set (lever is DOWN). 3. Pull the brake cable back to inspect freeplay between the cable end and the caliper bracket.
  • Page 72 MAINTENANCE Parking Brake Adjustment 1. Inspect and perform any needed service on the brake pads before adjusting the parking brake. 2. Position the vehicle on a level surface. Place the transmission in neutral. 3. Carefully elevate the rear of the vehicle slightly. Use an appropriate lift.
  • Page 73 (12-15 Nm) (23-27 Nm) NOTICE: Using non-recommended spark plugs can result in serious engine damage. Use POLARIS-recommended spark plugs or their equivalent. See page 100. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
  • Page 74 MAINTENANCE Spark Plug Spark Plug Removal and Replacement 1. Use a spark plug wrench to remove the spark plug. 2. Inspect the spark plug each time you change the oil. The electrodes should be kept clean and free of carbon. The presence of carbon or excess oil will reduce proper engine performance.
  • Page 75 MAINTENANCE Valve Adjustment Procedure NOTE: In order to properly set the valves, the engine must be at TDC on the compression stroke. To find TDC on the compression stroke, roll the engine over until the intake valve closes and stops at TDC. Intake Valve Clearance Adjustment 1.
  • Page 76 MAINTENANCE Valve Adjustment Procedure Exhaust Valve Clearance Adjustment 1. Remove the valve cover. 2. Verify cam lobes are pointed down. 3. Insert correct thickness feeler gauge between end of exhaust valave stem and adjuster screw. 4. Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge.
  • Page 77 • Always follow all recommended maintenance procedures. See your POLARIS dealer, or other qualified person, for service and repair assistance. • This CVT system is intended for use on POLARIS products only. Do not install it in any other product.
  • Page 78 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Access the air box near the right rear wheel. 1. To remove the air cleaning element, unlatch each metal clip holding the cover in place.
  • Page 79 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 38. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm.
  • Page 80 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. Brake Pad 3. Check the brake pads for wear, damage and looseness. 4. Inspect the brake pad wear surface for excessive wear.
  • Page 81 Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 102 for the part numbers of POLARIS products. After opening a bottle of brake fluid, always discard any unused portion.
  • Page 82 2. Lightly turn the steering wheel left and right. 3. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized POLARIS dealer or other qualified service facility before operating the vehicle. Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension.
  • Page 83 WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer or other qualified service facility. Position the vehicle on a level surface.
  • Page 84 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.
  • Page 85 Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for service.
  • Page 86 MAINTENANCE Lights Daytime Running Lights Replacement This vehicle’s daytime running lamps operate using LED lights. If they become inoperable, the entire assembly will need to be replaced by your authorized POLARIS dealer or other qualified service facility.
  • Page 87 2. Remove attachment nuts holding light assembly. 3. Install new light assembly and secure with attachment nuts. 4. Reconnect the light harness. 5. Start the engine to make sure the lights come on. If the lights do not operate, your POLARIS dealer can assist.
  • Page 88 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...
  • Page 89 MAINTENANCE 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. WARNING Battery electrolyte is poisonous.
  • Page 90 MAINTENANCE Battery Battery Removal 1. Access the battery through the left rear wheel well. 2. On conventional batteries, remove the battery vent tube (sealed batteries do not have a vent tube). 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last.
  • Page 91 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 91 before installing the battery. 1.
  • Page 92 See page 91. Tip: Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self- discharge.
  • Page 93 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.
  • Page 94 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Action Charge Time* Charge 100% 12.8-13.0 None, check at 3 None required volts mos. from date of manufacture 75%-100% 12.5-12.8 May need slight 3-6 hours volts...
  • Page 95 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. Before washing the vehicle, locate the CVT inlet and outlet ducts and the air box.
  • Page 96 MAINTENANCE Cleaning and Storage Washing the Vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
  • Page 97 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 98 See page 93. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel, and removes carbon deposits from pistons, rings, valves, and exhaust systems.
  • Page 99 Periodic Maintenance Chart beginning on page 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.
  • Page 100 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.
  • Page 101 Step 5 the seat is attached correctly and is not loose. NOTICE: Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.

  • Page 102: Specifications

    SPECIFICATIONS ACE 150 EFI Maximum Rider Weight 180 lbs. (81 kg) Maximum Weight Capacity 230 lbs. (104 kg) Gross Vehicle Weight 802 lbs. (364 kg) Dry Weight 572 lbs. (260 kg) Fuel Capacity 2.5 gal. (9.5 ltr) Engine Oil Capacity 35.5 oz.
  • Page 103 SPECIFICATIONS ACE 150 EFI Throttle Body Size 32 mm Ignition System Electronic Control Unit Ignition Timing Timing non-adjustable, ECU controlled Spark Plug / Gap NGK CR7HSA / 0.6-0.7 mm Front Suspension Dual A-arm w/5.1 in. (13 cm) travel Rear Suspension Dual Shock swing A-arm w/6 in.

  • Page 104: Polaris Products

    POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l) 2872348...

  • Page 105: Troubleshooting

    Your POLARIS dealer can assist. Poor engine Check for fouled plug or foreign material in gas tank or performance fuel lines. Your POLARIS dealer can assist. Wrong or missing belt Install the recommended belt. Improper break-in Always break in a new belt and/or clutch. See page 41.
  • Page 106 Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your POLARIS dealer can assist. Clogged fuel filter Your POLARIS dealer can assist. Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure Your POLARIS dealer can assist.
  • Page 107 Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your POLARIS dealer can assist. Incorrect spark plug gap/heat range Set gap to specs or replace plug Engine Runs Irregularly, Stalls or Misfires Possible Cause...
  • Page 108 Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your POLARIS dealer can assist. Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections...

  • Page 109: 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.
  • Page 110 WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: •...
  • Page 111 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.
  • Page 112 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.
  • Page 113 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.
  • Page 114 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.
  • Page 115 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.
  • Page 116 U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

  • Page 117: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 118 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 119 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 121: Index

    INDEX Adjustment Drive Belt Wear ....103 Steering Wheel ....30 Drive Chain Lubrication ..68 Air Filter .
  • Page 122 Plugs, Fouled ....71 Polaris Products ....102 Pre-Ride Inspection ... . 43 Lamp Replacement Public Lands .
  • Page 123 INDEX Steering Wheel Adjustment ..30 Steering Wheel Inspection ..80 Safe Operation Practices ..44 Stopping the Engine ... . 46 Safety Labels .
  • Page 125 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. 99 Rev 01...

Table of Contents