Polaris Frontier Classic, Frontier Touring Owner's Manual

Download

2004

Frontier Classic

Frontier Touring

Owner's Manual

for Vehicle Maintenance

and Safety

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.

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S New product introductions

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www.polarisindustries.com/owner

Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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 Polaris 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 m anual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris 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.

TABLE OF CONTENTS

Introduction 5...............................

This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual.

Safety 8.....................................

This section describes safe vehicle operation and identifies warning decals and their locations.

Features and Controls 28.....................

This section i dentifies the locations of your snowmobile’s controls and features.

The Perfect Fit 33............................

This section explains how to tailor the suspension and other features for an optimum riding experience.

Pre-Ride Inspections 53......................

This section explains procedures that must be performed before riding.

Operation 58.................................

This section explains proper engine break-in, operation of features and general operating procedures.

Maintenance 71..............................

This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance.

Specifications 116............................

Troubleshooting 118.........................

This section i s a quick reference guide to solving problems.

Polaris Products 124.........................

Warranty 125................................

Index 131....................................

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.

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. Pl ease 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.

INTRODUCTION

Vehicle Identification Numbers

The tunnel vehicle identification number (VIN) and engine serial number are important for m odel 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:

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

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.

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 track.

Never attempt adjustments with the engine running. Turn off the ignition, raise t he hood, make the adjustment, secure shields and guards, secure the hood, and t hen 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

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 m ost 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

SAFETY

Operator Safety

Cargo Overload

Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier.

Riding Apparel

Be aware of the weather forecast, especially 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 in 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

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

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 i ce is thick enough to support the machine and its operator, as well as the force created by a moving vehicle. You may drown if you and the 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.

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 t he steering linkage. Snow screens and bib kits are available through your dealer to help reduce snow 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

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

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 if 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

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.

SAFETY

Operator Safety

Powder Snow Operation

Since snow provides the only lubrication for the power slide suspension and cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too little snow will result in excessive wear and damage to the slide 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 m ay 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

SAFETY

Operator Safety

Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program (beginning on page 71) to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Rider Capacities

Some Polaris snowmobiles are designed for a single rider only. Machines designed for two riders should never be operated with more than two people on board. When traveling with a passenger, it’s the driver’s responsibility to operate the machine safely.

Slow down! Control becomes more difficult with two people on board. More space is required to make turns, and longer distances are necessary for stopping.

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 t urns, 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 suspension 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.

SAFETY

Operator Safety

Windchill/Temperature Charts

The following charts will help you determine when t emperatures become dangerous for riding.

WIND CHILL CHART (°F)

Estimated Wind Speed

Actual Thermometer Reading (°F)

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

tleAdde

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)

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

SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Clutch Cover Warning

This warning decal 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.

Air Box Warning

This warning decal is found under the hood on applicable models:

CAUTION Do not operate above 40 mph with hood-to-airbox

foam removed or engine failure will result.

Pressure Cap Warning

This warning decal is found on the coolant bottle cover of liquid cooled models:

WARNING Do not open hot. Test or replace when changing coolant. Press down and turn to release cap. 13 PSI

SAFETY

Safety Decals And Locations

Track Warning

The track warning decal is located on the rear of the tunnel:

Passenger Warning

Some snowmobiles are designed for the operator only, while others are designed for the operator and one passenger. The passenger warning decal is located on the right side of the console next to the steering post. For more information on operating capacities, see page 20.

Decal found on 1-Up Models:

This vehicle is designed for operator only. “NO PASSENGER”

Decal found on 2-Up Models:

This vehicle is designed for operator and “ONE” passenger only.

SAFETY

Safety Decals and Locations

Electronic Reverse Warning

Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal.

WARNING AVERTISSEMENT

SAFETY

Safety Decals and Locations

Operation Warning

Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English.

WARNING

SAFETY

Safety Decals and Locations

Operation Warning

AVERTISSEMENT

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 S witch

17. Park Brake Lock

18. Handlebar Grip Warmer Switch

19. Thumbwarmer Switch

20. Shock Adjust Switch

FEATURES AND CONTROLS

Touring Model Shown

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Passenger Seat (Touring)

7. Cargo Box (Touring)

8. Taillights

9. Snow Flap

10. Suspension

11. Track

12. Trailing Arm

13. Block Heater (under hood)

14. Nosepan

15. Front Bumper

16. Skis

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

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 EF I 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 low 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 124 for the part numbers of Polaris 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.

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 -13° F. (-25° C.).

Open the hood to access the block heater plug-in (see page 29 for location). Plug 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

THE PERFECT FIT

Front Suspension Adjustments

Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before making any fine-tuning adjustments.

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, one change at a time, under the same conditions (trail and snow conditions, vehicle speed, riding position, etc.) after each adjustment until the best ride is achieved.

Independent Front Suspension (IFS)

The IFS is made up of the skis (1), front shocks and springs (2), and the components t hat 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.

NOTE: Although the front suspension on your machine may not look exactly like the illustration, it will have the same parts and functions as those illustrated.

IFS Adjustment Options

S Front shock spring preload S Optional springs S Toe (ski alignment) (see page 107) S Camber (see your dealer)

THE PERFECT FIT

Front Suspension Adjustments

For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming. To determine if your machine is using full travel, push the jounce bumper down on the shock rod until it contacts the body and test ride the machine. The bumper will move up on the rod in relation to the amount of travel that was used during the ride. If the travel is full, the bumper will be seated at the top of the rod.

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 107 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected.

WARNING

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 s ki-to-ground pressure. When adjusting, be sure the 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. Illustration B indicates high preload and illustration C indicates low preload.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch of preload beyond the factory settings, and ensure that both sides are adjusted the same. When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring preload adjuster nut on the shock body.

NOTE: Some models do not have shocks with thread adjustable spring preload. See your dealer for more information.

Front Springs

For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired t o control suspension stiffness. S ee your Polaris dealer for more information.

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

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 suspension set up for trail riding would bottom out harshly on a snow-cross course.

A decal outlining rear suspension setup options is located either under the hood or on the clutch cover. It provides a guideline for initial suspension setup. Additional adjustments can be made from this point. Make adjustments to one area at a time so you can evaluate the change. For 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 setup. These adjustments are easy t o 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 the suspension components. Grease rear suspension pivots before adjusting the rear suspension. Refer to Suspension Lubrication beginning on page 76.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential and achieve the best possible ride. Please take the time to read and understand all the possible adjustments available with the M-10 suspension.

Static Sag and Ride Height Settings

Static sag describes the difference in height of the rear bumper from the suspension’s fully extended position to its loaded height, with the rider seated on the snowmobile.

A good initial starting point is four inches of sag, measured at the rear bumper. Too much sag will result in bottoming, and too little sag will result in reduced rider comfort.

Sag travel is used to control ride quality and rebound travel. On the M-10 suspension, sag is controlled by two settings, the full range adjuster (FRA) position and the rear spring preload.

1. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as shown in the illustration. Record the m easurement.

2. Have the rider sit on the snowmobile and bounce up and down on the seat a few times t o set in the suspension. While the rider remains seated, measure the distance from the ground to the top of the bumper (dimension Y) and record it.

3. Subtract Y from X and you will have the SAG setting (X - Y = sag setting. Example: 21 - 17 = 4). The correct amount of SAG for the M-10 rear suspension is 3-5 inches.

If the measured sag is incorrect, adjust the FRA position and rear spring preload.

Unloaded Loaded

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

FRA Position

The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA:

1. Refer to the initial setup reference chart (located under the hood of your snowmobile and on page 43) to determine the desired FRA position.

2. To adjust, loosen the hex bolts (A) attaching the rear lower shock cross shaft to the rail beam.

3. Using a 9/16” wrench, loosen the jam nuts (B) on the preload bolts.

4. Adjust the preload bolts (C) to the desired FRA position.

5. Tighten the jam nuts. NOTE: Make sure the preload bolt contacts the slide block before tightening the jam nut.

6. Tighten the hex bolts and torque to 35 ft. lbs. (47 Nm).

NOTE: If the M-10 suspension is new, it will take from 25 to 200 miles to properly break in the springs and shocks, at which time the suspension will be softer and may require FRA readjustment.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Static Sag and Ride Height Settings

Rear Spring Preload

The top section of the crossover tube (the tube at the top of the rear shock) has a threaded collar on it. The rear spring has a lock tab that fits into the collar to allow easy spring preload adjustment. Refer to the initial setup chart on page 43.

1. To increase preload, use the tool kit spanner wrench to rotate the crossover toward the left side of the snowmobile (clockwise when viewed from below). Rotate toward the right side to decrease preload (counter-clockwise when viewed from below). Be sure the aluminum locknut and adjuster collar are locked against each other before starting the adjustment.

2. While adjusting, keep in mind that spring preload is a fine tuning adjustment. Coarse adjustments should be made using the FRA.

NOTE: Preload is set “softest” when the preload (dimension B in illustration and setup chart) is equal to zero. Adjusting spring preload beyond this could cause damage to the threads.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

More M-10 Suspension Ride and Performance Settings

Overload Spring

The overload spring is located inside the m ain rear spring. Contact is made with this spring only when the crossover tube comes in contact with it toward the end of the travel, which reduces bottoming of the rear suspension. The correct setting of the crossover tube length enables the M-10 suspension to deliver superior performance in “bottoming” situations. This adjustment has no effect on spring pre-load or general ride characteristics of the M-10 rear suspension, it affects only bottoming resistance. To adjust the crossover tube length (dimension C in illustration and setup chart):

1. Use the spanner wrenches located in the tool kit to unlock the upper lock nut from the adjuster collar.

2. Turn the adjuster collar to the appropriate or desired dimension for the rider’s weight (refer to the initial setup reference chart located under the hood of your snowmobile and on page 43). Using the spanner wrenches, tighten the upper lock nut firmly against the adjuster collar.

Optional Springs

Optional springs have been designed to allow adaptation of the M-10 suspension to your specific needs. The 140 lbs./in. optional front arm spring would be used when very light load conditions exist, such as operation on very smooth trails, in deep powder or by very light riders. The 300 lbs./in. rear arm spring option would be used when high load conditions exist, such as operation by heavy riders on rough trails or very aggressive riding. The available springs for M-10 suspension are listed below.

Location Spring Rate Polaris PN

Front Arm Standard Front Arm Soft Front Arm Firm

160 lbs./in. 140 lbs./in. 180 lbs./in.

7041671-216 7041677-067 7041672-067

Rear Arm Standard Rear Arm Soft Rear Arm Firm

210/278 lbs./in. 135/240 lbs./in.

300 lbs./in.

7041935-216 7042010-216 7042011-067

Overload 1000 lbs./in. 7041936-067

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Other Ride and Performance Settings

Ski Pressure

Your M-10 rear suspension ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm mount.

1. To set the limiter, determine if the rider prefers comfort or control. Lean toward the #4 setting for comfort and toward the #3 setting for aggressive riding.

2. For full hole adjustments, remove the 5/16” nut and flat washers from the lower attachments of the limiter straps and relocate the straps to the desired position (i.e. move from position 4 to 3). Replace the nut and washer tighten securely.

3. For half-hole increments (such as 3/4), the limiter straps have slots at the upper pinch bolt. These slots allow the bolts to be loosened (rather than removed) for half-step adjustments. It is now easy to change to half-step hole positions (re-tighten the pinch bolts if loosened).

4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (A) increases ski pressure while the upper hole (B) decreases ski pressure.

NOTE: B y design, the BIASED COUPLE design of the M-10 suspension displaces the rear arm as the front arm is compressed. This means t hat when you raise the front limiter strap, at some point you will collapse the rear suspension arm, which will affect SAG height and reduce rear suspension travel.

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Other Ride and Performance Settings

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only after the track is warmed up and limber.

1. Turn the machine off.

2. Lift the rear of the machine and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track at the specified distance (see chart below) ahead of the center of the rear idler wheel. NOTE: Measure at the point where the weight is hanging.

4. Check for specified slack between the wear surface of the track clip and the plastic Hi-fax (C).

If the track needs adjustment:

5. Loosen the rear idler shaft bolts (D) and locknuts (A).

6. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track.

7. Tighten the locknuts (A). Then tighten the idler shaft bolts (D) to 35 ft. lbs. (47 Nm).

NOTE: Always inspect track alignment after track tension adjustment. Track alignment affects track tension. Misalignment will cause excessive wear to the track and slide rail. Excessive Hi-Fax wear will appear on units with track tension set too tight. Refer to the Master Repair Manual for track alignment procedure.

Track Tension Data

Suspension Weight Measurement

Location

Slack

Measurement

Edge Touring 10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

3/4 - 1″

(1.9 - 2.5 cm)

M-10 10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

7/8″ -11/8″

(2.2 - 2.9 cm)

M-10 ACE 10 lbs. (4.54 kg) 16″ ahead of rear

idler shaft

7/8″ -11/8″

(2.2 - 2.9 cm)

Track

Hi-fax

THE PERFECT FIT

FAST M-10 Rear Suspension Adjustments

Initial M-10 Suspension Setup Chart

NOTE: These positions are only preliminary. Experimentation should follow initial setup to obtain optimum results. Refer to the suspension troubleshooting decal for additional setup tips.

INITIAL SETUP REFERENCE CHART

This chart is a guideline to be used for initial suspension setups.

Your setup may vary based on your desired riding style.

FRA Position DimensionBDimension

Rider

SOFT FIRM Rear

Crossover

Limiter/Ski

Weight with

full ridin

Spring

Preload

Tube

Leng

Pressure

Settin

fullridin

gear

PreloadLengthSettings

Settings

In / mm In / mm Light / Firm

100 lbs. 1 11/4 005 5/8 143 4/4 3/3

125 lbs. 1 11/2 005 13/16 148 4/4 3/3

150 lbs. 1 11/2 5/16 8 5 13/16 148 4/4 3/3

175 lbs. 11/2 2 5/16 8 5 13/16 148 4/4 3/3

200 lbs. 2 21/2 5/16 8 5 3/4 146 4/4 3/3

225 lbs. 21/2 3 5/16 8 5 5/8 143 4/4 3/3

250 lbs. 3 31/2 5/16 8 5 9/16 141 4/4 3/3

275 lbs. 3 31/2 1/2 13 5 7/16 138 4/4 3/3

300 lbs. 3 31/2 1/2 13 5 3/16 132 4/4 3/3

325 lbs.* 3 31/2 5/8 16 5 3/16 132 4/4 3/3

350 lbs.* 31/2 4 5/8 16 5 3/16 132 4/4 3/3

375 lbs.* 4 5 7/8 22 5 3/16 132 4/4 3/3

*Might prefer optional spring (rear track) Refer to the list on page 40.

THE PERFECT FIT

FAST M-10 ACE Suspension Adjustments

The FAS T M-10 ACE (Adjustable Control Electronics) is a new feature available for some FAST M-10 rear suspensions. It enables a rider to easily adjust the suspension for weight and riding style.

The M-10 ACE is an electronically controlled module that replaces the standard M-10 FRA. The ACE changes the rear shock motion ratio by moving the lower shock pivot point a total of 1 1/4 inches, the same amount of adjustment as the standard FRA. A gauge on the console displays the current position of the shock, from soft to firm or somewhere in between.

M-10 ACE Settings

A switch labeled “ESC” on the left-hand control assembly is used to adjust the position of the ACE module. The following instructions describe all the features programmed into the ACE module.

1. By pressing the left hand control switch up (firm) or down (soft) one time, the lower pivot moves .14 inch, giving the operator a total of nine distinct positions. The console gauge will show the current ACE position.

2. If the soft or firm switch is pressed more than one time in succession, it will adjust as many increments as the switch is pressed. The electronics will “do the math” for the user to minimize t ravel time. For example, if the rider pushes “firm” twice, and then “soft” three times, the unit will move to one position softer than the current position.

3. If the soft or firm switch is held for five seconds or more, the ACE will adjust to the far end of the travel, corresponding to which button was pressed.

4. A fail-safe mode has been programmed into the controller to protect the electronics and to notify the operator of a system malfunction. If the module cannot adjust the suspension after one of the switches has been pressed (most likely due to an obstruction or heavy ice buildup), the controller will enter a failure mode, which is indicated by the gauge needle moving rapidly between soft and firm. This mode will continue indefinitely and is reset when the engine is turned off and restarted. If this mode is encountered, we recommend that the operator turn off the engine and inspect the unit for any obstruction or ice buildup on the shock or module.

THE PERFECT FIT

FAST M-10 ACE Suspension Adjustments

M-10 ACE Settings

IMPORTANT NOTES:

The time to move one position can take up to 12 seconds depending on the rear shock loads.

Due t o alternator limitations, the ACE module will operate only at engine speeds above 3500 RPM.

Similar to the FRA on the standard M-10, the ACE module will have the MOST effect on rear suspension performance.

Other M -10 ACE Ride and Performance Settings

Rear Spring Preload

Further fine tuning can be accomplished by adjusting the preload/crossover collar on the rear spring. This single adjustment changes BOTH the spring preload and crossover transition point. Increasing this setting will fine tune the overall ride stiffness AND increase bottoming resistance so a small change to this setting has a large effect on ride quality. To adjust the rear spring:

1. Slide the fabric cover t oward the top of the rear spring to reveal the middle spring collars.

2. Using the tool kit spanner wrenches, turn the preload collars to achieve the desired setting as illustrated.

3. Ensure the fabric cover is replaced correctly and is not interfering with shock and spring movement.

NOTE: Refer to the initial setup chart (on page 46 and under the hood) for preliminary settings.

Ski Pressure

See the Ski Pressure section for the standard M-10 suspension on page

41.

Track Tension

See the Track Tension section for the standard M-10 suspension on page 42.

THE PERFECT FIT

FAST M-10 ACE Suspension Adjustments

Initial M-10 ACE Setup Chart

NOTE: These positions are only preliminary. Experimentation should

follow initial setup to obtain optimum results. Refer to the suspension troubleshooting decal for additional setup tips.

INITIAL SETUP REFERENCE CHART

This chart is a guideline to be used

for initial suspension setup.

Your setup may vary based on your

desired riding style.

Rider Weight Dimension

imiter/Ski

RiderWeight

with full

Dimension

Preload and

Limiter/Ski

Pressure

riding gear

eoada

Crossover

essue

Settings

In. mm Light Firm

100 lbs. 004/4 3/3

125 lbs. 004/4 3/3

150 lbs. 0.10 3 4/4 3/3

175 lbs. 0.20 5 4/4 3/3

200 lbs. 0.25 6 4/4 3/3

225 lbs. 0.25 6 4/4 3/3

250 lbs. 0.30 8 4/4 3/3

275 lbs. 0.35 9 4/4 3/3

300 lbs. 0.40 10 4/4 3/3

325 lbs.* 0.45 11 4/4 3/3

350 lbs.* 0.50 13 4/4 3/3

375 lbs.* 0.50 13 4/4 3/3

THE PERFECT FIT

Edge T ouring Suspension (ETS) Adjustments

Torsion Springs

Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench.

The firm t orsion spring should be used if frequent bottoming is encountered during two up riding on rough trails.

The soft torsion spring should be used for frequent one up riding on smooth trails.

For soft tension, position the long end of the cam to the front (A). For firm tension, position the long end of t he cam up (B).

Front Track Shock and Spring Preload

Front track shock compression damping and spring preload can also be adjusted. Turn the screw (C) clockwise to tighten (stiffen) compression damping. Turn the spring (D) clockwise to increase (stiffen) spring preload.

Initial Setup Reference Chart

This chart is only a guideline for initial suspension setup. Your setup may vary based on your desired riding style.

Tor s io n

Spring & Block

Setting

RCA

Position

Front Track

Spring Preload

(Inches)

Front Track

Indy Select -

Turns From

Full Open

1 Rider Soft

Firm

Low Med

1-2 2-3

0.25

0.50

0-1 1-2

2 Riders Soft

Firm

Med

High

3-4 4-5

0.75

1.00 max

1-3 2-3

Optional Torsion Spring Optional Front Track

Spring

Left Hand Right Hand

Soft

Firm

7042139-067 7042282-067

7042140-067 7042283-067

7041351-067

-------------

THE PERFECT FIT

Edge T ouring Suspension (ETS) Adjustments

Initial Setup and Calibration

The following information has been compiled to assist you in tuning your ETS to its maximum potential.

The Ride Control Adjuster (RCA)

1. Refer to the initial setup reference chart (located under the hood of your snowmobile and on page 47) to determine the desired RCA position.

2. To adjust, loosen the hex bolts (A) attaching the rear lower shock cross shaft to the rail beam.

3. Using a 9/16” wrench, loosen the jam nuts (B) on the preload bolts.

4. Adjust the preload bolts (C) to the desired RCA position.

5. Tighten the jam nuts (B). NOTE: Make sure the preload bolt contacts the slide block before tightening the jam nut.

6. Tighten the hex bolts (A) and torque to 35 ft. lbs. (47 Nm).

NOTE: The RCA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance.

Other Ride and Performance Settings

Ski Pressure

See the Ski Pressure section for the standard M-10 suspension beginning on page 41.

Track Tension

See the Track Tension section for the standard M-10 suspension on page 42.

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

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 i njury 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

Another way to tailor your machine is to install traction products. S ee your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.

Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products.

NOTE: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.

If traction products are added to the track, wear strips must be installed in the tunnel to avoid excessive wear.

Never add shims to the wear strip. T rack damage will result because of lack of clearance between upper carrier wheels and track.

Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel.

CAUTION

THE PERFECT FIT

Accessories

Traction Products

Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control. Similarly, if your machine is equipped with carbide skags or you’re adding them, it may be necessary to add track studs to maintain proper vehicle control. Proper balance must be maintained between the number of studs and the length of carbide on skags. The more studs used, the longer the carbide on the skags should be. See your dealer’s track studding chart for recommended studding and skags.

Inspect skags and studs frequently. Worn studs or skags may reduce steering and braking control on hard-packed snow and ice. Replace worn studs and skags to maintain proper balance and vehicle control.

When studded tracks are used, i ncreased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are available. S ee your dealer for more information.

Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8″ (2.86 cm) from outside edge of the track.

CAUTION

Loss of control can result in serious personal injury or death. Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard-packed snow or ice. See your dealer for assistance.

WARNING

THE PERFECT FIT

Accessories

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information.

Some models are manufactured with tunnel wear strips or wear strip coolers installed. Refer to your model’s specifications on pages 116-117 to determine if it has wear strips.

Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories.

Components as viewed from the rear of the track:

1. Top of tunnel

2. Wear strip

3. Track

4. Wearstrip mounting holes

Whenever wear strips are relocated, be sure there’s adequate stud clearance to the heat exchangers. Lack of clearance may result in damage to heat exchangers.

CAUTION

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. W e’ve attempted to provide as much information as possible t o 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 throttle lever compresses evenly and smoothly. The lever should immediately return to the idle position without binding or hesitation. If the t hrottle 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 65.

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

PRE-RIDE INSPECTION

Hydraulic Brakes

Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine.

Brake Lever Travel

When the brake lever is squeezed, it should move no closer to the handgrip than 1/2″ (1.3 cm) (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 92.

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 92 for more information, or see your dealer for s ervice.

Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. We recommend that you use only Polaris brake fluid. See page 124 for the part numbers of Polaris products.

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

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 l ocked 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 and Cover

4. Fluid Level Indicator

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

PRE-RIDE INSPECTION

Steering System

Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing t he 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 i n 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 the dipstick. See page 64.

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

PRE-RIDE INSPECTION

The following items must be checked before each use of the vehicle. Check these items after starting the engine (see page 58), 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 65.

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 65.

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.

OPERATION

Starting the Engine

Do not depress the throttle until the engine starts.

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

2. Turn the key to START and crank the engine. NOTE: There will be a half second delay before the starter engages to allow the ACS system to “wake up.”

3. After the engine starts, release the key to the ON position. NOTE: If the engine doesn’t start on the first attempt when the air temperature is below -5° F. (-20° C.), wait 15 seconds for the electrical system to recover, then attempt to start again.

NOTE: The F rontier is equipped with a recoil for emergency starting. Seepage67.

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 53.

WARNING

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 this 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 500 miles (800 km). See page 83.

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.

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 64.

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 124 for the part numbers of Polaris 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

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.

OPERATION

Track Warm-Up

Follow these steps to ensure proper warm-up

of the engine, drive train and track.

1. Use an appropriate stand to 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

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

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.

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. See page 124 for the part numbers of P olaris products.

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

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

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

CAUTION

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.

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

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.

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

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

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 65 for more i nformation 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

OPERATION

Reverse Operation

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

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″ (10 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.

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

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), 500 miles (800 km), and 1000 miles (1600 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.

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.

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

miles

(240 km)

500

miles

(800 km)

1000

miles

(1600 km)

See

Page

Check brake operation and adjustment

Daily 54, 89

Test engine stop switch Daily 57

Test tether strap Daily 57

Check track condition Daily 56

Test throttle safety switch Daily 65

Check throttle lever operation Daily 53, 66

Check operation of headlights, taillight, brakelight

Daily 57, 93

Check park brake function Daily 55

Check oil level Daily 64

Check coolant level Daily 86

Check track alignment X 104

Steering arm and tie rod ends X 106

Check throttle cable condition X -

Check battery fluid level X 113

Check track tension X 42

Check chaincase oil level X 79

Check gearcase o il level X 79

Check drive chain tension X 88

Check drive belt condition X 98

Check for and tighten loose suspension mounting bolts

X 110

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 108

MAINTENANCE

Maintenance Chart

Item Weekly or

before

long trip

150

miles

(240 km)

500

miles

(800 km)

1000

miles

(1600 km)

See

Page

Check Hi-fax thickness, have dealer replace when worn

X 109

Tighten rear idler wheel bolts X 104

Tighten idler adjust bolt jam nuts X 104

Check spark plug condition, replace annually

X 81

Inspect coolant filter, replace if necessary

X X X 87

Grease ski pivots X X X 76

Grease ski spindles X X X 76

Grease center steering arm(s) X X X 76

Lubricate steering post support bracket and pivot (aerosol)

X X X 76

Grease lower steering post pivot X X X 76

Change oil (annually) X X 83

Grease driveshaft bearing (always perform before storage)

X X 78

Flush chaincase X X 79

Grease rear suspension pivot shafts

X X 77

Grease jackshaft bearing (always perform before storage)

X X 76

Lubricate throttle cable X X 78

Check clutch alignment and offset X X 96

Check cooling system level, specific gravity

X X 86

Inspect fuel filter and replace X X 82

Check brake fluid level X X 91

Inspect fuel lines and replace X 82

Inspect exhaust system for weak or missing retaining springs

X 84

Inspect exhaust pipe for cracks or damage

X 84

Inspect clutch sheaves for damage, wear, belt residue

X 95

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 Technician

Date Mileage

500 Mile (800 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

1000 Mile (1600 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

2000 Mile (3200 km) Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

MAINTENANCE

Maintenance Log

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date Mileage

Type of Service

MAINTENANCE

Lubrication

Lubricate the suspension and steering components with Polaris Premium grease at 500 miles (800 km) and annually or about every 1000 miles (1600 km) thereafter. See page 124 for the part numbers of P olaris 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 124.

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.

M10 Suspension

Edge Touring Suspension

M -10 ACE Suspension

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.

MAINTENANCE

Lubrication

Chaincase Oil

Check the chaincase oil level weekly and before any long trips. Place the machine on a level surface. Remove the dipstick (A) and read the oil level. The oil level should be

between the SAFE marks on the dipstick. Add Polaris chaincase oil through the dipstick opening if needed. Do not overfill. Seepage124 for the part numbers of Polaris 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.

MAINTENANCE

General Maintenance

Spark Plugs

S Use Champion RC7YC spark plugs. S P roper electrode gap is .035” (.9 mm) S S park 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

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 a faulty EFI system.

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 a faulty EFI system.

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.

MAINTENANCE

General Maintenance

Intake Filter

The intake foam filters limit snow ingestion into the intake system. When operating i n 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.

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

MAINTENANCE

General Maintenance

Oil and Filter Chan g e

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 t urn.

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. S top 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.

MAINTENANCE

General Maintenance

Exhaust System

Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing 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

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 124 for the part numbers of Polaris 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 the 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.

MAINTENANCE

General Maintenance

Coolant Level

The coolant level in the coolant bottle must be maintained at the FULL COLD mark (A) to prevent overheating and serious engine damage.

The engine coolant level is controlled by the recovery system. The recovery system components are:

S Coolant bottle 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.

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

CAUTION

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 idle 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

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.

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.

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

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 89, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.

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 124 for the part numbers of P olaris 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

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 t he 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 t he bleeder valve in a solid stream free of air bubbles.

7. After bleeding is complete, refill the reservoir to the recommended level. See page 91.

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

MAINTENANCE

General Maintenance

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following procedure:

1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall.

2. Measure the distance from the floor to the center of t he 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)

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.

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

MAINTENANCE

General Maintenance

Clutch Alignment and Offset

Clutch center distance and alignment (A) are crucial to maintaining optimum performance. See the specifications section on pages 116-117 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.

MAINTENANCE

Frontier Classic Clutching Chart

Altitude

Meters (Feet)

Shift

Weight

Drive Clutch Spring

Driven Clutch Spring

Driven

Helix

Chaincase

Gearing

0-900

(0-3000)

10-62 Yellow Silver R-11

19:39 72P

HYVO

900-1800

(3000-6000)

10-62 Yellow Silver R-11

19:39 72P

HYVO

1800-2700

(6000-9000)

10-58 Yellow Silver R-11

17:39 72P

HYVO

2700-3700

(9000-12000)

10-56 Yellow Silver R-11

17:39 72P

HYVO

Frontier Touring 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 R-11

20:41

74P

900-1800

(3000-6000)

10-62 Yellow Silver R-11

20:41

74P

1800-2700

(6000-9000)

10-58 Yellow Silver R-11

19:41

74P

2700-3700

(9000-12000)

10-58 Yellow Silver R-11

19:41

74P

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.

Polaris Frontier Classic, Frontier Touring Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual