Polaris ACE 150 EFI 2019 Owner's Manual
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Polaris ACE 150 EFI 2019 Owner's Manual

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2019
Owner's MAnual
POLARIS ACE® 150 EFI

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Summary of Contents for Polaris ACE 150 EFI 2019

  • Page 1 2019 Owner’s MAnual POLARIS ACE® 150 EFI...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone. Downloaded from ManualsNet.com search engine...
  • Page 3 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.
  • Page 4 POLARIS®, ACE™, OUTLAW®, and SPORTSMAN® 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.
  • Page 5 WELCOME 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.
  • Page 6 WELCOME Downloaded from ManualsNet.com search engine...

  • Page 7: Table Of Contents

    Specifications ....99 POLARIS Products ....101 Troubleshooting ....103 Warranty .
  • Page 8 Downloaded from ManualsNet.com search engine...

  • Page 9: Introduction

    POLARIS vehicle. Before your children drive or ride in the vehicle, please read and make sure they read this owner’s manual.
  • Page 10 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 11 INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS 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. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
  • Page 12 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 13 Polaris Sales Europe Sàrl Place de l’Industrie 2 1180 Rolle, Switzerland Telephone +41213–218–700 DECLARATION OF CONFORMITY Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements to all terrain vehicles. APPLICABLE EUROPEAN TEST / EVALUATION METHODS:...
  • Page 14 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.

  • Page 15: Safety

    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. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
  • Page 16 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.
  • Page 17 MUST be avoided at all times. See the OPERATION section of this owner’s manual for proper operating procedures. FOR MORE INFORMATION ABOUT SAFETYcall POLARIS at 1–800–342– 3764. OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident.
  • Page 18 SAFETY RIDER HEIGHT Some riders may be too tall to ride safely in this vehicle. 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).
  • Page 19 SAFETY 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. 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.
  • Page 20 SAFETY 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.
  • Page 21 SAFETY 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. 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.
  • Page 22 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.
  • Page 23 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.
  • Page 24 SAFETY 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.
  • Page 25 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 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 SAFETY DASH WARNING LABEL (7186510) 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. General Alert •...
  • Page 28 SAFETY REAR WARNING LABEL (7191281) WARNING • Passengers are prohibited on this vehicle. • Read the owner’s manual. • Never carry fuel on this vehicle. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. •...

  • Page 29: Features And Controls

    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.
  • Page 30 FEATURES AND CONTROLS Cab Frame Brush Guard Steering Wheel Muffler (Spark Arrester) Running Lights Downloaded from ManualsNet.com search engine...
  • Page 31 FEATURES AND CONTROLS SEATS DRIVER’S SEAT ADJUSTMENT 1. Lift the seat latch lever located under the right front edge of the driver’s seat. 2. While holding the lever upward, slide the seat forward or rearward to the desired position, then release the lever.
  • Page 32 Ensure bolt is fully tightened prior to operating the vehicle. 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. The driver’s seat belt is equipped with an interlock. Vehicle speed will be limited if the seat belt is not secured.
  • Page 33 FEATURES AND CONTROLS SHOULDER STRAP POSITION ADJUSTMENT The position of the shoulder strap can be adjusted to the height of the operator. Have an adult relocate the mounting bolt to a different position, making sure the nut and bolt are tightened securely.
  • Page 34 Never allow a child to refuel or handle gasoline. The fuel tank filler cap is located on the left-hand side of the vehicle. Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See the POLARIS Products chapter for part numbers.
  • Page 35 FEATURES AND CONTROLS IGNITION SWITCH The ignition switch is a three- position, key-operated switch. Use the ignition switch to start the engine. See the Starting the Engine section for starting procedures. The key can be removed from the switch when it is in the OFF position. START The engine is off.
  • Page 36 FEATURES AND CONTROLS GEAR SELECTOR 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.
  • Page 37 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. Downloaded from ManualsNet.com...
  • Page 38 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 passenger seat and forward.
  • Page 39 FEATURES AND CONTROLS SPEED CONTROL SYSTEM This vehicle has an adjustable speed control system that controls the speed of the vehicle. The speed of this vehicle is restricted to 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.
  • Page 40 FEATURES AND CONTROLS 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. Downloaded from ManualsNet.com search engine...
  • Page 41 FEATURES AND CONTROLS 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. Downloaded from ManualsNet.com search engine...
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  • 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. 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.
  • Page 44 OPERATION BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. CVT BREAK-IN (CLUTCHES / BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance.
  • Page 45 OPERATION PRE-RIDE INSPECTION WARNING 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...
  • Page 46 OPERATION Seat Belts Check length of belt for damage, check latches for page 30 proper operation Cab Nets Check for wear or damage, page 32 ensure proper installation page 22 Grass and Leaves Remove grass, leaves, and other flammable material or debris, especially near the HOT exhaust system.
  • Page 47 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.
  • Page 48 OPERATION 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.
  • Page 49 OPERATION DRIVING ON SLIPPERY SURFACES When driving on slippery surfaces such as wet trails, loose gravel, sand or ice, be alert for the possibility of skidding and sliding. Follow these precautions when driving in slippery conditions: 1. Slow down before entering slippery areas. 2.
  • Page 50 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 previous sections of this owner’s manual about starting the engine, stopping the engine, braking, and parking.
  • Page 51 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 52 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 53 (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, and take the vehicle in for service at the first opportunity.
  • Page 54 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 55 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 56 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 57: Emission Control Systems

    EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. 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.
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  • Page 59: Maintenance

    PERIODIC 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 MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. 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.
  • Page 61 MAINTENANCE 25 HOUR / 250 MILE (400 KM) SERVICE ITEM REMARKS Inspect; cycle key to pressurize fuel pump; Fuel System check lines and fittings for leaks and abrasion Battery Check terminals; clean; test Engine Oil Change 50 HOUR / 500 MILE (800 KM) SERVICE ITEM REMARKS Inspect;...
  • Page 62 MAINTENANCE 100 HOUR / 1000 MILE (1600 KM) SERVICE ITEM REMARKS Battery Check terminals; clean; test Transmission (Main Replace transmission fluid Gearcase) Engine Oil Change Valve lash adjustment Valve Clearance Lubricate all fittings, pivots, cables, etc. General Lubrication Shift Linkage Inspect, lubricate, adjust Steering Lubricate...
  • Page 63 MAINTENANCE 150 HOUR / 1500 MILE (2400 KM) SERVICE ITEM REMARKS Inspect; cycle key to pressurize fuel pump; Fuel System check lines and fittings for leaks and abrasion Battery Check terminals; clean; test Inspect level; change yearly Main Gearcase Oil Engine Oil Change Valve lash adjustment Valve Clearance...
  • Page 64 MAINTENANCE ITEM REMARKS Throttle Body Intake Inspect duct for proper sealing/air leaks Duct Cycle key to pressurize fuel pump; check for Fuel System / Filter leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years Spark Plug Inspect;...
  • Page 65 MAINTENANCE ITEM REMARKS Steering Lubricate Front Suspension Lubricate Rear Suspension Lubricate Throttle Body Intake Inspect duct for proper sealing/air leaks Duct Downloaded from ManualsNet.com search engine...
  • Page 66 Transmission Oil AGL Gearcase Lubricant & See the page 67 for details (Main Gearcase) Transmission Fluid Drive Chain POLARIS Chain Lube or SAE See the page 70 for details 80/90 A-Arm Pivots POLARIS All Season Grease Grease at general lubrication...
  • Page 67 ENGINE OIL OIL RECOMMENDATIONS Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart. POLARIS recommends the use of PS-4 Synthetic Engine Oil for this vehicle. NOTICE Mixing brands or using a non-recommended oil may cause serious engine damage.
  • Page 68 MAINTENANCE OIL CHANGE 1. Position the vehicle on a level surface. Set the parking brake. 2. Clean the area around the pre-filter plug. 3. Start the engine. Allow it to idle for two to three minutes. 4. Stop the engine. CAUTION Hot oil can cause burns to skin.
  • Page 69 Follow Fluid Change Procedure to verify transmission is filled with fluid Always check and change the fluid at the intervals outlined in the Periodic Maintenance Interval Chart. Polaris recommends the use of AGL Gearcase Lubricant and Transmission Fluid for this vehicle.
  • Page 70 Do not overfill. Always change the fluid at the intervals outlined in the Periodic Maintenance Interval Chart. Polaris recommends the use of AGL Gearcase Lubricant and Transmission Fluid for this vehicle. The fill plug is located on the side of the transmission gearcase.
  • Page 71 6. Add the recommended amount of lubricant through the fill plug hole . Do NOT overfill or fill to the bottom of the fill plug hole. FLUID CAPACITY Recommended Transmission Lubricant: Polaris AGL Capacity: 25 oz. (750 ml) 7. Reinstall the fill plug and torque to specification. TORQUE...
  • Page 72 MAINTENANCE DRIVE CHAIN LUBRICATION AND ADJUSTMENT 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.
  • Page 73 MAINTENANCE PARKING BRAKE 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 74 MAINTENANCE PARKING BRAKE ADJUSTMENT 1. Inspect and perform any needed service on the brake pads before adjusting the parking brake. 2. Position the vehicle on a level surface. Place the transmission in neutral. 3. Carefully elevate the rear of the vehicle slightly. Use an appropriate lift. 4.
  • Page 75 Immediately check the spark plug for correct color. • Using non-recommended spark plugs can result in serious engine damage. Use POLARIS-recommended spark plugs or their equivalent. See the Specifications section for details. WARNING A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
  • Page 76 MAINTENANCE 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 77 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 78 POLARIS dealer, or other qualified person, for service and repair assistance. • This CVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the CVT housing is securely in place during operation.
  • Page 79 MAINTENANCE AIR FILTER 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 2.
  • Page 80 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.
  • Page 81 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 Polaris Products chapter for part numbers. WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
  • Page 82 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.
  • Page 83 Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer or other qualified service facility. 1. Place machine on a smooth level surface and set steering wheel in a straight ahead position.
  • Page 84 MAINTENANCE 4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line. 5. Again measure the distance between the marks and record. Call this measurement “3”. Subtract measurement “3” from measurement “2”. The difference between measurements “2”...
  • Page 85 3 mm (1/8”) or less. FRONT WHEEL HUB TIGHTENING Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer or other qualified service facility. Downloaded from ManualsNet.com...
  • Page 86 MAINTENANCE FRONT WHEEL REPLACEMENT 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. Set the parking brake. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame.
  • Page 87 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. Downloaded from ManualsNet.com search engine...
  • Page 88 MAINTENANCE TAIL LIGHT LAMP REPLACEMENT If the brakelight doesn't work, the light assembly may need to be replaced. 1. Disconnect the tail light from the harness. 2. Remove attachment nuts holding light assembly. 3. Install new light assembly and secure with attachment nuts. 4.
  • Page 89 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.
  • Page 90 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.
  • Page 91 MAINTENANCE BATTERY REMOVAL 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. 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).
  • Page 92 Check battery voltage each month during storage and recharge as needed to maintain a full charge. 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 FLUID (CONVENTIONAL BATTERY) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper lower level marks. Add only distilled water. Tap water contains minerals that are harmful to a battery.
  • Page 94 MAINTENANCE STATE OF VOLTAGE ACTION CHARGE TIME* CHARGE *(USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY) 100% 12.8-13.0 volts None, check at 3 None required mos. from date of manufacture 75%-100% 12.5-12.8 volts May need slight 3-6 hours charge, if no charge given,...
  • Page 95 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.
  • Page 96 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.
  • Page 97 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. STORAGE AREA / COVERS Be sure the storage area is well ventilated.
  • Page 98 MAINTENANCE 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.
  • Page 99 MAINTENANCE TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle. 1. Place the transmission in neutral. Set the parking brake. 2. Stop the engine. 3. Remove the key to prevent loss during transporting. 4. Secure the fuel cap and seat. Ensure that the seat is attached correctly and is not loose.
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  • Page 101: Specifications

    SPECIFICATIONS SPECIFICATIONS ACE 150 EFI Maximum Rider Weight 81 kg (180 lbs.) Maximum Weight Capacity 104 kg (230 lbs.) Gross Vehicle Weight 364 kg (802 lbs.) Dry Weight 252 kg (556 lbs.) Fuel Capacity 9.5 ltr (2.5 gal.) Engine Oil Capacity 1050 ml (35.5 oz.) Transmission Oil Capacity 750 ml (25 oz.)
  • Page 102 SPECIFICATIONS ACE 150 EFI Rear Suspension Dual Shock swing-arm w/15.2 cm (6 in.) travel Lubrication System Wet Sump Driving System Type Automatic Constant Variable Transmission Final Drive Chain Shift Type F/N/R Tire Size - Front 22x7-10 Tire Size - Rear 22x10-10 Tire Pressure - Front 20.7 kPa (3 psi)

  • Page 103: Polaris Products

    POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PART NUMBER DESCRIPTION Engine Lubricant Fogging Oil (12 oz. Aerosol) 2870791 Gearcase / Transmission Lubricants AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l)
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  • Page 105: Troubleshooting

    Inspect clutch seals for damage if repeated leaking system 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.
  • 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...
  • Page 107 POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plugs Worn or defective spark plug Your POLARIS dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plugs heat range Loose ignition connections...
  • Page 108 Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plugs Worn or defective spark plug Your POLARIS dealer can assist wires Incorrect spark plug gap or Set gap to specs or replace plug heat range...

  • Page 109: Warranty

    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.
  • Page 110 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 111 TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW. 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;...
  • Page 112 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 113: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS Downloaded from ManualsNet.com search engine...
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  • Page 115 Adjustment......70 Lubrication ......70 Age Restrictions ......15 Driver’s Seat Adjustment..... 29 Air Filter........77 Driving Downhill ......50 Air Filter / Air Box....... 94 Driving Downhill Improperly ..19 Driving in Reverse ..... 53 Driving on a Sidehill (Sidehilling) ... 50 Driving on Slippery Surfaces ..
  • Page 116 Passengers ......16 Periodic Maintenance Chart ..57 Physical Control of the Vehicle ..18 Letter to Parents......7 Polaris Products ...... 101 Letter to Young Operators ..... 8 Polishing the Vehicle ....94 Limited Warranty ..... 107 Pre-Ride Inspection ....43 Lubricants / Service Products ..
  • Page 117 Safe Operation Practices .... 45 Valve Adjustment Procedure ..75 Safe Riding Gear ....... 13 Vehicle Break-in Period....41 Vehicle Identification Numbers ..12 Safety Labels and Locations ..24 Vehicle Immersion ..... 87 Safety Symbols ......9 Safety Warnings ......15 Seat Belt Inspection ....
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  • Page 119 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Sales Europe Sarl Place de l’Industrie 2 1180 Rolle, Switzerland Printed in China Part No. 9929351 Rev 02...

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