Polaris 2003 Frontier- User Manual

Polaris 2003 Frontier

Polaris 2003 Frontier– User Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 2 – WARNING; PROPOSITION 65
  • Page 3 – What’s the hottest thing on snow?; Our new web site. And it’s designed just for YOU!; Technical tips
  • Page 5 – WELCOME; Polaris Recreational Vehicles; RANGER; Polaris Professional Series Workmobiles
  • Page 6 – TABLE OF CONTENTS; be recorded in your owner’s manual.
  • Page 7 – INTRODUCTION; Important Notes for Owners and Drivers
  • Page 8 – Preservation of the Environment; Respect your snowmobile; Noise Level
  • Page 9 – Vehicle Identification Numbers
  • Page 10 – SAFETY; Operator Safety; The following signal words and symbols appear throughout this; CAUTION
  • Page 11 – The warranty on your entire machine is terminated
  • Page 12 – Stay Away From Moving Parts; Never
  • Page 13 – Riding Position; tell someone where you’re going and how long you expect to be gone.
  • Page 14 – Cargo Overload; passenger to sit on the seat back or the cargo carrier.; Riding Apparel; Be aware of the weather forecast,; Disabled Operators
  • Page 15 – Excessive Speed
  • Page 16 – Driver Awareness
  • Page 17 – Ice and Snow Build-up; obstructing the steering linkage. Snow screens and bib kits are; Driving on Slippery Surfaces; Excessive shifting of operator body weight when turning on
  • Page 18 – Driving in Hilly Terrain
  • Page 19 – Driving Downhill
  • Page 20 – Intake Silencer; Do not attempt to service the clutches.; Cold Weather Drive-Away
  • Page 21 – Powder Snow Operation; Since snow provides the only lubrication for the power slide
  • Page 22 – Rider Capacities
  • Page 23 – Driving Responsibly
  • Page 24 – Windchill/Temperature Charts; The following charts will help you determine when temperatures
  • Page 25 – Safety Decals and Locations; Warning decals have been placed on the vehicle for your; Clutch Cover Warning Decal; The airbox warning decal is found under the hood:; Pressure Cap Warning Decal; The water bottle cap warning decal is found on the water bottle
  • Page 26 – Safety Decals And Locations; Track Warning Decal
  • Page 27 – Operation Warning Decal; An operation warning decal is
  • Page 28 – Reverse Warning Decal; The reverse warning decal (PN 7170112) is located on the center
  • Page 29 – FEATURES AND CONTROLS
  • Page 31 – MIL Diagnostic Code Summary
  • Page 32 – Check Engine Light
  • Page 33 – Block Heater
  • Page 34 – THE PERFECT FIT; Front Suspension Adjustments; IFS Adjustment Options
  • Page 35 – Shock Absorber Components
  • Page 36 – Adjusting Front Shock Spring Preload
  • Page 37 – Indy Select IFS Shock; increases, stiffening the ride. By turning counterclockwise, the
  • Page 38 – Rear Suspension Adjustments; Suspension Performance Tips
  • Page 39 – M10 Suspension; Long Travel
  • Page 40 – Internal Floating Piston Shock; Tuning Terms; Spring Rates
  • Page 41 – Optional Spring Rates; Location; Preload
  • Page 42 – SAG SETTINGS
  • Page 43 – Initial Setup and Calibration
  • Page 44 – These positions are; only; Experimentation should follow INITIAL SETUP to obtain optimum
  • Page 45 – Rear Compression Spring Preload - Dimension B
  • Page 47 – Sag/Ride Height Settings
  • Page 48 – Track Tension; Track Tension Data
  • Page 49 – Edge Touring Suspension; Edge Touring Features
  • Page 50 – Torsion Springs; Initial Set-up Reference Chart
  • Page 51 – Front Arm Mounting Holes
  • Page 53 – Torsion Spring Tension; Refer to the setup chart on page 48 and under the hood of the
  • Page 54 – Handlebar Adjustments
  • Page 55 – Accessories; must; Traction Products
  • Page 57 – Wear Strips; To avoid excessive tunnel wear, tunnel wear strips
  • Page 58 – Read and Understand Your Owner’s Manual; Read the Owner’s Manual completely and refer to it often. We’ve; Throttle Lever; the engine. Have the throttle serviced immediately.; Throttle Safety Switch
  • Page 59 – Hydraulic Brakes; Brake Lever Travel
  • Page 60 – Park Brake Lever Lock
  • Page 61 – Under no; Oil Level
  • Page 63 – OPERATION; Starting the Engine; RUN
  • Page 64 – No single action on your part is as important to long, trouble-free; Perform Fluid Checks
  • Page 65 – Lubrication; Always check the oil level when refueling. Oil must be maintained
  • Page 67 – Fuel
  • Page 68 – a minimum of 87 octane non-oxygenated or 89 octane oxygenated; Fuel System Deicers; (8-16 milliliters per liter) of gasoline to prevent engine damage
  • Page 69 – Oil; ADD
  • Page 70 – Engine Stop Switch; ON
  • Page 72 – Emergency Stopping; SYSTEM; Emergency Starting
  • Page 73 – Reverse Operation; The gears may not always be aligned for shifting into reverse, and
  • Page 74 – Daily Storage
  • Page 75 – Towing
  • Page 77 – MAINTENANCE; Polaris Recommended Maintenance Program; of authorized warranty repairs, become the responsibility of the; EFI System
  • Page 78 – Maintenance Chart; may need to increase frequency based on riding conditions. When
  • Page 80 – Maintenance Log; 50 Mile (240 km) Initial Maintenance Inspection
  • Page 81 – Mileage; Mileage
  • Page 83 – All Season Grease at 500 miles (800 km) initially, every 1000 miles
  • Page 84 – Jackshaft Bearing
  • Page 85 – Chaincase Oil; between the SAFE marks on the dipstick. Add Polaris chaincase oil
  • Page 86 – General Maintenance; Spark Plugs
  • Page 87 – Normal; Spark Plug Removal and Replacement
  • Page 88 – Intake Filter
  • Page 89 – Oil and Filter Change
  • Page 90 – Exhaust System
  • Page 91 – Coolant Mixture; NOTE; Coolant High Temperature Indicator Light; ECU
  • Page 92 – Coolant Level; FULL COLD; Flushing the Cooling System
  • Page 93 – Bleeding the Cooling System
  • Page 94 – Drive Chain Tension
  • Page 95 – Hydraulic Brake Inspection
  • Page 96 – Brake Components; 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
  • Page 97 – Brake Fluid; All DOT 3 brake fluid is not the same. We recommend the use of only
  • Page 98 – Bleeding the Hydraulic Brake System
  • Page 99 – Headlight Adjustment
  • Page 100 – Headlights; Installing the Bulb
  • Page 101 – Clutch System; Periodically inspect the clutch sheaves for damage, wear, or belt
  • Page 102 – Clutch Alignment and Offset
  • Page 103 – Frontier Classic Clutching Chart
  • Page 104 – Drive Belt Removal
  • Page 105 – Drive Belt Installation
  • Page 106 – Drive Belt Deflection; Measure belt deflection with both; Drive Belt Adjustment; counterclockwise to reduce the distance between the sheaves.; Clutch Center Distance
  • Page 107 – Reverse Kit Maintenance; snowmobile is equipped with reverse.
  • Page 108 – Tool Kit
  • Page 109 – Emergency Supplies
  • Page 110 – Track Alignment; slowly
  • Page 111 – Track Maintenance; Track Inspection
  • Page 112 – Steering System; Steering Inspection and Adjustment; Specific fasteners that should be checked are marked with a
  • Page 113 – Ski Alignment; With the handlebars in a straight ahead position, and with vehicle
  • Page 114 – Ski Skags; any; Skag Replacement
  • Page 115 – Suspension Maintenance; Replace Hi-fax when a thickness of
  • Page 116 – Cleaning and Preservation of Hood, Chassis, and Trim
  • Page 117 – Extended Storage; Bearings; corrosion. See page 128 for part numbers.; Clutch and Drive System; Polaris Cable Lubricant. See page 128 for part numbers. Do not; Electrical Connections; Do not grease the TPS; Battery; Always prepare and maintain the battery as outlined on page 119.
  • Page 118 – Engine Protection
  • Page 119 – Track and Suspension; Battery Fluid
  • Page 120 – Battery Connections; Keep battery terminals and connections free of corrosion. When; Battery Removal; sideways or spill electrolyte.
  • Page 121 – Charge Condition; Battery Installation
  • Page 122 – SPECIFICATIONS; Frontier Classic
  • Page 123 – Frontier Touring
  • Page 124 – TROUBLESHOOTING; M10 Suspension Troubleshooting; Problem
  • Page 125 – Edge Touring Suspension Troubleshooting
  • Page 126 – Belt Troubleshooting
  • Page 127 – Engine Troubleshooting; All engine service and repair should be performed by a
  • Page 130 – POLARIS RECOMMENDED PRODUCTS
  • Page 131 – WARRANTY; Service And Warranty Information; Polaris Anti-Theft System; Administration; Obtaining Service and Warranty Assistance
  • Page 132 – Limited Warranty; Limitations of warranties and remedies
  • Page 134 – Conditions and Exclusions
  • Page 135 – Polaris Second Year Engine Service Contract; Consumer Exclusions
  • Page 136 – Coverage
  • Page 137 – INDEX
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2003

Owner's Manual

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Vehicle Maintenance

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Summary

Page 2 - WARNING; PROPOSITION 65

Read, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels. Failure to follow the safety precautions could resultin serious injury or death. WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects ...

Page 3 - What’s the hottest thing on snow?; Our new web site. And it’s designed just for YOU!; Technical tips

1 What’s the hottest thing on snow? Our new web site. And it’s designed just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.com/owner

Page 5 - WELCOME; Polaris Recreational Vehicles; RANGER; Polaris Professional Series Workmobiles

3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft S RANGER utility veh...

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