Polaris SPORTSMAN ACE 2014 Owner's Manual
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Polaris SPORTSMAN ACE 2014 Owner's Manual

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Failure to heed the warnings and safety precautions
contained in this manual can result in severe injury or death.
Read this manual carefully.
SPORTSMAN ACE
™
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris SPORTSMAN ACE 2014

  • Page 1 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Read this manual carefully. SPORTSMAN ACE ™ Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 • On public roads (unless designated for off-road use). • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death.
  • 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 POLARIS® and SPORTSMAN ACE™ are trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales 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 7: Table Of Contents

    Specifications ......128 POLARIS Products..... 130 Troubleshooting .

  • Page 8: 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 9 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 10: Vehicle Identification Numbers

    Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys.

  • 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. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-267-2751.

  • Page 12: Safe Riding Gear

    Helmet 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. Department of Transportation (DOT) label.
  • 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. General Warning...

  • Page 15: General Warning

    SAFETY Safety Labels and Locations General Warning WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license. •...
  • Page 16 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING Load/Passenger/Tire • Never carry passengers in cargo box. Pressure Warning • Passengers can be thrown off. This can cause serious injury or death. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

  • Page 17: Hitch Capacity Label

    Always look for and remove debris inside and around clutch and vent system when replacing belt. Read owner's manual or see authorized Polaris dealer. PVT System Warning 7177469 Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS.

  • Page 18: Safety Warnings

    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 19: Protective Apparel

    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 perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.

  • Page 20: Carrying A Passenger

    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 21: Improper Tire Maintenance

    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 22: Turning Improperly

    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 23: Crossing Hillsides

    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 24: Skidding Or Sliding

    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 63. Before shifting into reverse gear, always check for obstacles or people behind the vehicle.

  • Page 25: Operating A Damaged Vehicle

    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 26: Improper Cargo Loading

    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 64.

  • Page 27: Exposure To Exhaust

    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 28: 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 Fuel Cap Shifter Brake Pedal Throttle Pedal...
  • Page 29 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 64-66.

  • Page 30: Steering Wheel

    FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. Always make sure the steering wheel position does not impede proper operation of Adjustment...
  • Page 31 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.

  • Page 32: Fuel Cap

    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 33: Seat Belt Inspection

    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 34 FEATURES AND CONTROLS Switches Instrument Cluster AWD Switch 12V Accessory Outlet Ignition Switch/Light Switch...

  • Page 35: Auxiliary Outlet

    FEATURES AND CONTROLS Switches Ignition Switch/Light Switch Use the ignition switch to start the engine START and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position. Turn the key to the OFF position to stop the engine.

  • Page 36: Gear Selector

    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 Gear Selector...

  • Page 37: Brake Pedal

    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 ROPS Label (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 39: Engaging Awd

    FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2WD (2X4), the vehicle is in two-wheel drive at all times. When the switch is on AWD (4x4), the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.

  • Page 40: Instrument Cluster

    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: Indicator Lamps

    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: Rider Information Center

    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 41 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: Clock Mode

    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: Engine Error Codes

    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 44-45 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: Diagnostic Codes

    FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition Throttle Position Sensor Voltage Too High Voltage Too Low Engine Temperature Sensor Voltage Too High Voltage Too Low Temperature Too High Engine Overheat Shutdown Intake Air Temperature Sensor Voltage Too High Voltage Too Low Manifold Absolute Pressure Sensor...

  • Page 50: 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 51: Brake System Break-In

    OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 87. Add the recommended oil as needed to maintain the oil level in the safe operating range. 3.
  • Page 52 Indicator lights/switches Ensure proper operation Air filter, pre-filter Inspect, clean 102- Intake pre-filters Inspect, clean Headlamps Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamps Check operation, apply POLARIS dielectric grease when lamp is replaced Seat Latch...

  • Page 53: Trail Etiquette

    Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.

  • Page 54: Safe Operation Practices

    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. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).
  • Page 55 OPERATION Safe Operation Practices 10. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure. 11. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

  • Page 56: Starting The Engine

    OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in PARK. 4.

  • Page 57: Stopping The Engine

    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 58 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751.
  • Page 59 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 60: Turning The Vehicle

    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 61: Driving On Slippery Surfaces

    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 62: Driving Uphill

    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 63 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1.

  • Page 64: Driving Downhill

    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 65: Driving Through Water

    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 66: Driving Over Obstacles

    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 67: Driving In Reverse

    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 68: Hauling Cargo

    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 69: Belt Life

    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 70: Towing Loads

    OPERATION Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2.

  • Page 71: 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 72: Winch Safety Precautions

    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 73 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 74: Winch Operation

    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 75 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 76 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 77 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 76.
  • Page 78 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 79: Winch Cable Care

    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 80 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 81: Winch Maintenance And Service Safety

    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 82: Emission Control Systems

    CFR 205) and local noise level requirements. 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 83: 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 84: Periodic Maintenance Chart

    Emission-related service (failure to conduct this maintenance will not void the emissions warranty but may affect emissions) 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...
  • Page 85 Demand drive fluid 25 H Break-in oil level check Transmission oil 25 H Break-in oil level check (main gearcase) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 86 Demand drive fluid 100 H 12 M Change fluid Transmission oil 100 H 12 M Change fluid (main gearcase) Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 87 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. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

  • Page 88: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 79, 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 89 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Rear Control Arm Pivot Bushings Tie Rod Front A-Arm Bushing Bushing Ball Joint Boot...

  • Page 90: Engine Oil

    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 130 for the part numbers of POLARIS products.

  • Page 91: Oil Check

    MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Always use the recommended engine oil. NOTICE: Allowing dirt or debris to enter the engine can result in serious engine damage.

  • Page 92: Oil And Filter Change

    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 79. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase.
  • Page 93 MAINTENANCE Engine Oil Oil and Filter Change 8. Using a clean dry cloth, clean the oil filter cover on the crankcase. 9. Place shop towels beneath the filter cover to catch oil drips. Remove the cover screws and remove the cover to access the oil filter. 10.

  • Page 94: Specifications

    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 79. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the...
  • Page 95 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase.

  • Page 96: Polaris Products

    MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 130 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 97: Spark Plug

    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 98 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 99: Fuse Box

    MAINTENANCE Fuses Fuse Box 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 100: Cooling System

    POLARIS recommends the use of POLARIS Antifreeze 60/40 premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. POLARIS Antifreeze is already premixed and ready to use.

  • Page 101: Radiator And Cooling Fan

    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 102: Coolant Level

    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 103 • 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 104 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 105: Pvt Drying

    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 106: Air Filter

    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 79. 1. Remove the cargo box access panel. Cover Clips (2) 2.

  • Page 107: Breather Hoses

    MAINTENANCE Breather Hoses The breather hoses run between the engine and breather box, and between the breather box and air box. 1. Remove the hose clamps from the engine valve cover and breather box. Remove the hose. 2. Remove the hose clamps from the air Breather box and breather box.

  • Page 108: Spark Arrester

    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 109: Throttle System

    Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your POLARIS dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation.

  • Page 110: Throttle Freeplay Adjustment

    Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat. Remove the engine access panel. See page 28.
  • Page 111 See page 108 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 112: 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 page 130 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 113: Brake Inspection

    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 114: Steering Wheel Inspection

    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 autho- rized POLARIS dealer. Rear Spring The rear shock absorber spring is adjusted...

  • Page 115: Tire Tread Depth

    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 116: Wheel Removal

    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 117: Headlight Lamp Replacement

    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 vis- ibility 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 118: Headlight Beam Adjustment

    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 119: Vehicle Immersion

    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 120 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 121: Battery Removal

    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 122: Battery Installation

    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 120 before installing the battery. 1.

  • Page 123: Battery Storage

    See page 120. 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 124 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 117. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
  • Page 125 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 126: Cleaning And Storage

    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 127: Washing The Vehicle

    • 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 128 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

  • Page 129: Storage Tips

    122. 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 130 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 131: Removal From Storage

    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 132: Specifications

    SPECIFICATIONS SPORTSMAN ACE Gross Vehicle Weight 1455 lbs. (660 kg) Dry Weight 835 lbs. (379 kg) Test GVW - Rollover Protection 1505 lbs. (682.7 kg) per OSHA 29 CFR 1928.53 System (ROPS) Front Rack/Box Capacity 120 lbs. (54 kg) Rear Rack/Box Capacity 240 lbs.
  • Page 133 SPECIFICATIONS SPORTSMAN ACE 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 134: Polaris Products

    Pump for Gallon (3.8 l) Jug 2877922 Demand Drive Fluid (qt./.95 l) 2877923 Demand Drive Fluid (gal./3.8 l) Coolant 2871534 POLARIS Antifreeze 60/40 Premix (qt./.95 l) 2871323 POLARIS Antifreeze 60/40 Premix (gal./3.8 l) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season 2871322 All Season Grease (3 oz./89 ml cartridge)

  • Page 135: 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 136 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 137 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 138 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 139: 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 140 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 141 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 142 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 143 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase...
  • Page 144 *As related to the evaporative emission control system. 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 145 POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • 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....34 Accessory Outlet.

  • Page 148: Gearcase Oil

    INDEX Electromagnetic Interference..78 Fluid Levels During Storage ..125 Emission Control, Crankcase..78 Fluid Recommendations, Gearcase . . 92 Emission Control, Exhaust ..78 Fluid, Battery .
  • Page 149 Nets, Cab..... . 27 Polaris Products ....130 New Operator Procedures .
  • Page 150 INDEX PVT Break-In....47 Spark Arrester, Cleaning ..104 PVT Drying ....101 Spark Plug .
  • Page 151 INDEX Torque, Axle Nuts....111 Warning Symbols ....4 Torque, Spark Plug ....92 Washing the Vehicle.

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