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Discussion Starter #1
Had to take our Ace in for service again. This time the brake pressure sensor switch went bad and wasn't allowing it turn over every time you pushed the brake in to start it. We came home from riding Saturday and I washed both atv's off and put them in the garage and came out the next morning and nothing...wouldn't turn over. It was 10 degree's outside so I turned on the heater in the garage for about 2 hours and came out and it started fine. I let it warm up and took a short ride around the neighborhood and came back and put it back in the garage and thought everything would be fine. I got up the next morning and the same thing, wouldn't turn over. I took it into dealer that day and they found that water was frozen in the sensor and wire clip so they dried it out and put grease around it and said it was ok. Drove home, got in it to pull it off the trailer and same thing, wouldn't turn over. Drove it right back to dealer pushed it off the trailer and said don't call me until you are sure you have it fixed. Called me yesterday and said it was the sensor and Polaris is going to ship a new one to them. They said all problems are reported to Polaris and they look at them and decide if there is a need for a recall on that issue. I sure think they need to put a rubber boot over the wire and sensor to stop water from getting into those parts and freezing. Hope the down time won't be long since most of any parts are not available for it. Guess this is what we go through when the first model comes out.
 

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Discussion Starter #3
Just wanted to give a heads up to everyone in case yours don't start either if you get it wet and freezes up. The dealer just took a paper clip and stuck into the wires to jumper it and got it started. I am going add one in my tool kit just in case!!
 

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That's a known issue with the RZR line-up.
I'm very surprised that Polaris didn't solve that with the ACE, because when poking around my ACE, I noticed a lot of other small things that Polaris seems to have learned from the RZR series and got right in the ACE.
 

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Just wanted to give a heads up to everyone in case yours don't start either if you get it wet and freezes up. The dealer just took a paper clip and stuck into the wires to jumper it and got it started. I am going add one in my tool kit just in case!!
Where is that switch located? I know where it is in my RZR but am having trouble finding it in my ACE.
BTW, I never had a problem with mine but it rarely gets that cold here.

It's useful to know about it and be prepared to jumper it if needed, but only if we can find it!
 

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Discussion Starter #6
It is located on the front right side right behind the radiator if your looking in from under the front fender. Follow the front brake line to a block with a 2 wire sensor on it. If mine wasn't in the shop I could post a picture of it....when I get it back I can or if someone else finds it they can. Just a little rubber boot over it would help out for us that ride in the freezing conditions.
 

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Got it, thank you.
That's a much better location than the RZR. In the RZR, there is a brake line junction on the floor under the seat, with the brake sensor switch sticking out of it.
That switch regularly gets immersed in water and gets all muddy. A lot of guys moved it or jumped it for that reason. I never had a problem with it myself.
This one is at least fairly high up.

But I think that a rubber boot over it would just collect and hold water, since it is mounted horizontally, and the problem would remain.
Without a boot, it can drain if the water does not freeze first.
That's a tough one to resolve for extreme weather.

I just smeared some waterproof silicone grease on mine as a preventative step against corrosion.
It rarely freezes around here, so most likely won't be a problem for me.

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Had to take our Ace in for service again. This time the brake pressure sensor switch went bad and wasn't allowing it turn over every time you pushed the brake in to start it. We came home from riding Saturday and I washed both atv's off and put them in the garage and came out the next morning and nothing...wouldn't turn over. It was 10 degree's outside so I turned on the heater in the garage for about 2 hours and came out and it started fine. I let it warm up and took a short ride around the neighborhood and came back and put it back in the garage and thought everything would be fine. I got up the next morning and the same thing, wouldn't turn over. I took it into dealer that day and they found that water was frozen in the sensor and wire clip so they dried it out and put grease around it and said it was ok. Drove home, got in it to pull it off the trailer and same thing, wouldn't turn over. Drove it right back to dealer pushed it off the trailer and said don't call me until you are sure you have it fixed. Called me yesterday and said it was the sensor and Polaris is going to ship a new one to them. They said all problems are reported to Polaris and they look at them and decide if there is a need for a recall on that issue. I sure think they need to put a rubber boot over the wire and sensor to stop water from getting into those parts and freezing. Hope the down time won't be long since most of any parts are not available for it. Guess this is what we go through when the first model comes out.
Polaris is known for letting the public test there units for them. You would think that they would have things pretty dialed in before sending them out.
 

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Whether that's true or fair or not, you gotta admit that it is a pretty unusual circumstance, water getting into that switch and then freezing and forcing the switch apart before it has a chance to drain/dry out.
Kind of an extreme condition, I'd say.
 

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I suppose one could encase it in epoxy or hot glue or something. But that would be a lot of fun for maintenance down the road.
 

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I think you could squeeze some silicon RTV in there to keep the water out.
 

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I could be wrong, but I believe extremegsxr said that the actual switch itself (not just the plugs connecting to the switch) got damaged by freezing water.
So it's more than just protecting the plug and its blade connections.
 

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Discussion Starter #16
Your right Scoundrel, they had to replace the actual switch and then bleed the brake system. I just picked it up today and hopefully everything will be ok. The weather here got up to 50 today so won't really know until next week when it goes back down to freezing again.
 

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Please keep us updated.
It's possible that you just got "lucky" and it was a bad switch with a crack already in it that the water got into.
If it happens again we definitely want to know about it.
 

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Polaris is known for letting the public test there units for them. You would think that they would have things pretty dialed in before sending them out.
Hard to test thousands and thousands of different parts in different extremes with thousands of different circumstances..
 

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It is a common problem I replaced 3 this week on rangers. The sensor being bad. We keep a few in stock so no biggy it is a 15 min fix. I took a plastic plug protector off a scrap wiring harness slid it over the plug and then over the sensor with a piece of black tape hanging on it then plugged it back in and wrapped the tape around the brake ends to hold against the brake fluid container. It will also help keep mud and debris off of it or it from working its way unplugged. Another common problem, with rangers any way.
 
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