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Polaris ACE 570 Owner's Manual

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2017
ACE™ 570
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris ACE 570

  • Page 1 2017 ACE™ 570 Owner's Manual for Maintenance and Safety...
  • Page 2 For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 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 4 POLARIS® and ACE™ are trademarks of POLARIS Industries Inc. Copyright 2016 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    Specifications ......132 POLARIS Products..... 134 Troubleshooting .

  • Page 6: Introduction

    INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. 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.
  • Page 7 Failure to heed 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 8 INTRODUCTION European Vibration and Noise 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: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
  • Page 9 Business Center A5 1180 Rolle, Switzerland Telephone +41213-218-700 DECLARATION OF CONFORMITY January 1, 2016 Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements applicable to all terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES: TEST / EVALUATION METHODS...
  • Page 10 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 11: Safety

    SAFETY Safety Training Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.
  • Page 12 Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S.
  • Page 13 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 14 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. 680 kg...
  • Page 15 SAFETY Safety Labels and Locations Passenger/Tire Pressure Alert 7181427 Clutch Cover Alert < 55 kg 7182092 Storage Capacity Alert (on access cover under rack) Passenger/Tire Pressure Alert (7182090) Read Operation and Maintenance Manual for more detailed loading information. Do not carry a passenger in the cargo box. Maximum Cargo Box Load: 110 kg Tire Pressure: 45 kPa Maximum Weight Capacity...
  • Page 16 SAFETY Safety Warnings WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.
  • Page 17 SAFETY Safety Warnings Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances. The operator MUST wear the seat belt at all times.
  • Page 18 SAFETY Safety Warnings Carrying a Passenger This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components.
  • Page 19 SAFETY Safety Warnings Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.
  • Page 20 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers.
  • Page 21 SAFETY Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual.
  • Page 22 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 67. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.
  • Page 23 SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle. Always follow proper procedures for operating in water as described in this owner’s manual.
  • Page 24 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying/towing cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See page 68.
  • Page 25 Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 26: Features And Controls

    FEATURES AND CONTROLS Component Locations ROPS Frame Single-Rider Seat Steering Wheel Cargo Bars Front Box Taillights Cover Headlights Engine Intake Pre-Filter Cab Nets Brush Guard Radiator Brake Pedal Throttle Shifter Fuel Cap Pedal Park Brake...
  • Page 27 FEATURES AND CONTROLS Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 68-70.
  • Page 28 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. WARNING! Always unlock the steering before starting the engine. NOTICE: Always remove the steering lock key before operating the vehicle. Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost.
  • Page 29 FEATURES AND CONTROLS Mirrors Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle. Front Box Cover Cover Fasteners Remove the front box cover and access panel to access the radiator cap, coolant overflow bottle and brake master cylinder reservoir.
  • Page 30 Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer. Extreme Use Battery An optional extreme use battery may be available for your model.
  • Page 31 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right side of the vehicle near the seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with ethanol content greater than 10 percent, such as E- 85 fuel.
  • Page 32 FEATURES AND CONTROLS Seat Belt This POLARIS vehicle is equipped with three-point lap and diagonal seat belts. Always secure the seat belt before riding. To wear the seat belt properly, follow this procedure: 1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat.
  • Page 33 FEATURES AND CONTROLS Switches Turn Signal Lever Before turning, activate a turn Turn Signal/Flasher signal to alert others of your Indicators intentions. Check turn signal Horn lamps before each ride. Switch Tip: The key must be in the ON position to activate the turn signals.
  • Page 34 FEATURES AND CONTROLS Switches Instrument Cluster Hazard Switch AWD Switch 12V Accessory Outlet HEADLIGHTS POSITION Ignition Switch/Light LIGHTS ON Switch START Ignition Switch/Light Switch Use the ignition switch to start the engine and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position.
  • Page 35 FEATURES AND CONTROLS Switches All Wheel Drive (AWD) Switch (if equipped) The AWD switch has three positions: • All Wheel Drive (AWD) • Differential Lock/Two Wheel Drive (2WD) • Off (1WD/Turf Mode) Press the top of the rocker switch to engage All Wheel Drive.
  • Page 36 FEATURES AND CONTROLS Gear Selector 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. P: Park R: Reverse N: Neutral...
  • Page 37 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 38 FEATURES AND CONTROLS Park Brake Lever Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, engine speed is limited.
  • Page 39 (ROPS) on this vehicle meets (on ROPS behind rear cab) OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover.
  • Page 40 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage Speedometer Indicator components. Wash the vehicle by Lamps hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens.
  • Page 41 FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected, speed displays in Vehicle miles per hour. Speed When metric mode is selected, speed displays in kilometers per hour. Over This lamp illuminates to indicate an overheated Temperature engine.
  • Page 42 If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory.
  • Page 43 6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your POLARIS dealer for scheduled maintenance. See page 43 for resetting instructions. 7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is on 4X4).
  • Page 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) MODE Button The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit the set-up mode, turn the key off.
  • Page 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 46 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
  • Page 47 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See pages 46-51 for code definitions and failure descriptions. Please see your POLARIS dealer for all major repairs.
  • Page 48 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • Page 49 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Accelerator Data Erratic, Intermittent Or Incorrect Position 2 Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Throttle Position Data Valid But Above Normal Operational Range - Most Sensor 1 Severe Level Data Valid But Below Normal Operational Range - Most...
  • Page 50 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Intake Air Data Erratic, Intermittent Or Incorrect Temperature Sensor Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Data Valid But Above Normal Operating Range - Least Severe Level Engine Temperature...
  • Page 51 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Fan Relay Driver Voltage Above Normal, Or Shorted To High Source 1071 Circuit Voltage Below Normal, Or Shorted To Low Source 1071 Current Below Normal Or Open Circuit 1071 Ignition Coil Primary Voltage Above Normal, Or Shorted To High Source...
  • Page 52 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Throttle Position Sensor 2 Data Valid But Above Normal Operational Range - 520198 Most Severe Level Data Valid But Below Normal Operational Range - 520198 Most Severe Level Data Erratic, Intermittent Or Incorrect 520198 Voltage Above Normal, Or Shorted To High Source...
  • Page 53 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Throttle Body Control - Position Deviation Condition Exists 520284 Fault ECU Monitoring Error Condition Exists 520286 ECU Monitoring Error (Level 3) Condition Exists 520287 ECU Monitoring of Injection Cut Off Condition Exists 520288 (Level 1)

  • Page 54: Operation

    Vehicle Break-in Period The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break- in period.
  • Page 55 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 29. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 92. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 56 Indicator lights/switches Ensure proper operation Air filter, pre-filter Inspect, clean 108-109 Intake pre-filters Inspect, clean Headlamps Check operation, apply POLARIS dielectric grease when lamp is replaced Turn Signals Ensure operation of all signal lamps Mirrors Adjust for best side/rear vision Horn...
  • Page 57 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 58 OPERATION Starting the Engine WARNING! Always unlock the steering before starting the engine. 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3.
  • Page 59 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off. 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 60 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Take a training course. 3. Perform the pre-ride inspection. See page 54. 4. Do not tow or carry cargo during this period. 5.
  • Page 61 OPERATION New Operator Driving Procedures 11. Apply the brakes and shift into low gear. 12. Check your surroundings and determine your path of travel. 13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 14.
  • Page 62 OPERATION Turning the Vehicle Your vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.
  • Page 63 OPERATION Driving on Slippery Surfaces Turn in Sideways direction of skid skid When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1.
  • Page 64 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending any hill. Never drive on hills with excessively slippery or loose surfaces. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain.
  • Page 65 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1.
  • Page 66 OPERATION Driving Downhill Whenever descending a hill, follow these precautions: 1. Avoid excessively steep hills. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3.
  • Page 67 If your vehicle becomes immersed or is operated in water that exceeds the floor level, take it to your POLARIS dealer for service before starting the engine. If it's impossible to bring the vehicle to...
  • Page 68 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.
  • Page 69 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.
  • Page 70 OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
  • Page 71 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo.
  • Page 72 OPERATION Towing Loads WARNING Towing is approved OFF-ROAD ONLY. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road. Towing improperly can alter vehicle handling and may cause loss of control or brake instability.
  • Page 73 OPERATION All Wheel Drive (AWD) System Engaging AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). Once enabled, the AWD remains enabled until the switch is turned off. The AWD switch may be turned on or off while the vehicle is moving. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction.
  • Page 74 OPERATION All Wheel Drive (AWD) System Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction. In some situations, the front gearcase may remain locked after turning the AWD switch off.

  • Page 75: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 76 WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed. 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible.
  • Page 77 WINCH GUIDE Winch Safety Precautions 18. Never release the clutch on the winch when the winch cable is under load. 19. Never use the winch for lifting or transporting people. 20. Never use the winch to hoist or suspend a vertical load. 21.
  • Page 78 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 79 WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
  • Page 80 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times.
  • Page 81 WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 82.
  • Page 82 WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
  • Page 83 WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
  • Page 84 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
  • Page 85 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

  • Page 86: Emission Control Systems

    Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on- road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.

  • Page 87: Maintenance

    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 or see your POLARIS dealer.
  • Page 88 Description Perform these operations more often for vehicles subjected to severe use. Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
  • Page 89 Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks Engine mounts 100 H 12 M 1000 (1600) Inspect Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services.
  • Page 90 5000 (8000) Inspect; adjust as needed D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services.
  • Page 91 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 85, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method...
  • Page 92 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Rear Control Arm Pivot Bushings Tie Rod Front A-Arm Bushing Bushing Ball Joint Boot...
  • Page 93 Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. See page 134 for the part numbers of POLARIS products.
  • Page 94 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Always use the recommended engine oil. See page 91. Oil Check The oil dipstick and fill tube is located on the engine, behind the passenger seat.
  • Page 95 MAINTENANCE Engine Oil Oil and Filter Change Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase.
  • Page 96 MAINTENANCE Engine Oil Oil and Filter Change 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed.
  • Page 97 MAINTENANCE Gearcases Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Refer to the Gearcase Specifications Chart on page 98 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the...
  • Page 98 MAINTENANCE Gearcases Demand Drive Unit (Front Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4.
  • Page 99 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Refer to the Gearcase Specifications Chart on page 98 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase.
  • Page 100 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 134 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Drain Plug/ Torque Level Check Plug Torque Transmission AGL Gearcase 44 oz.
  • Page 101 MAINTENANCE Spark Plug Spark Plug Removal and Replacement 1. Remove the cargo box access panel. 2. Remove the spark plug cap. 3. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise. 4. Reverse the procedure for spark plug installation. Torque to specification.
  • Page 102 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Main Fuse Feature Supported Lights: Headlights, Taillights Drive: AWD...
  • Page 103 MAINTENANCE Fuses 1. Remove the seat to access Release Tabs the fuse box. 2. Squeeze the cover release tabs inward and remove the fuse box cover. 3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating.
  • Page 104 POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 134 for the part numbers of POLARIS products. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
  • Page 105 4. Use a funnel and slowly add coolant as needed. Tip: Use of a non-standard Overflow Bottle pressure cap will not allow the recovery system to function properly. See your POLARIS dealer for the correct replacement part.
  • Page 106 Reinstall the cap. Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer.
  • Page 107 • See your POLARIS dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.
  • Page 108 3. Remove all debris from the entire clutch air duct passage. 4. Check for signs of damage to seals on the transmission and engine. See your POLARIS dealer promptly for service if any seals appear to be damaged. Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.
  • Page 109 Apply the brakes. Shift the transmission to the lowest available range. 5. Test for belt slippage. If the belt slips, repeat the process. 6. Take the vehicle to your POLARIS dealer for service as soon as possible.
  • Page 110 MAINTENANCE Air Filter Always clean all dirt and debris away from the air box area before servicing the air filter. Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. 1. Remove the cargo box access panel. Cover Clips (2) 2.
  • Page 111 MAINTENANCE Breather Hose Inspection 1. Remove the breather hose clamp at the engine (near the exhaust outlet). 2. Pull the other end of the breather hose assembly away from the airbox. 3. Remove the breather hose assembly from the vehicle. 4.
  • Page 112 MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.
  • Page 113 See page 112 for brake fluid information. If you discover any irregularities in brake system operation, including excessive pedal travel, contact your POLARIS dealer for proper diagnosis and repairs. WARNING! Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death.
  • Page 114 Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 134 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.
  • Page 115 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage.
  • Page 116 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. Rear Spring The rear shock absorber spring is adjusted...
  • Page 117 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 118 Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 3. Attach the wheel nuts and washers and finger-tighten.
  • Page 119 MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
  • Page 120 MAINTENANCE Lights Front Turn Signal Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not Position Light touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
  • Page 121 MAINTENANCE Lights Headlight Beam Adjustment 25 ft. (7.6 m) 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 122 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the vehicle to your POLARIS dealer for service as soon as possible, whether you succeed in starting it or not. 8. If water has been ingested into the PVT follow the procedure on...
  • Page 123 MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 124 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. Battery Removal 1.
  • Page 125 POLARIS dealer. Ask your dealer to provide any installation procedures that may differ for an extreme use battery.
  • Page 126 See page 125. 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 127 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 122. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 128 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required mos.
  • Page 129 Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
  • Page 130 • Labels and decals • Electrical components and wiring • Air intake components If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. 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 131 127. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 132 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug cap to the spark plug.
  • Page 133 Secure or remove all cargo, and inspect the unit for loose parts prior to transport. 4. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to...

  • Page 134: Specifications

    SPECIFICATIONS ACE 570 Gross Vehicle Weight 660 kg Dry Weight 392.4 kg (+/- 5%) Test GVW - Rollover Protection 682.7 kg per OSHA 29 CFR 1928.53 System (ROPS) Front Rack/Box Capacity 55 kg Rear Rack/Box Capacity 110 kg Maximum Weight Capacity...
  • Page 135 SPECIFICATIONS ACE 570 Lubrication System Wet Sump Engine Oil PS-4 5W-50 Driving System Type Automatic POLARIS Variable Transmission Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 28.84:1 Gear Reduction - Reverse 25.83:1 Gear Reduction - High 9.65:1 Drive Ratio - Front 2.989:1...

  • Page 136: Polaris Products

    U-Joint Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger...

  • Page 137: Troubleshooting

    See your POLARIS dealer. Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines. See your POLARIS dealer. Slippage from failure to Always warm up the belt by operating below 30 mph for warm up belt one mile (5 miles or more when temperature is below freezing).
  • Page 138 Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your POLARIS dealer...
  • Page 139 Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Engine Runs Irregularly, Stalls or Misfires Possible Cause...
  • Page 140 Recharge the battery to 12.8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your POLARIS dealer Overheated engine Clean radiator screen and core, clean engine exterior, see your POLARIS dealer...

  • Page 141: 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 142 Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
  • Page 143 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 144 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 145 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 con- sult an authorized dealer to determine this product's warranty or service coverage if you have any questions.

  • Page 146: Maintenance Log

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

  • Page 147: Index

    INDEX Access Panels 25 Cab Frame, ROPS 37 Accessory Outlet 33 Cab Nets 28 Adjustment Cap, Fuel 29 Seat 29 Cargo 68, 69 Steering Wheel 26 Chart, Periodic Maintenance 85, 86, 87, Age Restrictions 14 Air Filter 108 Check Engine Indicator 45 Air Filter Cleaning 108 Cleaning and Storage 127, 128, 129, All Wheel Drive 71, 72...
  • Page 148 INDEX Electromagnetic Interference 84 Gasoline Handling 22 Emission Control, Exhaust 84 Gear Selector 34 Emission Control, Noise 84 Gear Shifter 34 Engaging AWD 71 Gearcase Capacities 98 Engine Break-In 53 Gearcases 95, 96, 97, 98 Engine Fogging 130 Demand Drive Unit 95, 96 Front Gearcase 95, 96 Engine Intake Pre-Filter 109 Main Gearcase 97...
  • Page 149 INDEX Maintenance Log 144 Park Brake Lever 36 Maintenance, Periodic 85, 86, 87, 88 Parking on an Incline 67 Metric Display 42 Parking the Vehicle 57 Mirrors 27 Periodic Maintenance Chart 85, 86, 87, Mode Button 38 Muffler Cleaning 110 Plug, Accessory 33 Polishing the Vehicle 128 Position Light Lamp 118...
  • Page 150 INDEX Safe Operation Practices 55 Tachometer 43 Safety Labels 12, 13 Taillight Lamp Replacement 117 Safety Symbols 4 Throttle Pedal 35 Safety Training 9 Tire Tread Depth 115 Safety Warnings 14, 15, 16, 17, 18, 19, Tires 115, 116 20, 21, 22, 23 Towing Loads 70 Safety, Winch Maintenance 83 Towing Speed 70...
  • Page 152 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Route de l’Etraz Business Center A5 1180 Rolle, Switzerland Part No. 9927489 Rev 01...

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