Polaris 2003 Frontier- Manuals

4 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE OF CONTENTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The introduction contains h...

5 INTRODUCTION Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual may be general representations. Your model may differ. n Follow t...

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and veg...

7 INTRODUCTION Vehicle Identification Numbers The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these ...

8 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual...

9 SAFETY Operator Safety WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated o...

10 SAFETY Operator Safety Stay Away From Moving Parts Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become ent...

11 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably...

12 SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Riding Apparel Be aware of the weather forecast, especially t...

13 SAFETY Operator Safety Excessive Speed Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machi...

14 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...

15 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Snow...

16 SAFETY Operator Safety Driving in Hilly Terrain Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. If climbing a hill is unavoidable, keep all your weight low and forward.If you must cross the face of a slope, keep your weight on the uphill side of the ma...

17 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine’s compression to help slow the machine and keep it from rolling freely downhill...

18 SAFETY Operator Safety Intake Silencer Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is d...

19 SAFETY Operator Safety Powder Snow Operation Since snow provides the only lubrication for the power slide suspension and cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too little snow will result in excessive wear and damage to the slide rai...

20 SAFETY Operator Safety Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program (beginning on page 75) to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage int...

21 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. E...

22 SAFETY Operator Safety Windchill/Temperature Charts The following charts will help you determine when temperatures become dangerous for riding.WIND CHILL CHART ( ° F) Estimated Wind Speed in MPH Actual Thermometer Reading ( ° F) p in MPH 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 Equivalent Tempera...

23 SAFETY Safety Decals and Locations NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any safety decal becomes illegible or comes off, contact your Polaris dealer for a free replacement. The part number is printed...

24 SAFETY Safety Decals And Locations Track Warning Decal The track warning decal is located on the rear of the taillight housing: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. Passenger Warning Some snowmobil...

25 SAFETY Safety Decals And Locations Operation Warning Decal An operation warning decal is present on the console of the Polaris Frontier snowmobiles in both English (PN 7079886) and French (PN 7079887): To avoid serious injury or death, read and understand all warnings and the Owner’s Manual befor...

26 SAFETY Safety Decals And Locations Reverse Warning Decal The reverse warning decal (PN 7170112) is located on the center console: Reverse operation, even at low speeds, can cause loss of control resulting in severe injury or death. To avoid loss of control, always: S Look behind before and while ...

27 FEATURES AND CONTROLS 1. Fuel Filler Cap 2. Ignition Switch 3. Brake Lever 4. Electronic Fuel Gauge 5. Speedometer 6. Headlight High Beam Light 7. Low Oil Pressure Light 8. Brake Light 9. Check Engine Light 10. Reverse Indicator Light 11. Temperature Light 12. Tachometer 13. Engine Stop Switch 14...

29 FEATURES AND CONTROLS Malfunction Indicator Lamp (MIL) The Frontier is equipped with a malfunction indicator lamp (CHECK ENGINE light) to assist your Polaris dealer in diagnosing problems. The MIL codes are for reference only. Full diagnostics must be performed by a Polaris dealer trained to serv...

30 FEATURES AND CONTROLS Check Engine Light Your EFI system has an Electronic Control Unit (ECU), which is pre-coded for any potential problems your EFI system will have. If a problem with your EFI system occurs, a code is triggered and the CHECK ENGINE light will come on. If the light comes on, tak...

31 FEATURES AND CONTROLS Block Heater To improve cold-weather starting, a block heater has been installed on the engine of your snowmobile. When connected to a 110V electrical outlet, the block heater warms the engine, making it easier to start in subzero temperatures. We recommend the use of this b...

32 THE PERFECT FIT Front Suspension Adjustments Before fine-tuning adjustments are made, break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail condition...

33 THE PERFECT FIT Front Suspension Adjustments The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming. To determine if your machine is...

34 THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure springs on both the left and right sides of the machine are at ...

35 THE PERFECT FIT Front Suspension Adjustments Indy Select IFS Shock The Frontier Touring model is equipped with Indy Select IFS shocks, which allows you to make adjustments to the compression valving of the front shocks by turning adjustment screws (A) located near the base of the shocks.By turnin...

36 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs a...

37 THE PERFECT FIT M10 Suspension Before proceeding with the tuning of your M10 suspension, you should familiarize yourself with the following terms: M10 Features Long Travel - Refers to the over 10 ″ of REAL travel that the M10 has between the rear arm cross-shaft and the slide rail. this is the lo...

38 THE PERFECT FIT M10 Suspension M10 Features NOTE: The M10 has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. or more might require ap- propriate changes in FRA settings. Refer to the chart on page 42 for specifications. Internal Floating Piston Shock - A hi...

39 THE PERFECT FIT M10 Suspension M10 Features Optional Spring Rates - Optional springs have been designed to allow adaptation of the M10 to the varied needs of our customers. The 140 lb./in. option front arm spring would be used when very light loads are encountered such as very smooth trails, deep...

40 THE PERFECT FIT M10 Suspension M10 Features SAG SETTINGS - Describes the difference in height of the rear bumper from the sleds fully extended position to its loaded height with the rider seated on the sled.A good initial starting point is 4 ″ of SAG. Note that this measurement is at the rear bum...

41 THE PERFECT FIT M10 Suspension Initial Setup and Calibration Your M10 is a precision instrument which MUST be optimized for your specific needs and riding conditions. The following information has been compiled to assist you in tuning your M10 to its maximum potential. The Full Range Adjuster (FR...

42 THE PERFECT FIT M10 Suspension INITIAL SETUP REFERENCE CHART This chart is a guideline to be used for initial suspension setups. Your setup may vary based on your desired riding style. FRA Position Dimension B Dimension C Rider Weight with SOFT FIRM Rear Spring X-over Tube Limiter/Ski Pressure We...

43 THE PERFECT FIT M10 Suspension Rear Compression Spring Preload - Dimension B 1. Using the spanner wrenches in your tool kit, rotate the x-over tube assembly to achieve the desired spring preload setting. Be sure the aluminum lock nut and adjuster collar are locked against each other before starti...

45 THE PERFECT FIT M10 Suspension Sag/Ride Height Settings 1. To check if the FRA settings are close before riding, check the SAG settings. Raise the rear bumper until the suspension is fully extended (rear shock will not extend any further). Measure the distance from the ground to the bottom of the...

46 THE PERFECT FIT M10 Suspension Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment.Tension adjustments should be made only after the track is warmed up and limber.1. Turn the machine off.2. Lift the rear of the machine and safely support i...

47 THE PERFECT FIT Edge Touring Suspension Before proceeding with the tuning of your Edge Touring Suspension (ETS), you should familiarize yourself with the following terms: Edge Touring Features Long Travel - Refers to the over 10” of REAL travel that the ETS has between the rear arm cross-shaft an...

48 THE PERFECT FIT Edge Touring Suspension Edge Touring Features Torsion Springs - Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. Optional Spring Rates - Optional springs have been designed to al...

49 THE PERFECT FIT Edge Touring Suspension Initial Setup and Calibration The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of your snowmobile and...

51 THE PERFECT FIT Edge Touring Suspension Torsion Spring Tension To adjust rear torsion spring tension, rotate the two-position cam using the engine spark plug tool.Different rate torsion springs are available if greater tension is desired. Refer to the setup chart on page 48 and under the hood of ...

52 THE PERFECT FIT Handlebar Adjustments Follow these steps to adjust the handlebars for a personal fit.1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts (A). 2. Using a 7/16 ″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn handle...

53 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to saddlebags, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories. NOTE: The accessory tether switch is available for all mod...

55 THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information.Some models are manufactured with tunnel wear strips or wear strip coolers installe...

56 PRE-RIDE INSPECTION Before starting the engine, always check all of the items outlined on the following pages. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to ensure a safe and enjoyabl...

57 PRE-RIDE INSPECTION Hydraulic Brakes Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine. Brake Lever Travel When the brake lever is squeezed, it should move no closer to the handgrip than 1/2 ″ (1.3 cm) (...

58 PRE-RIDE INSPECTION Park Brake Lever Lock Your snowmobile has a park brake lever lock located over the brake lever. Use the brake lever lock when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. To apply the lock, squeeze the ...

59 PRE-RIDE INSPECTION Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated. Track Condition Driving a...

61 OPERATION Starting the Engine Do not depress the throttle until the engine starts.1. Pull the kill switch (shut-off switch) up to the RUN position. 2. Turn the key to START and crank the engine. NOTE: There will be a half second delay before the starter engages to allow the ACS system to “wake up...

62 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. During the first three hours of operation, operate the snowmobile as outlined in the Engine Break-In section. Avoid Heat Build-Up Excessive hea...

63 OPERATION Engine Break-In Lubrication Always check the oil level when refueling. Oil must be maintained between the SAFE and ADD marks on the dipstick. See page 67. We highly recommend the use of only Polaris products for your snowmobile. We’re continuously testing lubricants and provide the high...

65 OPERATION Fuel Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area w...

66 OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant. Your Polaris engine is designed to run on a minimum of 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 ...

67 OPERATION Oil Oil Level Always check the oil level on the dipstick before each ride and when refueling. The dipstick is located on the lower left side of the engine.When the oil reaches the ADD mark, add 8 fl. oz. of recommended oil to the engine. Maintain the oil level between the SAFE (A) and A...

68 OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. Throttle Safety Switch Test the throttle safety ...

70 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 68 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circui...

71 OPERATION Reverse Operation Make sure the shift lever is shifted completely into forward or reverse position. Do not force the shift lever into reverse if resistance is felt. The gears may not always be aligned for shifting into reverse, and forcing the lever may cause damage. If resistance is fe...

72 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 ″ (20 cm) off the ground.Remove the key and cover the machine. NOTE: Polaris has accessory covers and t...

73 OPERATION Towing For your safety, do not attempt to use the tow hitch until you’ve read the following warnings and understand the proper hitch functions. If the snowmobile becomes inoperable and must be towed, and if it isn’t possible to use a rigid tow bar, attach the tow rope to the ski spindle...

75 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual.The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections ...

76 MAINTENANCE Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item Weekly...

78 MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized P...

79 MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing DealerServicing TechnicianDate Mileage Type of Service Additional Services Performed Authorized Polaris Servicing DealerServicing TechnicianDate Mileage Type of Service

81 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the ...

82 MAINTENANCE Lubrication Jackshaft Bearing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Pus...

83 MAINTENANCE Lubrication Chaincase Oil Check the chaincase oil level weekly and before any long trips.Place the machine on a level surface.Remove the dipstick (A) and read the oil level. The oil level should be between the SAFE marks on the dipstick. Add Polaris chaincase oil through the dipstick ...

84 MAINTENANCE General Maintenance Spark Plugs S Use Champion RC7YC spark plugs. S Proper electrode gap is .035” (.9 mm) S Spark plug torque is 18-22 ft. lbs. (24-30 Nm). Change spark plugs annually and whenever inspection reveals fouled or damaged plugs. Always use the recommended spark plugs for y...

85 MAINTENANCE General Maintenance Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. Normal T...

86 MAINTENANCE General Maintenance Intake Filter The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the filters periodically to remove any accumulation of snow.1. Airbox foam filter 2. Air intake box 3. Hood foam filters Fuel Filter The be...

87 MAINTENANCE General Maintenance Oil and Filter Change The Frontier does not have a crankcase drain. The oil in the crankcase must be drawn out through the dipstick hole using a Polaris oil vacuum pump (PN PU-46219) or similar tool from another manufacturer. This type of tool is commonly used in t...

88 MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing ret...

89 MAINTENANCE General Maintenance Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34 ° F (-37 ° C). If greater protection is required, the percentage of antifreeze to ...

90 MAINTENANCE General Maintenance Coolant Level The coolant level in the coolant bottle must be maintained at the FULL COLD mark (A) to prevent overheating and serious engine damage. The engine coolant level is controlled by the recovery system. The recovery system components are: S Coolant bottle ...

91 MAINTENANCE General Maintenance Bleeding the Cooling System If the pressure cap needs replacement, contact your dealer for the correct part. Use of a non-standard pressure cap will not allow the recovery system to function properly. 1. Remove the pressure cap and fill the coolant bottle with prop...

92 MAINTENANCE General Maintenance Drive Chain Tension To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A). 3. ...

93 MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2 ″ (1.3 cm). Brake pads mu...

94 MAINTENANCE General Maintenance Brake Components 1. Brake Caliper 2. Chaincase 3. Brake Disc 4. Backing Plate 5. Brake Pad Material (Replace when thickness is less than 1/16 ″ ). Excessive Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as de...

95 MAINTENANCE General Maintenance Brake Fluid All DOT 3 brake fluid is not the same. We recommend the use of only Polaris DOT 3 high temperature brake fluid. See page 128 for the part numbers of Polaris-recommended products.The brake fluid level can be seen through a plastic sight glass in the brak...

96 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this po...

97 MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure:1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the hea...

98 MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlights Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases...

99 MAINTENANCE General Maintenance Clutch System Periodically inspect the clutch sheaves for damage, wear, or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. If you become aware of higher than normal clutch engagement or an unusual vibratio...

100 MAINTENANCE General Maintenance Clutch Alignment and Offset Clutch center distance and alignment (A) are crucial to maintaining optimum performance. See the specifications section on pages 120-121 for the recommended offset between the drive and driven clutches with the belt removed.The drive be...

101 MAINTENANCE Frontier Classic Clutching Chart Altitude Meters (Feet) Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing 0-900 (0-3000) 10-62 Yellow Black R-11 #2 18:39 72P HYVO 900-1800 (3000-6000) 10-62 Yellow Black R-11 #2 18:39 72P HYVO 1800-2700 (6000-9000) 1...

102 MAINTENANCE General Maintenance Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. Drive Belt Remo...

103 MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack (A). NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read...

104 MAINTENANCE General Maintenance Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position.Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. Drive Belt Adjustment Belt ...

105 MAINTENANCE General Maintenance Reverse Kit Maintenance Always maintain track tension as specified on pages 46 and 50 when a snowmobile is equipped with reverse. Allow the engine to reach idle speed before attempting to shift into or out of reverse. Improper track tension can cause serious damag...

106 MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance.1. Phillips Screwdriver2. Tubular Socket3. Tubular Socket Handle4. Wrench5. Shielded Screwdriver6. Adjuster Wrench (M10 Models)7. Box End Wrench NOTE: Always keep the tool kit ...

107 MAINTENANCE General Maintenance Emergency Supplies For added protection, carry the following items on your snowmobile at all times: S Spare Drive Belt S Extra Set of Spark Plugs S Tow Rope S Extra Oil S Fuel Deicer S Winter Survival Kit S Trail Map S Owner’s Manual S First Aid Kit Fall Tune-Up F...

108 MAINTENANCE Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amoun...

109 MAINTENANCE Track Maintenance Track Inspection Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for possible damage.Carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage. T...

110 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if needed. Specific fasteners that should be checked are marked with a + . + + + + + + +

111 MAINTENANCE Steering System Ski Alignment With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt. The measurement between the skis at point X should be 1/8 ″ to 1/4 ″ ...

112 MAINTENANCE Steering System Ski Skags Check skags weekly to maintain positive steering characteristics. Skags must be replaced when worn to half their original diameter. NOTE: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the fron...

113 MAINTENANCE Suspension Maintenance Hi-Fax Wear Replace Hi-fax when a thickness of 5/16 ″ (.8 cm) is reached. Check Hi-fax wear by measuring the thickness at several points along the rail (A). Take the machine to your dealer for Hi-fax replacement. 7/16 ″ (1.1 cm) A A A A

114 MAINTENANCE Suspension Maintenance Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long tri...

115 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. See page 128 for part numbers. Clutch and Drive System Remove the drive belt and store in a cool dry locat...

116 MAINTENANCE Extended Storage Engine Protection Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with fogging oil....

117 MAINTENANCE Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Battery Battery Fluid A poorly maintained battery will deteriorate rapidly. Che...

118 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water an...

119 MAINTENANCE Battery When your snowmobile is placed in storage for one month or more: S Remove the battery. S Charge it to the proper level. S Store it in a cool dry place. S Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging.Batteries may fre...

120 SPECIFICATIONS Frontier Classic Capacities and Dimensions Body Style Edge Riders 1 Coolant 5.9 qts./5.6 l Chaincase Oil 12 oz./.34 kg Engine Oil 2 qts./1.9 l Dry Weight (est.) 560 lbs./254 kg Fuel Tank 11.8 gal./44.7 l Height 49 in./124.5 cm Length 113 in./287 cm Ski Center Distance 42.5 in./108...

121 SPECIFICATIONS Frontier Touring Capacities and Dimensions Body Style Edge Riders 2 Coolant 6 qts./5.7 l Chaincase Oil 12 oz./.34 kg Engine Oil 2 qts./1.9 l Dry Weight (est.) 618 lbs./280 kg Fuel Tank 12.25 gal./46.4 l Height 49.5 in./125.7 cm Length 119 in./302.3 cm Ski Center Distance 42.5 in./...

122 TROUBLESHOOTING M10 Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Increase FRA position (see setup decal under hood for initial position - Increase X-over tube length (see setup decal under hood)- Increase rear track shock co...

123 TROUBLESHOOTING Edge Touring Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Adjust RCA forward (see setup decal under hood)- Adjust coil over spring on front track shock to increase preload (1” maximum preload) - Increase tors...

124 TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check beltdeflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt offthe machine in extremely cold wea...

125 TROUBLESHOOTING Engine Troubleshooting CAUTION: All engine service and repair should be performed by a qualified Polaris dealer with training in EFI engines. Problem Probable Cause Solution Erratic engineoperating RPMduring accelera-tion or loadvariations Drive clutch bind-ing Driven clutchmalfu...

128 POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Grease / Specialize...

129 WARRANTY Service And Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying th...

130 WARRANTY Limited Warranty Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defecti...

132 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre- Delivery Inspection, perform all applicable service bulletins and have the co...

133 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is...

134 WARRANTY Polaris Second Year Engine Service Contract Coverage S Failure due to unauthorized service. S Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. S Failure due to use of unauthorized part...

135 INDEX A Accessories 53-55 . . . . . . . . . . . . . . . . . Airbox 23 . . . . . . . . . . . . . . . . . . . . . . B Battery 115-119 . . . . . . . . . . . . . . . . . . Battery Connections 118 . . . . . . . . . . . Battery Fluid 117 . . . . . . . . . . . . . . . . . Battery Installation 119 . . ....