Polaris 2015 ATV Sportsman ACE 570- Manuals

5 INTRODUCTION 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. A collision or rollover ...

6 INTRODUCTION 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 o...

7 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...

8 SAFETY Safe Riding Gear Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always w...

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing mark...

10 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructi...

12 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Never carry passengers in cargo box.• 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 DEAT...

13 SAFETY Safety Labels and Locations PVT System Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH.Always look for and remove debris inside and around clutch and vent system when replacing belt.Read owner's manual or see authorize...

14 SAFETY Safety Warnings 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. ...

15 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 co...

16 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 vehicl...

17 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 ow...

18 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...

19 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 t...

20 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 65.Before shifting into reverse gear, always check for obstacles or people ...

21 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 ...

22 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 66. • Never...

23 SAFETY Safety Warnings Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system ...

24 FEATURES AND CONTROLS Component Locations Hip Bars Cargo Box Shifter Cab Nets Steering Wheel Throttle Pedal Brake Pedal ROPS Frame Front Box Cover Headlights Taillights Engine Intake Pre-Filter Radiator Single-Rider Seat Brush Guard Fuel Cap

25 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 66-68....

26 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 su...

27 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used at all times. Make sure all latches on both sides of the vehicle are sec...

28 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...

29 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 inne...

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

31 FEATURES AND CONTROLS Switches 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. All Wheel Drive (AWD) Switch (if equipped) The AWD Switch has two positions: • All Wheel...

32 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: ParkR: ReverseN: NeutralL: Low Gear H: High Gear NOTICE: Do not atte...

33 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. Always check that the throttle peda...

34 FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets 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 ass...

35 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 instrumen...

36 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components. Wash the vehicle by 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. Speedometer The speedometer displays vehicle spee...

37 FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition VehicleSpeed When standard mode is selected, speed displays in miles per hour.When metric mode is selected, speed displays in kilometers per hour. Over Temperature This lamp illuminates to indicate an overheated eng...

38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cl...

39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately. Tip: If the...

40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit ...

42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a c...

43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but wil...

44 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 a...

49 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in peri...

50 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 88 (325) or page 91 (570). Add the recommended oil as needed to maintain the oil level in...

51 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel Ens...

52 OPERATION Safe Operation Practices 1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751. 2. Do not allow anyone under 16 years ...

53 OPERATION Safe Operation Practices 12. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. 13. Do not touch ...

54 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. Apply the brakes. Do not press the throttle pedal while starting the en...

55 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, th...

56 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 866-2...

57 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. Drive ...

58 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...

59 OPERATION Driving on Slippery Surfaces 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. Do not operate on excessively rough, slippery or loose terrai...

60 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...

61 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. Engage all-wheel dr...

62 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. Slow dow...

63 OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the water level is lowest and...

64 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. Travel slowly and us...

65 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. Avoid making sharp turns. Parkin...

66 OPERATION Hauling Cargo 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 GR...

67 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 s...

68 OPERATION Towing Loads 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. When towing a disabled vehicle, place the disable...

69 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. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may...

72 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. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all wi...

73 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip: A “tow strap” is NOT in...

74 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 t...

75 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 Loadi...

76 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. 15. After winching is complete, especially if winc...

77 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. 1. Always inspect your w...

78 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 D...

79 WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable....

80 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle...

81 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace par...

82 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key 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. Perform all services at whichever maintenan...

85 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubricati...

87 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-50 4-cycle oil for this engine. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, an...

88 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87. NOTICE: Allowing dirt or debris to enter the engine can result in serious engine damage. Always clean away a...

89 MAINTENANCE Engine Oil Oil and Filter Change (325) Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the...

93 MAINTENANCE Engine Oil Oil and Filter Change (570) 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed. 10. Lubricate the o-ring...

94 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 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications. Flui...

96 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. Spark Plug Spark Plug Gap/Torque NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use ...

97 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 ...

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. The fuse box is located under the seat. Spare fuses are provided ...

99 MAINTENANCE Fuses Fuse Box 1. Remove the seat to access 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. 4. Reinstall the fuse box cover. 5....

100 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (he...

101 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of th...

102 MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The coolant level in the bottle ...

103 MAINTENANCE POLARIS Variable Transmission (PVT) System Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been...

104 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt c...

105 MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. NOTICE: When washing the vehicle, always avoid spraying water directly toward the PV...

106 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 81. 1. Remove the cargo box access panel. 2. Clean all dirt and debris fr...

107 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. Inspect the hoses for debris. Blow gently through th...

108 MAINTENANCE Spark Arrester 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 ...

109 MAINTENANCE Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.Never start or operate this vehicle if it has a sticking or improperly operating throttle p...

110 MAINTENANCE Throttle System Throttle Pedal Freeplay Adjustment NOTICE: Engine idle speed is established at the factory and is not adjustable. Never attempt to adjust engine idle speed by adjusting throttle pedal freeplay. At operating temperature, idle speed should be 1250 +/- 50 RPM. If engine ...

111 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 33. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate...

112 MAINTENANCE Brakes 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 134 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store o...

113 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. Clean ...

114 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should...

115 MAINTENANCE Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8” (3 mm) or less.Improper tire inflation or the use of non-sta...

116 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the whee...

117 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 residu...

118 MAINTENANCE Lights Headlight Beam Adjustment 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. ...

119 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the LIGHTS ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel. If the ligh...

120 MAINTENANCE Battery 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...

121 MAINTENANCE Battery 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. Ba...

122 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 124 before installing the battery. An optional extreme use ba...

123 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...

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 121. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...

125 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos....

126 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: Water in the PVT system could cause the drive belt to become wet and slip in the clutches. Always avoid spra...

127 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items: • Wheel bearings• Rad...

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...

129 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as...

130 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 81. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the c...

131 MAINTENANCE Cleaning and Storage Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight...

132 SPECIFICATIONS SPORTSMAN ACE / SPORTSMAN ACE 570 Gross Vehicle Weight 1455 lbs. (660 kg) Dry Weight 835 lbs. (378.7 kg) (325)865 lbs. (392.4 kg) (+/- 5%) (570) Test GVW - Rollover Protection System (ROPS) 1505 lbs. (682.7 kg) per OSHA 29 CFR 1928.53 Front Rack/Box Capacity 120 lbs. (54 kg) Rear ...

133 SPECIFICATIONS Clutching (325) Please see your dealer for clutching specifications. Clutching (570) SPORTSMAN ACE / SPORTSMAN 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 - L...

134 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubric...

135 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 60. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...

136 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose ...

137 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause 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 Possi...

138 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Se...

139 WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the e...

140 WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items,...

141 WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YO...

142 WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to govern...

145 WARRANTY U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which PO...

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

147 INDEX A Access Panels . . . . . . . . . . . . . . . . . . 25Accessory Outlet . . . . . . . . . . . . . . . . 31Adding Coolant . . . . . . . . . . . . . . . . 100 Adjustment Seat . . . . . . . . . . . . . . . . . . . . . . . . 28Steering Wheel . . . . . . . . . . . . . . . 26 Adjustment, Headligh...