Polaris Frontier 2002 Owner's Manual

Read, understand, and follow all of the instructions and
safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in
serious injury or death.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

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

2

All information in this manual is based on the latest product data and specifications
available at the time of printing. Polaris Industries Inc. reserves the right to make
product changes and improvements that may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of
Polaris Industries Inc.

Copyright 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

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 vehicles
S Victory motorcycles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs)
S Personal Task Vehiclest (PTVs)
S All-Surface Loaders (ASLs)

We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your P olaris vehicle, making it the finest machine we’ve ever
produced.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the P olaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.

4

TABLE OF CONTENTS

WELCOME 3........................................

TABLE OF CONTENTS 4.............................

INTRODUCTION 5...................................

The introduction contains helpful information for owners and drivers,
including the location of important identification numbers that should
be recorded in your owner’s m anual.

SAFETY 8..........................................

The safety section outlines practices for safe vehicle operation and
identifies warning decals and their locations.

FEATURES AND CONTROLS 28......................

The features and controls of your snowmobile are identified in this
section.

THE PERFECT FIT 33................................

Learn how to tailor the suspension and other features for an optimum
riding experience.

PRE-RIDE INSPECTION 47...........................

Always perform these procedures and inspections before riding.

OPERATION 52.....................................

Learn how to properly break in your new snowmobile, how to operate
the controls and features, and how to drive

MAINTENANCE 67..................................

The maintenance section outlines service procedures that must be
performed by you or your dealer to keep the snowmobile operating at
peak performance.

SPECIFICA TIONS 112...............................

POLARIS RECOMMENDED PRODUCTS 113...........

TROUBLESHOOTING 114............................

WARRANTY 119....................................

INDEX 125..........................................

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 the maintenance program outlined in this manual.

Preventive maintenance ensures that critical components of the
snowmobile are inspected by your dealer at specific mileage
intervals.

n You and your dealer must complete the registration form included

with your snowmobile and forward it to us. This completed form
is necessary to ensure warranty coverage.

n Protect and preserve your right to ride by joining your local trail

riding clubs.

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 vegetation.

Snowmobile clubs and other organizations are working together to
protect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

Noise Level

One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may
not be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.

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
numbers are essential to its recovery and identification.

Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with one of your
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.

NOTE: Record your snowmobile’s ID numbers and key number in the
spaces provided.

Tunnel VIN (lower right side of the tunnel) :

Engine Serial Number (right side of engine cylinder head):

Vehicle Model Number:

Key Number:

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, alerts
you to the potential for personal injury.

The safety alert warning indicates a potential hazard that may result
in serious injury or death.

The safety alert caution indicates a potential hazard that may result
in minor personal injury or damage to the vehicle.

CAUTION

NOTE:

A note will alert you to important information or instructions.

A caution indicates a situation that may result in damage to the
vehicle.

CAUTION

WARNING

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 or under the influence of drugs.

Polaris produces high performance snowmobiles capable of
traveling at high speeds. Extra caution must be observed to
ensure operator safety. Make sure your snowmobile is in
excellent operating condition at all times. We strongly
recommend that the operator check major and vital safety
components before every ride.

All Polaris snowmobiles are designed and tested to provide
safe operation when used as directed. Failure of critical
machine components may result from operation with any
modifications, especially those that increase speed or power.
DO NOT MODIFY YOUR MACHINE. The snowmobile may
become aerodynamically unstable at speeds higher than those
for which it is designed. Loss of control may occur at higher
speeds. Modifications may also create a safety hazard and
lead to bodily injury.

The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the snowmobile.

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 entangled in the t rack.

Never attempt adjustments with the engine running. Turn off the
ignition, raise the hood, make the adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.

Never hold the snowmobile up or stand
behind it while warming up the track. A
loose track or flying debris could cause
serious personal injury or death.

We recommend having your dealer perform
track service and alignment procedures.

WARNING

If fingers or clothing contact the moving parts of an engine,
serious injury can result. Always stop the engine before
attempting adjustments.

WARNING

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 positioned for proper
throttle, brake, and steering control.

Survival Equipment

For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone.
If it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the
conditions you may encounter. Such equipment may include, but is
not limited to: extra clothing, a sleeping bag, a flashlight, food and
water, a signaling mirror, a means of building a fire, and a two-way
radio or cellular telephone.

Improper riding position may seriously reduce your ability to
control the machine and may result in serious injury or death.
Always be properly seated and in position to control your vehicle.

WARNING

Use of a backrest may hinder your weight shifting ability. This
could affect your ability to control this rider-active vehicle in
certain extreme driving situations.

WARNING

12

SAFETY

Operator Safety

Cargo Overload

Too much weight on the rear of the m achine 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 the wind chill. A wind chill
table is provided on page 22 for your
reference. To better enjoy your ride, be
prepared, be warm and be comfortable.

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have
an increased risk of loss of control, which could result i n serious injury
or death.

Control becomes more difficult with two people on board. More
space is required to make turns, and longer distances are needed
for stopping. Make sure the passenger remains seated behind the
driver, facing forward, with both feet placed firmly on the running
boards. Slow down and avoid “jumping” your snowmobile.

WARNING

Loose clothing or long scarves may easily become entangled in
moving parts and cause serious personal injury. Avoid wearing
loose clothing and long scarves while riding a snowmobile. Always
wear an approved helmet and eye protection.

WARNING

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 machine travels. If your speed is 40 MPH, your machine is
traveling about 60 feet per second. If you look back for only two
seconds, your machine will travel about 120 feet. If your speed is 60
MPH, your machine will travel about 180 feet.

Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t “over drive” your headlight
beam. Always be able to bring your machine to a stop in the distance
illuminated by the headlight.

High speed driving, especially at night, could result in serious
personal injury or death. Obey local traffic laws pertaining to
snowmobile use and avoid using excessive speed.

WARNING

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 wires on utility poles
are also difficult to distinguish.

Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or
highways. Steep embankments may also
hide your view. Always leave yourself a
way out.

Variances in snow depth and/or water
currents may result in uneven ice
thickness. Always check with local
residents or authorities for general information on conditions when
traveling on lakes and streams that are strange to you. Before riding
your machine on a frozen body of water, be sure the ice is thick enough
to support t he machine and its operator, as well as the force created by
a moving vehicle. You may drown if you and t he snowmobile break
through the ice.

When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.

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 screens and bib kits are
available through your dealer to help reduce s now and ice build-up.

Driving o n Slippery Surfaces

Excessive shifting of operator body weight when turning on
hard-packed snow or ice may lead to loss of vehicle control and result
in serious injury or death. Slow down to maintain control under these
conditions.

It’s dangerous to drive on ice or other slippery surfaces. If it’s
unavoidable, use extreme caution and operate at speeds no faster than a
walk. Never attempt an abrupt change of direction. The chance of
“spin-out” increases under these conditions.

Ice and snow build-up may interfere with the steering of your
machine, resulting in serious injury or death. Keep the underhood
area free of snow and ice.

WARNING

Driving on ice or hard-packed snow reduces steering and braking
control, which may result in serious injury or death. Slow down
and use caution.

WARNING

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 machine to maintain proper balance and avoid possible
roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops, or other people or vehicles that may be on the
other side of the hill.

If you’re unable to continue up a hill, turn the machine downhill before
it loses momentum. If this isn’t possible, spin the track just enough to
dig in to prevent it from rolling back down the hill. Stop the engine
and set the parking brake (if equipped). Keeping away from the
downhill side of the machine, pull the rear of the snowmobile around
and point the front end and skis downhill. Remount the machine,
restart the engine, release the parking brake, and descend the hill
carefully.

Climbing a hill or crossing the face of a slope may result in loss
of balance and machine roll-over, causing serious injury or death.
Use caution and good judgement when driving in hilly terrain.

WARNING

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.

Do Not Operate Engine With Clutch Guard Removed

The clutch guard is designed to protect the operator from metal parts i f
the clutch should fail. Although the chance of failure is extremely
remote, don’t defeat the purpose of the guard by removing it. It’s
provided for your safety.

Do Not Operate Engine With Drive Belt Removed

Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in personal injury or damage to the engine.

When driving on long downhill stretches, pump the brakes. Riding
the brakes may cause the brake system to overheat, which may
result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.

WARNING

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
dynamically balanced before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the machine into motion, but always operate
within safety limits.

Maneuverability

Control and maneuverability comes not only through the steering and
skis, maximum control is achieved by shifting of body weight.
Maneuverability will change for lighter operators or machines designed
to carry a load or a passenger.

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 i n too little snow
will result in excessive wear and damage to the slide rail, track and/or
engine.

If the machine becomes stuck in snow, clear the running board area of
snow, then step down the snow in front of the machine so that when
the throttle is opened, the snowmobile will be able to climb up and
over. You may then mount the machine and continue riding.

Do not drive for prolonged periods on blacktop, gravel, or ice.
Doing so could cause irreversible track damage and lead to serious
personal injury.

WARNING

When operating on icy surfaces or hard-packed snow, avoid
overheating the slide rail and track. Lack of lubrication and cooling
will cause overheating of the slide rail and track, resulting in
premature wear and failure. If frequently operating in low cooling
conditions, see your dealer for an optional wheel kit that will reduce
the wear from overheating.

CAUTION

20

SAFETY

Operator Safety

Your Polaris snowmobile is a well-engineered and well-constructed
recreational vehicle. Follow the recommended maintenance program
(beginning on page 67) to ensure that all critical components on the
snowmobile are thoroughly inspected by your dealer at specific
mileage intervals.

Rider Capacities

The Polaris Frontier snowmobile is designed for two riders. A decal
on the console indicates that the vehicle is designed for one operator
and one passenger only . See page 25 for decal location.

Machines designed for two riders should never be operated with more
than two people on board. When traveling with a passenger, it’s t he
driver’s responsibility to operate the machine safely.

Slow down! C ontrol becomes m ore difficult with two people on board.
More space is required to make turns, and longer distances are
necessary for s topping.

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. Even
seasoned drivers should spend some time getting the feel for a machine
before attempting ambitious maneuvers.

S A snowmobile depends on the rider’s body position for proper bal-

ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.

S Before allowing someone else use your snowmobile, know the ex-

tent of their operating skills. Check to see if they’ve taken a snow­mobile safety course and have an operator’s certificate. For their
protection, as well as yours, make sure they take a snowmobile safe­ty course. Everyone can benefit from the course.

S Don’t “jump” your snowmobile. Jumping may injure your back be-

cause of spinal compression. The seat and s uspension of your snow­mobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.

S Be courteous to oncoming traffic by dimming your headlights and

reducing your speed. Your snowmobile is equipped with a high out­put headlamp system that may cause discomfort to operators of on­coming vehicles when on high beam.

S When traveling in a group of snowmobiles, don’t tailgate (follow too

closely). Allow ample stopping distances, and keep track of those
following you. Drive defensively to avoid accidents.

S Remove the key from the ignition when leaving the snowmobile un-

attended.

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

Actual Thermometer Reading (°F)

p

in MPH

50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

Equivalent Temperature (°F)

Calm 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

5 48 37 27 16 6 -5 -15 -26 -36 -47 -57 -68

10 40 28 16 4 -9 -21 -33 -46 -58 -70 -83 -95

15 36 22 9 -5 -18 -36 -45 -58 -72 -85 -99 -112

20 32 18 4 -10 -25 -39 -53 -67 -82 -96 -110 -124

25 30 16 0 -15 -29 -44 -59 -74 -88 -104 -118 -133

30 28 13 -2 -18 -33 -48 -63 -79 -94 -109 -125 -140

35 27 11 -4 -20 -35 -49 -67 -82 -98 -113 -129 -145

40 26 10 -6 -21 -37 -53 -69 -85 -100 -116 -132 -148

Wind Speeds Greater

Than 40 MPH Have

Li

t

tleAdde

d

Eff

ect

Little Danger

(For Properly

Clo

the

dPers

on)

Increasing

Danger

Great

Danger

LittleAddedEffectClothedPerson)

Danger From Freezing of Exposed Flesh

WIND CHILL CHART (°C)

Estimated Wind Speed

Actual Thermometer Reading (°C)

p

in KPH

5 0 -5 -10 -15 -20 -25 -30 -35 -40

Equivalent Temperature (°C)

0 5 0 -5 -10 -15 -20 -25 -30 -35 -40

10 1 -4 -11 -16 -22 -27 -33 -38 -45 -50

20 -4 -9 -17 -23 -29 -36 -42 -48 -54 -61

30 -7 -13 -21 -28 -35 -42 -48 -55 -63 -69

40 -9 -16 -24 -32 -39 -47 -53 -61 -69 -76

50 -11 -18 -26 -34 -41 -49 -57 -64 -73 -80

60 -12 -19 -27 -35 -43 -51 -59 -66 -75 -82

70 -13 -20 -28 -36 -44 -52 -60 -68 -76 -84

Wind Speeds Greater

Than 70 KPH Have Little

Little Danger

(For Properly

Increasing

Danger

Great

Danger

Added Effect

(py

Clothed Person)

Danger From Freezing of Exposed Flesh

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 on the decal.

Clutch Cover Warning Decal

The clutch cover warning decal (PN 7075350) is found under the hood
on the clutch cover:

Do not operate engine with hood open.
Do not attempt adjustment with engine running.
Do not operate engine with this guard open.
Never run engine with drive belt removed.
Never service clutches yourself - see your dealer.

Airbox Warning Decal

The airbox warning decal (PN 7075351) is found under the hood:

Do not operate above 40 mph with hood-to-airbox foam removed
or engine failure will result.

Pressure Cap Warning Decal

The water bottle cap warning decal (PN 7170063) is found on the
water bottle pressure cap:

WARNING
DO NOT OPEN HOT
Test or replace when changing coolant.
Press down and turn to release cap.
13 PSI

24

SAFETY

Safety Decals And Locations

Track Warning Decal

The track warning decal (PN 7076360) is
located on the rear tunnel:

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.

Cargo Carrier Warning Decal

The cargo carrier warning decals (PN 7072225
English and P N 7072266 French) is located on
the side of the rear rack:

Do not sit in or on cargo area.
Cargo load should not exceed 40 lbs.

(18 kg).
Cargo load affects machine steering

and response.
Never allow person(s) to use carrier

as a means of hand support, (skiing,
skidding or dragging).

Severe injury may result due to track
entanglement, falling off, or loss of
steering control if warnings are not
followed.

+

+

25

SAFETY

Safety Decals And Locations

Passenger Warning

The Frontier snowmobile is
designed for the operator and one
passenger. The passenger warning
decal (PN 7075439) is located on
the right side of the console. For
more information on operating
capacities, see page 20.

This vehicle is designed for
operator and ONE passenger
only .

Caution Decal

A caution decal (PN 7078363) is
located on the center console of the
snowmobile:

BEFORE STARTING ENGINE:
Check throttle and brake for
proper operation. Check to
see that hood is securely
latched. Check surroundings
to verify clear operation area.
Determine that steering is free and functional.

BRAKE LEVER LOCK: May relax when used for long periods. Do
not leave brake engaged for more than five minutes.

ALWAYS: Be seated and in position to control vehicle. Stop
engine before attempting adjustments. Know the limitations of the
vehicle and your skills as a driver. Understand your Owner’s
Manual. Wear clothing designed for snowmobiling. Stops from
high speed may cause fading or unexpected loss of braking ability.

OIL INJECTION SYSTEM: Unmixed fuel only. Check oil level
when refueling.

If Owner’s Manual is missing, contact a Polaris dealer for a
replacement.

+

+

26

SAFETY

Safety Decals And Locations

Operation Warning Decal

An operation warning decal is
present on the console of the Polaris
Frontier snowmobile in both
English (PN 7078056) and French
(PN 7078057):

S Read and understand warnings

and the Owner’s Manual before
operation. Severe injury or death
can result from not heeding the
warnings.

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Night riding, limited visibility , or excessive speeds may cause over-

driving of headlights resulting in insufficient time to react to terrain
changes or avoid unexpected obstacles.

S This vehicle is capable of high speeds. Buried objects or uneven ter-

rain can cause loss of control. Exercise extreme caution when oper­ating in unfamiliar terrain.

S This vehicle is designed for adult use only. The vehicle size, speed

capabilities and control requirement prohibit operation by children.

S Operating this vehicle with a passenger (on approved models only)

reduces your ability to control the vehicle due to the added weight
and change in weight distribution. Reduce vehicle speeds and allow
extra space for maneuvering since steering control may be reduced.

S Always wear an approved helmet, eye protection, and adequate

clothing while operating this vehicle.

S The Auxiliary Shut-Off Switch is the primary means of stopping this

vehicle in case of an emergency and is located on the top of the
throttle control assembly. Depress the switch to stop the engine and
vehicle. Routinely check this switch for proper function with the en­gine idling.

S Steering and braking ability are greatly reduced when operating on

hard-packed snow, ice, or when crossing roads. Reduced speed and
extra care are required to maintain vehicle control.

S Carbide skags and studs enhance vehicle control on ice or hard-

packed surfaces. Care must be taken to maintain a proper balance
of ski carbides to track studs to maintain proper vehicle control. (See
the Owner’s Manual for proper use of traction accessories.)

S Never permit a guest to operate this vehicle unless the guest has

read the Owner’s Manual and warnings.

+

27

SAFETY

Safety Decals And Locations

Standard Reverse Warning Decal

The reverse warning decal (PN 7079002) is located above the
instrument housing:

CAUTION

Do not attempt to shift until
machine has come to a
complete stop or chaincase
damage may occur.

WARNING

VEHICLE CAPABLE OF
EXCESSIVE REVERSE
SPEED!

Reverse operation may be
dangerous even at low
speeds. Steering control
becomes difficult in reverse.
Misuse of reverse may result in injury. Avoid turning at sharp
angles in reverse.

Transmission may not always be in the gear indicated by the shift
lever. Always apply throttle slowly.

On machines with reverse it is especially important to maintain
track tension as specified in the Owner’s Manual. If specified track
tension is not maintained severe damage to the machine may
occur, which may result in loss of vehicle control. Loss of vehicle
control may result in severe personal injury or death.

For more information: See Operator’s Safety and Maintenance
Manual supplied with reverse kit.

+

28

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. Throttle Control

15. Reverse Lever

16. Headlight Dimmer Switch

17. Park Brake

18. Handlebar Grip
Warmer Switch

19. Thumbwarmer S witch

1

13

14

2

3

5

12

4

9

10

11

7

8

6

15

16

17

18

19

29

FEATURES AND CONTROLS

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Storage/Rear

7. Taillights

8. Cargo Carrier

9. Snow Flap

10. Suspension

11. Tr ack

12. Trailing Arm

13. Block Heater (under hood)

14. Nosepan

15. Front Bumper

16. Skis

1

2

3

4

5

6

7

11

10

14

12

16

15

8

9

13

30

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 service EFI systems.

When enabled, the CHECK ENGINE light
will blink in numerical sequences to
indicate the type of failure. For example: two blinks, pause, one blink
is the sequence for code 21. To enable the blink codes, put a 30 amp
automotive fuse in the ACS bypass three times within 2 1/2 seconds,
leaving it in the third time. NOTE: Disconnect the negative battery
lead for 10 seconds to clear the code.

MIL Diagnostic Code Summary

CODE MIL Description

21 Yes Lost synchronization

Synchronization of crankshaft position lost

22 Yes Throttle position sensor circuit error

Sensor signal is shorted to ground or at battery potential

23 Yes RAM error

Hardware failure or serial EEPROM not initialized or failure

24 Yes Speed circuit / sensor error

Crankshaft position sensor failure (if MIL stays on when cranking
there is no speed sensor input)

31 Yes System too lean

Lambda sensor shorted to ground or battery voltage

32 Yes 02 Sensor circuit error

Short to battery or no activity detected

33 No System too rich

Short term adaption at upper or lower limit.

34 No Maximum adaption limit reached

Long-term adaption at upper or lower limit

42 Yes Temperature sensor circuit error

Sensor short to ground/battery voltage/implausible signal

61 NA End of sequence message

If the ACS 30 AMP bypass fuse is left in, electrical drainage will
occur. To avoid electrical drainage, always remove the fuse from the
ACS bypass AFTER the End of Sequence message (61) appears.

CAUTION

31

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, take your
Frontier to a qualified Polaris dealer for diagnostic service.

Low Oil Pressure Light

A l ow oil pressure indicator light will alert you to a low oil condition.
When the low oil pressure indicator light is on, visually check the oil
level on the dipstick. If the oil level is below the SAFE mark,
continued operation will cause serious engine damage. Add the
recommended oil before further operation of the snowmobile. See
page 113 for the part numbers of Polaris-recommended products.

CAUTION

Operating the snowmobile without proper engine lubrication can
result in serious engine damage. Always check the oil level on the
dipstick when the low oil pressure light illuminates. Add the
recommended oil to maintain the oil level between the SAFE and
ADD marks on the dipstick.

CAUTION

Mixing brands or using a non-recommended oil may cause serious
engine damage. We recommend the use of Polaris Premium 4
Synthetic 0W-40 engine oil for your snowmobile. Never mix brands.

32

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 block heater
whenever temperatures drop below --20° F. (-- 30° C.).

Open the hood to access the block heater plug-in (see page 29 for
location). P lug the cord into a 110 V outlet when the snowmobile will
be parked in subzero temperatures overnight or for more than a few
hours. Unplug the cord and return it to its storage area before starting
and operating the snowmobile.

Driving the snowmobile before unplugging the block heater could
result in damage to the heater and other components. Always
unplug the block heater before operating the snowmobile.

CAUTION

33

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 conditions. We recommend
starting with factory settings and then customizing each adjustment
individually to suit rider preference. The machine should be
methodically tested under the same conditions (trail and snow
conditions, vehicle speed, riding position, etc.) after each adjustment
until the best ride is achieved. Adjustments should be made to one
area at a time in order to properly evaluate the change.

All snowmobile suspensions have a front and a rear suspension, each
of which has adjustment options.

Independent Front Suspension (IFS)

The IFS is made up of the skis (1),
front shocks and springs (2), and
the components that connect these
parts to both the steering, such as
the tie rods (3), and to the machine
itself, such as the trailing arms (4).
Front suspension adjustments
include shocks, springs, toe, and
camber.

IFS Adjustment Options

S Front shock spring preload
S Optional springs
S Optional valving (if equipped with Fox

t, RYDE FXt or Walker/

Evanst shocks)

S Indy Select (if equipped)

1

2

3

4

34

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 using full travel of the ski
shock, push the jounce bumper down as far as it will go on the shock
rod and test ride the machine. The bumper will move up on the rod in
direct relation to the amount of travel. If the shock travel is full, the
bumper will be seated at the top of the shock.

Shock Absorber Components

1. Retainer

2. Shock Rod

3. Jounce Bumper

4. Body

5. Threaded Spring Preload Adjuster Nut

Always verify ski alignment before making adjustments to the IFS.
See page 103 to check alignment. If the skis are misaligned, see
your dealer, as the camber adjustment may also be affected.

WARNING

1

2

3

4

5

35

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 the same adjustment.

To increase front shock spring preload,
grasp the spring and turn it to the
right. Turn it to the left to decrease
preload. In the illustrations at right, B
indicates high preload and C indicates
low preload.

Increasing the spring preload too much may adversely affect the
handling of the snowmobile and the performance of the rear
suspension. Decreasing the spring preload too much may allow the
upper spring retainer to fall off. Always leave at least one thread
showing above the nut (A).

C

A

B

Always leave one thread showing above the adjuster nut.
On models equipped with a plastic adjuster nut, if the nut is
unscrewed from the threaded body, the nut will break.

CAUTION

36

THE PERFECT FIT

Front Suspension Adjustments

If the spring preload is at its maximum and you want more adjustment:

S Remove the existing spring and install the next highest rate spring,

or

S Increase compression damping on Indy Select shocks (PE 52)

See your dealer for details.

37

THE PERFECT FIT

Front Suspension Adjustments

Indy Select IFS Shock

Some snowmobiles are equipped with Indy Select IFS shocks, which
allow 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 turning the screw clockwise, the compression of the shock
increases, stiffening the ride. By turning counterclockwise, the
compression decreases, softening the ride.

The factory setting is in the softest position (screw all the way out ­counterclockwise). If bottoming occurs, the Indy Select feature should
be used to achieve the desired ride effect. One-half turn will affect the
ride considerably. There are about three turns of adjustment available.
If experimenting with this adjustment feature, turn the screw only 1/4
turn at a time. And always adjust both shocks equally.

A

38

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 and adjustments involve a compromise, or
trade-off. For example, a suspension set up for snow-cross racing
would provide a very stiff ride on the trail. A s uspension set up for
trail riding would bottom out harshly on a snow-cross course.

A decal outlining rear suspension set-up options is located on the
clutch cover. It provides a guideline for initial suspension set-up.
Additional adjustments can be made from this point. Make
adjustments to one area at a time so you can evaluate the change. F or
further assistance, see your dealer.

Suspension Performance Tips

S Rider weight usually determines the position at which the spring pre-

load should be set. However, this may vary with riding style. With
a little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.

S In deep snow, a new Hi-fax will offer improved performance over

worn Hi-fax. It can also improve top speed.

S When riding on ice or hard-packed snow, adding a set of bogie

wheels to the rail may enhance the machine’s performance. Bogie
wheel kits are available from your dealer.

S Polaris offers track kits for improved flotation in deep snow. See

your dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce
moisture and rust build-up and ensure proper function of t he
suspension components. Grease rear suspension pivots before
adjusting the rear suspension. Refer to Suspension Maintenance on
pages 105-106.

39

THE PERFECT FIT

Rear Suspension Adjustments

Rear Spring Tension

To adjust rear torsion spring tension, rotate the three-position cam
using the engine spark plug t ool.

Different rate torsion springs are available if a firmer ride is desired.
Contact your dealer for more information.

The following information is provided only as a guideline to be used
for initial suspension set-up. Your set-up may vary based on your
desired riding style.

1 - Turn screw clockwise to stiffen compression.
2a - Low tension
2b - Medium tension
2c - High tension

2c

1

2a 2b

40

THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the EDGE rear suspension
torsion spring preload, measure the
distance between the ground and rear
bumper. This is measurement X.

Take the first measurement with no
rider and with the rear suspension at
full extension. NOTE: The rear
bumper may need to be lifted upward
slightly to fully extend the rear
suspension.

Next, have the rider drop down hard
on the seat and bounce up and down
several times, collapsing the rear
suspension. W ith the rider seated,
measure the distance between the
ground and the rear bumper at the
exact location used for measurement
X. This is measurement Y.

To determine sag, commonly referred
to as ride-in, subtract measurement Y
from X (Sag=X-Y). Adjust sag by
rotating the torsion spring preload cams located on the rear torque arm.
Use the illustration or the decal found under the hood for reference.
The ideal amount of Sag for the EDGE rear suspension is four inches
(X-Y=4).

If the rear suspension rides in less than three inches or more than five
inches with the torsion spring preload cams at t heir maximum range of
adjustment, optional torsion springs (softer or stiffer, respectively) may
be required. This is only an initial set-up, and final spring preload may
vary based on rider preference and riding conditions.

X

Y

41

THE PERFECT FIT

Rear Suspension Adjustments

Indy Select Rear Shock

The Indy Select rear shock allows for adjustments to the compression
valving. Locate the adjustment screw (A) near the base of the shock.
In half-turn increments, turn the screw clockwise to increase
compression valving and stiffen the ride, or counterclockwise to reduce
compression and soften the ride. There are approximately three full
turns of adjustment available.

If bottoming continues after the screw has been turned fully clockwise,
the torsion spring should be adjusted (see page 39). Return the screw
to its original starting position after the torsion spring has been
tightened.

A

42

THE PERFECT FIT

Rear Suspension Adjustments

Optional Coil Springs

Different rate coil springs are available for some shocks if a firmer ride
is desired. Contact your dealer for more information.

Suspension Coupling

On all Polaris snowmobile rear suspensions, there are two torque arms
that control the movement of the rail beam. Prior to the advent of
suspension coupling, these torque arms could move independently of
each other. Rear suspension coupling links the movement of the front
and rear torque arms to each other . There are two types of rear
suspension coupling.

Front To Rear Coupling and the Front Rear Scissor
Stop (FRSS)

The front rear scissor stop (FRSS) couples the movement of the front
torque arm with the rear torque arm and limits the amount of
independence between the movement of the front torque arm and the
rear torque arm.

When hitting a bump, the front torque arm starts to compress. The
FRSS links that movement to the rear torque arm, causing it to
compress and raise the rear suspension up as one, allowing the
suspension to hit the bump only once and eliminating kickback. Your
FRSS is preset at the factory.

43

THE PERFECT FIT

Rear Suspension Adjustments

Rear To Front Coupling and th e Rear Rear Scissor
Stop (RRSS)

The rear rear scissor stop couples the movement of the rear torque arm
with the front torque arm and limits the amount of independent
movement between the rear torque and the front torque arm.

Adjusting the RRSS either allows more weight to transfer to the rear
for more traction, or allows less weight to transfer to the rear, resulting
in improved cornering performance. An adjustment dot is located on
the RRSS. This dot is on the longest end of the scissor stop.

RRSS Attributes

Moving the RRSS to a higher position, or forward hole, will have the
following effects on the suspension:

S Reduced weight transfer
S Improved chatter bump ride
S Improved cornering performance

44

THE PERFECT FIT

Rear Suspension Adjustments

Weight Transfer During Acceleration

Rear Rear Scissor Stop (RRSS)

The preferred method for controlling weight
transfer during acceleration of the EDGE rear
suspension is by adjusting the RRSS. The
RRSS is located in the best overall trail riding
position when delivered from the factory.

To decrease weight transfer under acceleration (for
improved cornering), rotate the RRSS to a higher
position with the scissor stop tool (1) located in your tool kit.

To increase weight transfer or ski lift during acceleration, move the
RRSS to the rearward hole on high position. The RRSS may also be
rotated to a lower position for even more weight transfer if desired.

A - Stock Position - This setting is
most desirable for trail riding.

B - Medium or High Position (standard
hole location) - This setting will
decrease weight transfer.

C - Rearward Upper Position (optional
hole location) - This setting will
increase weight transfer.

NOTE: Your dealer can help you with
initial set-up and additional set-up in­structions to help you achieve your op­timum ride.

1

A

B

C

45

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 handlebar
to left or right for access to back
nuts).

NOTE: It may be necessary to pry the
adjuster blocks apart with a screw driver.

3. Adjust the handlebar to the desired height. Be sure handlebars,
brake lever and throttle lever operate smoothly and do not hit the
gas tank, windshield or any other part of the machine when turned
fully to the left or right.

4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-18
Nm).

5. Replace the handlebar cover.

Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control and
possible serious personal injury or death. Follow the adjustment
procedures exactly , or see your Polaris dealer for service.

WARNING

A

46

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 models. Order
PN 2870668.

Use only Polaris parts and accessories on your Polaris snowmobile.
Use of unapproved parts and accessories may result in:

S Non-compliance with government/industry requirements
S Voiding of warranty
S Personal injury to self or others

This applies to, but is not limited to: brakes, clutches, fuel systems
and exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use ap-
proved Polaris parts. Please see your Polaris dealer for service.

Traction Products

CAUTION

Use of traction products such as studs, ice growsers, etc. will
damage the rear close-off cooler of the Frontier. Never install
traction products on your Frontier snowmobile.

47

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 enjoyable snowmobiling experience.

Throttle Lever

The throttle is one of the primary controls of your snowmobile. If it
should malfunction, loss of control could result.

Make sure the t hrottle lever compresses evenly and smoothly. The
lever should immediately return to the idle position without binding or
hesitation. If the throttle does not function smoothly, DO NOT start
the engine. Have the throttle serviced immediately.

Throttle Safety Switch

Test the throttle safety switch system daily, before the machine is
operated. See page 60.

Worn, damaged, or malfunctioning components may cause serious
injury or death. Before starting the engine, check all Pre-Ride
Inspection components to be sure of proper operation.

WARNING

48

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 i s
squeezed, it should move no
closer to the handgrip than
1/2″ (1.3 cm) (A). A
distance less than this indicates low brake fluid level or air in the
hydraulic system. Refer to the brake bleeding information on page 88.

Brake Lever Feel

A hydraulic system multiplies the force of your hand squeezing the
brake lever. Proper operation depends on an adequate supply of air and
moisture-free hydraulic brake fluid in the system. If the brake lever
feels “spongy” when squeezed, check the level and condition of the
fluid. Also check for the presence of air in the fluid system. Refer to
page 88 for more information, or see your dealer for service.

Replace brake fluid at least every two years with Polaris DOT 3 high
temperature brake fluid. All DOT 3 brake fluid i s not alike. We
recommend that you use only Polaris brake fluid. See page 113 for the
part numbers of Polaris-recommended products.

A

Continued use of “spongy” brakes may cause a complete
loss of brakes, which could result in serious injury or death.
Always have the brakes serviced at the first sign of
sponginess.

WARNING

49

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 brake handle and push
forward on the brake lever lock. Hold the lock forward and release the
brake handle.

If the brake handle is squeezed tightly enough, the lock will move
freely into place. Do not force the lock or it may break. To release the
lock, squeeze and release the brake lever. The lever will return to the
unlocked position. The brake light on the console will light up when
the park brake lever is locked and the engine is running. It will also be
lit when the service brake is in use. If the brake light does not come on
when the park brake or service brake is in use, have it serviced by your
dealer.

1. Brake Lever

2. Park Brake Lever Lock

3. Master Cylinder Reservoir /
Cover

4. Fluid Level Indicator

4

3

1

2

If the park brake lever lock is partially or entirely engaged while
riding, overheating of the brakes could occur, resulting in brake
damage. In extreme cases it could cause a fire, which could result
in serious injury or death. Always release the park brake lock
before operating the snowmobile.

WARNING

50

PRE-RIDE INSPECTION

Steering System

Manually turn the skis completely to the right and t o t he 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 at high speeds for extended periods of time in marginal
lubrication could severely damage track rods, break track edges, and
cause other track damage. Examples of marginal lubrication would
include frozen bodies of water without snow cover, icy trails, and
no-snow conditions.

NOTE: Track damage or failure caused by operation on ice or in poor
lubrication conditions is not covered by warranty.

Hood Latches

The hood of the snowmobile protects the operator from moving parts
and aids in sound emission control and other functions. Under no
circumstances should your snowmobile be operated with the hood open
or removed.

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.
Maintain the oil level between the SAFE and ADD marks on t he
dipstick. See page 59.

Always inspect the track for damage before using the vehicle.
Operating the snowmobile with a damaged track increases the
possibility of track failure, which could cause loss of control
resulting in serious injury or death.

WARNING

51

PRE-RIDE INSPECTION

The following items must be checked before each use of the vehicle.
Check these items after starting the engine (see page 52), but before
putting the machine into motion.

Transmission

Make sure the reverse is not engaged before squeezing the throttle.

Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push down to
stop the engine. Pull up to release and start the engine. See page 60.

Tether Switch

If your machine has a tether switch, make sure the engine shuts off
when the tether is removed from the switch. See page 60.

Lights

Check the headlight (high and low beam), taillight, and brake light for
normal operation.

Mirrors

If equipped, adjust your mirrors so they can be used to their full
advantage.

Operating Area

Make sure you have a clear area all around your snowmobile, including
an area clear of bystanders. There’s always the possibility of some
sideways vehicle movement, of applying a little more throttle than
intended, or of debris being thrown by the track. If the surrounding
area is clear you before you start, you can devote your full attention to
operating the snowmobile.

52

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 t he ACS
system to “wake up.”

3. After the engine starts, release the key to the ON position.

NOTE: The Frontier is equipped with a recoil for emergency starting.
Seepage62.

Before starting the engine, always refer to all safety warnings
pertaining to snowmobile operation. Never start your snowmobile
without checking all components to be sure of proper operation.
See Pre-Ride Inspection section beginning on page 47.

WARNING

53

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 heat build-up during the first few hours of operation will
damage close-fitted engine parts. Do not operate at full throttle or high
speeds for extended periods during the first 100 miles (160 km)of use.
Vary the throttle openings and m achine speeds to reduce friction on all
close-fitting machined parts, allowing them to break in slowly without
damage.

Perform Fluid Checks

Perform regular checks on fluid levels, lines, and all other important
areas of the machine. Perform the first oil and filter change at 1000
miles (1600 km). See page 79.

CAUTION

Failure to follow the procedures outlined in the Engine Break-In
section of the owner’s manual could result in serious damage to
the snowmobile. Follow all procedures as outlined.

54

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 59.

We highly recommend the use of only Polaris products for your
snowmobile. We’re continuously testing lubricants and provide the
highest performance products available for your snowmobile’s engine.
See page 113 for t he part numbers of Polaris-recommended products.

Serious engine damage can occur without the proper lubrication.
Check the oil level often during the first tankful of fuel. Maintain
the oil level between the SAFE and ADD marks on the dipstick.

CAUTION

CAUTION

Mixing brands or using a non-recommended oil may cause serious
engine damage. We recommend the use of Polaris Premium 4
Synthetic 0W-40 engine oil for your snowmobile. Never mix brands.

55

OPERATION

Track Warm-Up

Follow these steps to ensure proper warm-up

of the engine, drive train and track.

1. Use an appropriate stand t o securely
support the rear of the snowmobile at
the rear bumper. The track should be
approximately 4″ (10 cm) off the
ground.

2. Start the engine and allow it to warm
up two to three minutes.

3. Depress the throttle abruptly and allow the track to rotate several
revolutions. NOTE: It will take longer to warm up the track
sufficiently during colder outdoor temperatures.

4. Release the throttle, apply the brakes, shut off the engine and lower
the machine to the ground.

5. Grasp the skis by their front loops and move them from side to
side. This will loosen frozen snow from the ski bottoms, allowing
the machine to move forward more easily.

6. The engine, drive system and track are now properly warmed up
and the machine may be driven following normal safety practices.

Inadequate cooling and lubrication will lead to overheating of the
slide rail and track, resulting in premature wear and failure.
Reduce speeds and frequently drive into fresh snow to allow
adequate cooling and polishing of the slide rail and track surfaces.
Avoid operating on ice, hard-packed surfaces or roads.

CAUTION

A loose track or flying debris could cause serious personal injury
or death. Stand clear of the front of the machine and the moving
track. Never hold the snowmobile up or stand behind it while
warming up the track. Do not use excessive throttle during
warm-up or when the track is free-hanging. Be sure the rear
support is stable.

WARNING

56

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 where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area. Engine

exhaust fumes are poisonous and can cause loss of con­sciousness or death in a short time.

The engine exhaust from this product contains chemicals known
to cause cancer , birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

WARNING

WARNING

57

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 octane gasoline available across the country, so we encourage the
use of premium fuel when possible.

Using fuels with a lower than recommended octane or operating with
obstructed fuel systems will result in serious engine damage.
Always use the recommended fuels for your machine.

CAUTION

58

OPERATION

Fuel

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 milliliters per liter) of gasoline to prevent engine damage
resulting from fuel system icing and lean fuel mixtures. Never use
deicers or additives containing methanol. S ee page 113 for the part
numbers of Polaris-recommended products.

If you use oxygenated fuel containing ethanol, additional alcohol
deicers or water absorbing additives are not required and should not be
used.

Prolonged exposure to petroleum based products may damage
paint. Always protect painted surfaces when handling fuel.

CAUTION

59

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 ADD
(B) marks on the dipstick.

Throttle Position Sensor (TPS)

All throttle bodies have been preset at the factory for adequate fuel
supply at all altitudes. No adjustment is required. Any service must be
performed by a Polaris dealer trained to service EFI systems.

A

B

Any attempt to adjust the TPS without proper tools and training
WILL result in deteriorated engine performance and could result
in SEVERE engine damage. NEVER attempt to adjust the TPS.
Always have your Polaris dealer perform any service on the TPS.

CAUTION

60

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 switch
system daily before operation.

While seated in a normal riding
position, and with the engine
idling, hold the throttle lever pin
stationary by exerting pressure on
the pivot pin in the direction shown
in the illustration (B). Apply a
slight amount of throttle. A
properly functioning switch must shut down the engine.

The throttle safety switch is designed to stop the engine whenever all
pressure is removed from the throttle lever and the throttle cable or
valves do not return to the normal closed position.

A

B

Operating the snowmobile with a faulty throttle safety switch
can result in serious injury or death in the event of an accident.
If the throttle safety switch does not shut off the engine during a
throttle system malfunction, immediately push down the engine
stop switch. Do not start the engine again until the malfunction
has been corrected by your dealer.

WARNING

61

OPERATION

Throttle Lever

If the engine stops abruptly when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and throttle body to determine
what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several
times. The lever and cable must return to the idle position quickly
and completely.

4. If the throttle lever operates properly, turn the ignition switch on
and go through normal starting procedures.

5. If the engine doesn’t start, take the snowmobile to an authorized
Polaris dealer for service.

Excessive free play in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, see your
authorized Polaris dealer for service.

If an emergency exists and it’s necessary to start the engine, the throttle
safety switch and engine stop switch may be disconnected from the
wire harness. When these switches are disconnected, the ignition key
switch must be used to shut off the engine. DO NOT continue to
operate the machine with the throttle safety switch disconnected. See
your authorized Polaris dealer for service as soon as possible.

An improperly functioning throttle lever may cause erratic machine
behavior and loss of control, which could result in serious injury or
death. If the throttle lever does not work properly, DO NOT start
the engine.

WARNING

62

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. Refer to page 60 for more information about
the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

Emergency Starting

Your machine is equipped with a recoil under the hood for emergency
starting.

1. Turn the key to ON.

2. Pull the kill switch (shut-off switch) up to RUN.

3. Grasp the starter handle and pull slowly until the recoil engages.

4. Slowly pull the recoil handle, rotating the engine until it becomes
harder to pull. The engine is now near top dead center.

5. Allow the rope to partially retract into the recoil (until a
comfortable stance for starting is achieved).

6. Pull the handle abruptly to start the engine.

Excessive or repetitive use of brakes for high speed stops will
cause an overheated brake system. This overheated condition
could cause sudden loss of brakes and/or fire, resulting in
serious injury or death.

When traveling on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat and
result in brake failure.

WARNING

63

OPERATION

Reverse Operation

Make sure the shift lever i s 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 felt, gently apply
the throttle to move the gears to a different position and try to shift
again.

The transmission may not always be in the gear indicated by the shift
lever. Apply the throttle slowly until you’re sure which gear is
engaged.

Sometimes the drive belt will drag in the drive clutch, causing slight
tension in the transmission and making it hard to shift. Shutting the
engine off will remove this tension and ease shifting. This should only
happen during the break-in of a new belt or when the drive/driven
clutch center distance is too long. If this is the case, belt tension
adjustments should be made by your dealer.

Improper reverse operation, even at low speeds, may cause loss
of control, resulting in serious injury or death.

S Always look behind the vehicle before and while backing.
S Always avoid sharp turns.
S Shift to or from reverse only when stopped.
S Always apply throttle slowly.

WARNING

64

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 track stands available to fit all mod­els. See your dealer for more information.

65

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
spindles (not to the ski loops) to prevent damage to the steering
components. Remove the drive belt before towing, and have a rider on
the towed snowmobile to operate the brake and steering when
necessary.

Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting
in serious injury or death. DO NOT tow toboggans, sleds,
saucers, or any type of vehicle with a rope. Only a stiff metal
pole connecting the towed object and the tow hitch on the
snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2
meters) long to prevent any possibility of contact between the
snowmobile’s track and a person riding in the towed object.

Braking distances increase when towing loads. Slow down to
maintain control of the snowmobile.

WARNING

Towing a disabled snowmobile with the drive belt in place can
result in serious damage to the engine and drive system. Always
remove the drive belt from a disabled snowmobile before towing.

CAUTION

66

-NOTES-

67

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 at 150 miles (240 km), 1000 miles
(1600 km) and 2000 miles (3200 km). These inspections should be
performed by a qualified service technician. For continued optimum
performance and component life, continue maintenance checks at 1000
mile (1600 km) intervals. Have your dealer perform a throttle body
adjustment at 4000 miles (3200 km).

All necessary replacement parts and labor incurred, with the exception
of authorized warranty repairs, become the responsibility of the
registered owner. If, during the course of the warranty period, part

failures occur as a result of owner neglect in performing recommended
regular maintenance, the cost of repairs are the responsibility of the
owner.

Personal safety is critical when attempting to service or adjust your
snowmobile. If you’re not familiar with safe service or adjustment
procedures and the use of tools, or if you don’t feel comfortable
performing these tasks yourself, contact an authorized Polaris dealer
for service.

EFI System

There are no maintenance adjustments required for the EFI system.
Any service to the EFI system must be performed by an authorized
Polaris dealer with training in EFI systems.

68

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 or

before

long trip

150 M.

(240 km)

1000 M.

(1600 km)

2000 M.

(3200 km)

See

Page

Check brake operation and
adjustment

Daily 48, 85

Test engine stop switch Daily 51

Test tether strap Daily 51

Check track condition Daily 50

Test throttle safety switch Daily 60

Check throttle lever operation Daily 47, 61

Check operation of headlights,
taillight, brakelight

Daily 51, 89

Check park brake function Daily 49

Check oil level Daily 59

Check coolant level Daily 82

Check track alignment X 100

Steering arm and tie rod ends X 102

Check throttle cable condition X -

Check battery fluid level X 109

Check track tension X 99

Check chaincase oil level X 75

Check gearcase oil level X 75

Check drive chain tension X 84

Check drive belt condition X 93

Check for and tighten loose
suspension mounting bolts

X 106

Tighten ski saddle/spindle bolts X -

Check front limiter strap
condition, tighten bolts

X -

Check ski skags- replace when
worn to half original diameter

X 104

Check Hi-fax thickness, have
dealer replace when worn

X 105

Tighten rear idler wheel bolts X 100

69

MAINTENANCE

Maintenance Chart

Item Weekly or

before

long trip

150 M.

(240 km)

1000 M.

(1600 km)

2000 M.

(3200 km)

See

Page

Tighten idler adjust bolt jam nuts X 100

Check spark plug condition, re ­place annually

X 77

Inspect coolant filter, replace if
necessary

X X X 83

Grease ski pivots X X X 72

Grease ski spindles X X X 72

Grease center steering arm(s) X X X 72

Lubricate steering post support
bracket and pivot (aerosol)

X X X 72

Grease lower steering post pivot X X X 72

Change oil and oil filter (annually) X X 79

Grease driveshaft bearing
(always perform before storage)

X X 74

Flush chaincase 500 mi. X X 75

Grease rear suspension pivot
shafts

500 mi. X X 73

Grease jackshaft b earing
(always perform before storage)

X X 72

Lubricate throttle cable X X 74

Check clutch alignment and offset X X 92

Check cooling system level,
specific g ravity

X X 82

Inspect oil filter and replace X X 79

Inspect oil line condition X -

Inspect fuel filter and replace X X 78

Check brake fluid level X X 87

Inspect fuel lines and replace X 78

Inspect exhaust system for weak
or missing retaining springs

X 80

Inspect exhaust pipe for cracks or
damage

X 80

Inspect clutch sheaves for
damage, wear, belt residue

X 91

70

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 Polaris Servicing Dealer

Servicing T echnician

Date Mileage

1000 Mile (1600 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing T echnician

Date Mileage

2000 Mile (3200 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing T echnician

Date Mileage

3000 Mile (4800 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing T echnician

Date Mileage

4000 Mile (6400 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing T echnician

Date Mileage

71

MAINTENANCE

Maintenance Log

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing T echnician

Date Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing T echnician

Date Mileage

Type of Service

72

MAINTENANCE

Lubrication

Lubricate the suspension and steering components with Polaris
Premium 4 all season grease annually or about every 1000 miles
(1600 km). See page 113 for the part numbers of
Polaris-recommended products.

The illustration shows the location of suspension and steering
components. A + indicates a grease point or fitting.

S Grease the left and right spindles. Raise the front end of the ma-

chine to permit better grease entry into the spindle area.

S Lubricate both of the front ski pivots at the fittings as shown.
S Grease the jackshaft and driveshaft clutch side bearings.
S Use an aerosol lubricant on the steering post support bracket.
S Grease the center steering arms.
S Grease the steering post lower pivot.
S Grease the rear suspension pivot shafts (raise the rear of unit).

A grease gun kit, complete with grease and adaptors, is available to
lubricate all fittings on Polaris snowmobiles. See page 113.

+

+

+

+

+

73

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
suspension. For detailed information about suspension lubrication and
adjustments, see your Polaris dealer.

NOTE: Lubrication points are indicated by a L.

L

L

L

L

74

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). Push the clutch back onto
the shaft and replace the clutch retaining bolt.
Torque to 18 ft. lbs. (24 Nm).

Driveshaft Bearing

Inject grease into the fitting on the speedometer
drive adaptor until grease purges from inside or
outside the bearing seal (approximately two
pumps).

Throttle Cable

Lubricate the throttle cable lightly with
grease or oil. With the engine off, turn
the handlebars to the left and lubricate
liberally as shown.

+

+

+

75

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 S AFE marks on the dipstick. Add Polaris chaincase oil
through the dipstick opening if needed. Do not overfill. Seepage113
for the part numbers of Polaris-recommended products.

Flush the chaincase after the first 500 miles, then every 1000 miles or
seasonally. Clean the magnetic plug (B) whenever checking or
changing lubricant.

A

B

76

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 your
machine. A spark plug with a heat range too high will cause engine
damage. A spark plug with a heat range too low will cause excessive
fouling and engine malfunctioning.

NOTE: Always carry spare spark plugs in case of an emergency.

Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.

CAUTION

77

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

The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect
carburetion adjustments.

Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil or
use of non-recommended injection oil.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the
tool pouch, rotate the spark plug
counterclockwise to remove.

3. Reverse the procedure for spark plug
installation.

4. Torque to 18-22 ft. lbs. (24-30 Nm).

5. Install spark plug cap.

WARNING

A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.

1

78

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 best way to check the fuel filter is with fuel pressure. If fuel
pressure is low, remove the filter and check pump pressure. If pressure
is still low, the pump may need replacement. See your dealer . But if
the pump pressure is good after removing the filter, then the fuel filter
is plugged and must be replaced. The fuel filter should last the life of
the machine if the fuel used is always of good quality.

Fuel Lines

Inspect the fuel lines regularly. Give special attention to the system’s
fuel line condition after periods of storage. Normal deterioration from
weather and fuel compounds may occur.

3

1

2

Operating the snowmobile without the intake filters may cause
throttle body icing and result in poor fuel economy or throttle
body malfunction. Always reinstall the filters before operating.

CAUTION

Kinking the fuel lines or using a pliers or similar tools to remove
fuel lines may cause damage to the lines. If a fuel line has been
damaged or kinked, replace it promptly.

CAUTION

79

MAINTENANCE

General Maintenance

Oil and Filter Chang e

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 the marine industry.

1. Position the vehicle on a level surface and run the engine for 2-3
minutes to slightly warm the oil. NOTE: Running the engine any
longer may cause engine overheating. It may also cause the oil to
become too hot for safe removal with the oil vacuum pump.

2. Remove the dipstick and draw out the oil, following the
instructions provided with the oil vacuum pump. Fish the vacuum
tube around in the crankcase to remove as much oil as possible.

3. Place shop towels beneath the oil filter to catch spills. Using an
appropriate oil filter wrench, such as Polaris PN PV-43527), turn
the filter counterclockwise to remove. Dispose of the used oil and
filter properly.

4. Clean the filter sealing surface on the crankcase with a clean, dry
cloth.

5. Lubricate the o-ring on the new filter with a film of new engine oil.
Check to make sure the o-ring is in good condition.

6. Install the new filter and turn by hand until the filter gasket
contacts the sealing surface, then turn an additional half turn.

7. Add 2 quarts (1.9 ltr) of Polaris Premium 4 synthetic oil through
the dipstick hole. Reinstall the dipstick.

8. Start the engine and allow it to idle for one to two minutes. Stop
the engine and inspect for leaks.

9. Check the oil level on the dipstick and add oil as needed to bring
the level to the SAFE mark on the dipstick.

80

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 m uffler and pipes for
cracks or damage. Check for weak or missing retaining springs or
damper/support grommets.

Engine Cooling

The cooling system on liquid cooled models consists of the following
major components:

S Coolant bottle
S Water pump
S Cylinders
S Heads
S Inlet and outlet manifolds
S Pressure cap
S Heat exchangers

Hot exhaust system parts can cause serious burns. Allow
adequate time for the exhaust system to cool. Never perform
this procedure with the engine running.

WARNING

81

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 water may be
increased. Use Premium 60/40 anti-freeze coolant, which is already
premixed and ready to use. Do not dilute with water. See page 113 for
the part numbers of P olaris-recommended products.

Never exceed a 60% antifreeze/40% water mixture. Contact you dealer
if greater protection is required.

NOTE: Never add tap water to the cooling system. Minerals cause
deposits and may react adversely with the metals in the engine and
cooling system.

Coolant High Temperature Indicator Light

The high temperature indicator light is controlled by t he electronic
control unit (ECU). If the engine coolant reaches a certain
temperature, the ECU completes a circuit that turns the light on. If
you must drive your machine after the high temperature indicator light
has come on, drive slowly and stop frequently to allow the engine to
cool down. See your dealer.

82

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 l evel is controlled by the recovery system. The
recovery system components are:

S Coolant bottle
S Engine filler neck
S Pressure cap
S Connecting hoses

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine,
the system should be completely drained every two years and a fresh
50/50 or 60/40 mixture of antifreeze and distilled water should be
added. This service must be done when the engine is cold. Ask your
Polaris dealer to check the coolant when he performs the fall tune-up
on your snowmobile.

A

Operating the snowmobile with insufficient coolant will result in
overheating and serious engine damage. Always maintain the
coolant level as recommended.

CAUTION

83

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 properly
mixed coolant to the FULL COLD mark.

2. Elevate the front end of the machine slightly to aid in bleeding of
the heat exchangers.

3. Add coolant to the coolant bottle to bring the level to the FULL
COLD mark.

4. Start the engine and run at a fast i dle for two to three minutes to
allow further bleeding of air.

5. Stop the engine and check the coolant bottle level. Fill as required.

6. Feel the heat exchangers under the running boards. If the system is
bled properly, they’ll be warm to the touch. If they’re not, repeat
step 4. Lift the front of the machine slightly to assist in the
bleeding.

7. Replace the pressure cap and carefully lower the front end of the
machine.

Steam and hot liquids will cause serious burns to your skin.
Never bleed the cooling system or remove the pressure cap
when the engine is warm or hot.

WARNING

If coolant flow becomes restricted, coolant loss, air lock or engine
damage may result. Periodically inspect and/or replace the cooling
system components as needed to prevent restricted coolant flow.

CAUTION

84

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. Finger tighten the adjuster bolt (B)
until it can no longer be adjusted
by hand, then back off 1/4 turn.

4. Tighten the jam nut while holding
the adjuster bolt.

5. The chain is now tensioned.
Release the brake lever lock.

A

B

85

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 must be replaced when the brake pad material becomes
thinner than the backing plate (approximately 1/16″). A kit is available
for replacing brake pads. See your dealer.

A

Brake failure during operation can result in serious injury or death.
Properly functioning brakes are vital to your safety. Be sure the
brake pads do not drag on the disc and that brake lever travel is
not excessive.

Always replace brake pads when the brake pad material becomes
thinner than the backing plate (approximately 1/16″).

WARNING

86

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 described on page 85, the machine should be
returned to an authorized Polaris dealer for inspection and adjustment.

1

2

3

4

5

87

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 113 for the part
numbers of Polaris-recommended products.

The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black.
If the sight glass is any color other than black, add brake fluid.
Maintain the brake fluid level between the MIN and MAX marks on
the master cylinder reservoir.

After opening a bottle of brake fluid, always discard any
unused portion. Never store or use a partial bottle. Brake
fluid is hygroscopic, meaning it rapidly absorbs moisture from
the air. The moisture causes the boiling temperature of the
brake fluid to drop, which can lead to early brake fade and the
possibility of accident or severe injury.

WARNING

Keep the master cylinder cover free of dirt and debris. The vent
slits allow for diaphragm movement, and if they become
plugged, movement of brake fluid below the diaphragm may be
restricted, altering brake function.

WARNING

Brake fluid will damage decals, paint and some plastics. Always
wipe up spills immediately.

CAUTION

88

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 position to minimize the
possibility of air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16″ (.6-.8 cm) below the lip of the reservoir
opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the
flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder
valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a
solid stream free of air bubbles.

7. After bleeding is complete, refill the reservoir to the recommended
level. See page 87.

8. Reinstall the gasket and cover.

Operating the vehicle with a spongy brake lever can result in
loss of brakes, which could cause an accident and lead to
serious injury or death. Never operate the vehicle with a
spongy-feeling brake lever.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or
death. Always maintain the brake fluid level between the MIN
and MAX marks on the reservoir as recommended.

WARNING

89

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 t he
floor to the center of the
headlight and make a mark on the
wall.

3. Start the engine and turn the
headlight switch to high beam.

4. Observe the headlight aim. The
most intense part of the headlight
beam should be aimed 2″ (5.1
cm) below the mark placed on the
wall in step 2. NOTE: Rider
weight must be included on the
seat.

5. Turn the adjustment nut (A),
located inside the hood, just
below the headlamp opening.
Turn the knob in or out as needed
to adjust aim.

25’ (7.6 m)

Lamp Center
Height

2″ (5.1 cm)

A

90

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
from the spring retainer.

2. Lift the spring carefully around
the wire harness (2) and flip to
the outside of the housing.

3. With the wire harness attached to
the bulb (3), withdraw the bulb
from the housing.

4. Grasp the bulb by the metal base
and carefully separate it from the
harness.

Installing the Bulb

1. Hold the bulb by the metal base
and install it into the wire harness.

2. Insert the bulb into the housing.

3. Carefully flip the spring back into
the housing, placing it around the
wire harness.

4. Squeeze the spring together until it’s over the spring retainer and
release.

5. Verify headlight aim.

Removing Halogen Bulbs - High Beam

1. Remove the wire harness (4).

2. Gasp the bulb (5) firmly and twist it 1/2 turn counterclockwise.

3. Remove the bulb from the housing and replace it with a new bulb.

4. Place the bulb and housing back inside the hole and turn the
housing 1/2 turn clockwise to lock into place.

5. Reinstall the wire harness to the housing.

2

1

3

4

5

91

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 vibration or shift pattern, see your dealer immediately.
Do not operate the machine until repairs have been made.

All clutch maintenance and repairs must be performed by an
authorized Polaris dealer. Any unauthorized modifications to
clutches, such as adding or removing weights, will void the
warranty.

WARNING

The bushings in the weights and rollers of Polaris clutches are
made of a material that may be damaged if lubricated. Do not
lubricate clutch bushings.

CAUTION

92

MAINTENANCE

General Maintenance

Clutch Alignment and Offset

Clutch center distance and alignment (A) are
crucial to maintaining optimum performance.
See the specifications section on page 112 for
the recommended offset between the drive
and driven clutches with the belt removed.

The drive belt is a very important part of the drive
system. Belt width and length must match the
center distance of the clutches and sheave width of
the drive clutch. For this reason, Polaris
recommends that only O.E.M. belts be used.
Other belts may match the dimensions, but can
drastically change the shift pattern, resulting in
poor performance. See your dealer for service and
adjustments.

NOTE: A worn belt will continue to function,
but will not deliver maximum performance. Al­ways carry a spare belt in case of an emergency.

Clutching Chart

Altitude

Meters (Feet)

Shift

Weight

Drive
Clutch
Spring

Driven
Clutch
Spring

Driven

Helix

Chaincase

Gearing

0-900

(0-3000)

10-62 Yellow Silver #2 R-11 20:41

900-1800

(3000-6000)

10-62 Yellow Silver #2 R-11 20:41

1800-2700

(6000-9000)

10-58 Yellow Silver #2 R-11 19:41

2700-3700

(9000-12000)

10-58 Yellow Silver #2 R-11 19:41

A

93

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 Removal

1. Be sure the key switch is off and the engine has come to a
complete stop. Apply the brake and lock the parking brake.

2. Open the hood, remove the clutch guard retaining pin and open the
clutch guard.

3. Firmly grasp the belt midway
between the clutches and pull
upward and rearward to remove.
See illustration.

94

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
them. If required, separate the
sheaves as outlined in the belt
removal procedures.

2. Turn the driven clutch
moveable sheave clockwise
while pushing inward and
forcing the belt down between
the sheaves.

3. Hold the belt down between the sheaves and roll the bottom
portion over the outer clutch sheave (B). Work the belt to the outer
edge of the sheave.

4. Close the clutch guard and reinstall the retaining pin.

5. Close and secure the hood and release the parking brake.

A

B

95

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 deflection can be adjusted without removing the clutch from the
jackshaft.

1. Pull the belt into the driven clutch to slightly open the sheaves.

2. Loosen the three bolts on the adjustment cam and turn the cam
counterclockwise to reduce the distance between the sheaves. Do

not rotate past the #1 position.

3. Torque the bolts to 4-6 ft. lbs. (5.5-8 Nm)

Clutch Center Distance

See the specifications section on page 112 for recommended center
distance for your machine. If adjustment is necessary, see your dealer.
Due to tolerances in belt length, it may be necessary for your dealer to
make minor adjustments in the driven clutch to achieve correct belt
tension.

A

B

96

MAINTENANCE

General Maintenance

Reverse Kit Maintenance

Always maintain track tension as specified on page 99 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 damage to the
snowmobile, which can result in loss of vehicle control and serious
injury or death. Always maintain the track tension as specified.

WARNING

Damage will occur to the chaincase or transmission if shifting is
attempted before the machine has come to a complete stop. Make
sure the snowmobile has completely stopped and the engine has
returned to idle speed before shifting gears.

CAUTION

97

MAINTENANCE

General Maintenance

Tool Kit

A tool kit is included with each machine for
emergency and routine maintenance.

1. Phillips Screwdriver

2. Tubular S ocket

3. Tubular Socket Handle

4. Wrench

5. Shielded Screwdriver

6. Scissor Stop Wrench

7. Box End Wrench

NOTE: Always keep the t ool kit with the
snowmobile. If necessary, a replacement
tool kit may be purchased from your Polaris dealer.

Tool Pouch Clip

A tool pouch clip (A) is located inside the flap
on the back of the seat. Use this clip to secure
the tools and keep them from bouncing around
during snowmobile use.

Chain Tension

Maintain the proper chain tension as outlined on page 84.

Oil Level

Maintain the oil level between the SAFE and ADD marks on the oil
dipstick. See page 59.

1

2

3

4

5

6

7

A

98

MAINTENANCE

General Maintenance

Emergency Supplies

For added protection, carry the following items on your snowmobile at
all times:

SSpare Drive Belt SExtra Set of Spark Plugs
STow Rope SExtra Oil
SFuel Deicer SW inter Survival Kit
STrail Map SOwner’s Manual
SFirst Aid Kit

Fall Tune-Up

For m aximum performance, arrange for a fall service tune-up with your
Polaris dealer. His experienced and trained service technicians will
keep your machine in peak operating condition.

Maintenance Tools

The tools and maintenance items mentioned in this book, as well as
other Polaris accessories, are available through your Polaris dealer.