Polaris Frontier Classic Owner'S Manual Download

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133

INDEX

Suspension Performance Tips

. . . . .

Suspension Setup Chart, ETS

. . . . .

Suspension Setup Chart, M10

. . . . .

Suspension Setup Chart, M10 ACE

Suspension Troubleshooting, ETS

119

Suspension Troubleshooting, M10 118

Suspension, Front

33-35

. . . . . . . . . . . .

Suspension, Rear

. . . . . . . . . . . . . . .

Suspension, Rear, ETS

47-48

. . . . . . . .

Suspension, Rear, M10

37-43

. . . . . . . .

Suspension, Rear, M10 ACE

44-46

. . .

TABLE OF CONTENTS

. . . . . . . . .

Temperature Chart

. . . . . . . . . . . . . .

Tether Switch

. . . . . . . . . . . . . . . . .

THE PERFECT FIT

33-50

. . . . . . . . . .

Throttle Cable

. . . . . . . . . . . . . . . . .

Throttle Lever

53, 66

. . . . . . . . . . . . . .

Throttle Position Sensor

. . . . . . . . .

Throttle Safety Switch

53, 65

. . . . . . .

Tool Kit

102

. . . . . . . . . . . . . . . . . . . . .

Tool Pouch

102

. . . . . . . . . . . . . . . . . .

Tools

103

. . . . . . . . . . . . . . . . . . . . . . .

Torsion Springs, ETS

. . . . . . . . . . .

Towing

. . . . . . . . . . . . . . . . . . . . . .

TPS

. . . . . . . . . . . . . . . . . . . . . . . . .

Track

24, 113

. . . . . . . . . . . . . . . . . . . .

Track Alignment

104

. . . . . . . . . . . . . .

Track Condition

. . . . . . . . . . . . . . .

Track Inspection

105

. . . . . . . . . . . . . .

Track Lubrication

105

. . . . . . . . . . . . .

Track Maintenance

105

. . . . . . . . . . . .

Track Tension Data

. . . . . . . . . . . . .

Track Tension, ETS

. . . . . . . . . . . .

Track Tension, M10

. . . . . . . . . . . .

Track Tension, M10 ACE

. . . . . . . .

Track Warm-Up

. . . . . . . . . . . . . . .

Traction Products

50-51

. . . . . . . . . . . .

Transmission

. . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

118-123

. . . . .

Tune-Up

103

. . . . . . . . . . . . . . . . . . . .

Vehicle Identification Numbers

. . . . .

Warning Labels

25-27

. . . . . . . . . . . . . .

WARRANTY

125-130

. . . . . . . . . . . . .

Wear Strips

. . . . . . . . . . . . . . . . . . .

WELCOME

. . . . . . . . . . . . . . . . . . .

Windchill Chart

. . . . . . . . . . . . . . . .

Summary of Contents for Frontier Classic

Page 1: ...2004 Frontier Classic Frontier Touring 2004 Frontier Classic Frontier Touring Owner s Manual for Vehicle Maintenance and Safety Owner s Manual for Vehicle Maintenance and Safety ...

Page 2: ...xhaust 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 spill...

Page 3: ...ow Our new web site And it s designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustries com owner ...

Page 4: ...duction 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 prohibite...

Page 5: ...king it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician You...

Page 6: ...ontrols 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 ...

Page 7: ...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 pres...

Page 8: ...ect 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 red...

Page 9: ...e 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 t...

Page 10: ...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 sit...

Page 11: ... 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 un...

Page 12: ... engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious personal injury or death We recommend having your dealer perform track service and alignment procedures WARN...

Page 13: ...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 you...

Page 14: ...dgement 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 fi...

Page 15: ...eet 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 ...

Page 16: ...our view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your machine on a frozen body of water be sure the ice is thick enough to support the machine and its operator as wel...

Page 17: ...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 ...

Page 18: ...her 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 downhi...

Page 19: ...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 ...

Page 20: ...nd 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 o...

Page 21: ... that when the throttle is opened the snowmobile will be able to climb up and over You may then mount the machine and continue riding Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious personal injury WARNING When operating on icy surfaces or hard packed snow avoid overheating the slide rail and track Lack of lubrication ...

Page 22: ...y 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 ...

Page 23: ...snow mobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safe ty 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 snow mobile have been designed to provide protection under normal riding conditions Your snowmo...

Page 24: ...21 37 53 69 85 100 116 132 148 Wind Speeds Greater Than 40 MPH Have Little Added Effect Little Danger For Properly Clothed Person Increasing Danger Great Danger Little Added Effect Clothed Person Danger From Freezing of Exposed Flesh WIND CHILL CHART C Estimated Wind Speed in KPH Actual Thermometer Reading C p in KPH 5 0 5 10 15 20 25 30 35 40 Equivalent Temperature C 0 5 0 5 10 15 20 25 30 35 40 ...

Page 25: ... 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 o...

Page 26: ...hile 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 ...

Page 27: ...25 SAFETY Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal WARNING AVERTISSEMENT ...

Page 28: ...26 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 ...

Page 29: ...27 SAFETY Safety Decals and Locations Operation Warning AVERTISSEMENT ...

Page 30: ...Oil Pressure Light 8 Brake Light 9 Check Engine Light 10 Reverse Indicator Light 11 Temperature Light 12 Tachometer 13 Engine Stop Switch 14 Throttle Control 15 Reverse Lever 16 Headlight Dimmer Switch 17 Park Brake Lock 18 Handlebar Grip Warmer Switch 19 Thumbwarmer Switch 20 Shock Adjust Switch 1 13 14 2 3 5 12 4 9 10 11 7 8 6 15 16 17 18 19 20 ...

Page 31: ...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 1 2 3 4 5 8 11 10 14 12 16 15 7 9 13 6 ...

Page 32: ...chronization 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 t...

Page 33: ... 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 ...

Page 34: ...mperatures 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 res...

Page 35: ...rail 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 that connect these parts to both the steering such as the tie rods 3 and to the machine itself such as the trailing arms 4 Front suspension adjustments include shocks springs ...

Page 36: ...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 t...

Page 37: ...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 ...

Page 38: ...ge 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 to make involve very little time or effort and greatly affect the ride S In deep snow a new Hi fax will o...

Page 39: ...lt 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...

Page 40: ...ition 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...

Page 41: ...ench 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 s...

Page 42: ...iate 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 wo...

Page 43: ... 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 ...

Page 44: ...ds 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 excess...

Page 45: ...imiter Ski Pressure Weight with full riding Spring Preload Tube Length Pressure Settings full riding gear Preload Length Settings Settings In mm In mm Light Firm 100 lbs 1 1 1 4 0 0 5 5 8 143 4 4 3 3 125 lbs 1 1 1 2 0 0 5 13 16 148 4 4 3 3 150 lbs 1 1 1 2 5 16 8 5 13 16 148 4 4 3 3 175 lbs 1 1 2 2 5 16 8 5 13 16 148 4 4 3 3 200 lbs 2 2 1 2 5 16 8 5 3 4 146 4 4 3 3 225 lbs 2 1 2 3 5 16 8 5 5 8 143 ...

Page 46: ...auge 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 travel 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...

Page 47: ...eload 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 toward 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...

Page 48: ...d for initial suspension setup Your setup may vary based on your desired riding style Rider Weight Dimension A Limiter Ski Rider Weight with full Dimension A Preload and Limiter Ski Pressure t u riding gear e oad a d Crossover essu e Settings In mm Light Firm 100 lbs 0 0 4 4 3 3 125 lbs 0 0 4 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 ...

Page 49: ...ock 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 Torsion Spring Block Sett...

Page 50: ...l 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 con tacts 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 rea...

Page 51: ...ndlebar 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 ...

Page 52: ...roducts Another way to tailor your machine is to install traction products See 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 installatio...

Page 53: ...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 increased wear to the brake pads will result from increased braking...

Page 54: ...ed 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 4 1 2 3 Whenever wear strips are relocated be sure there s adequate stud c...

Page 55: ... 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 throttle does not function smoothly DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system daily before the machine is op...

Page 56: ...er 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 service Replace brake fluid at least every two years with Polaris DOT 3 high temperature br...

Page 57: ...d release the brake lever The lever will return to the unlocked position The brake light on the console will light up when the park brake lever is locked and the engine is running It will also be lit when the service brake is in use If the brake light does not come on when the park brake or service brake is in use have it serviced by your dealer 1 Brake Lever 2 Park Brake Lever Lock 3 Master Cylin...

Page 58: ...e or failure caused by operation on ice or in poor lubrication conditions is not covered by warranty Hood Latches The hood of the snowmobile protects the operator from moving parts and aids in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Oil Level Always check the oil level on the dipstick before each ride and wh...

Page 59: ... 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 a...

Page 60: ...e 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 Frontier is equipped with a recoil for emergency starting See page 67 Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your sno...

Page 61: ...ull throttle or high speeds for extended periods during the first 100 miles 160 km of use Vary the throttle openings and machine 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 mil...

Page 62: ...erformance 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 CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We...

Page 63: ...ill 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 t...

Page 64: ...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 con sciousness or death in a short time The engine exhaust from this product contains chemicals known ...

Page 65: ...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 Polaris products If you use oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives are not required and should not b...

Page 66: ... on the dipstick Throttle Position Sensor TPS All throttle bodies have been preset at the factory for adequate fuel supply at all altitudes No adjustment is required Any service must be performed by a Polaris dealer trained to service EFI systems A B Any attempt to adjust the TPS without proper tools and training WILL result in deteriorated engine performance and could result in SEVERE engine dama...

Page 67: ...irection shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position A B Operating the snowmobile with a faulty throttle safety switch can result in s...

Page 68: ...essive 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 ...

Page 69: ...tarting 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 abruptl...

Page 70: ... 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...

Page 71: ...rface 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 mod els See your dealer for more information ...

Page 72: ...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...

Page 73: ...d 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 ...

Page 74: ...est 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...

Page 75: ...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 speci...

Page 76: ...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 Servici...

Page 77: ... 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 ...

Page 78: ...eft 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 suspensio...

Page 79: ... 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 ...

Page 80: ...earing 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 t...

Page 81: ...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 See page 124 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 A B ...

Page 82: ... 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...

Page 83: ...nsulator 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 ca...

Page 84: ...g the filter then the fuel filter is plugged and must be replaced The fuel filter should last the life of the machine if the fuel used is always of good quality Fuel Lines Inspect the fuel lines regularly Give special attention to the system s fuel line condition after periods of storage Normal deterioration from weather and fuel compounds may occur 3 1 2 Operating the snowmobile without the intak...

Page 85: ...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 sur...

Page 86: ... 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...

Page 87: ...olaris 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 ...

Page 88: ... Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine the system should be completely drained every two years and a fresh 50 50 or 60 40 mixture of antifreeze and distilled water should be added This service must be done when the engine is cold Ask your Polaris dealer to check the coolant when he performs the fall tune up on your snowmobile A Operating...

Page 89: ...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 S...

Page 90: ...k to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt 5 The chain is now tensioned Release the brake lever lock A B ...

Page 91: ...be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads ...

Page 92: ...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 1 2 3 4 5 ...

Page 93: ...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 co...

Page 94: ...he flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles 7 After bleeding is complete refill the reservoir to the recommended level See page 91 8 Reinstall t...

Page 95: ...the center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 2 NOTE Rider weight must be included on the seat 5 Turn the adjustment nut A located inside the hood just below the headlamp opening Turn the k...

Page 96: ...etal 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 ...

Page 97: ...r 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...

Page 98: ... 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 t...

Page 99: ...700 6000 9000 10 58 Yellow Silver R 11 2 17 39 72P HYVO 2700 3700 9000 12000 10 56 Yellow Silver R 11 2 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 2 20 41 74P 900 1800 3000 6000 10 62 Yellow Silver R 11 2 20 41 74P 1800 2700 6000 9000 10 58 Yellow Sil...

Page 100: ...t 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 illustrati...

Page 101: ...at you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave B Work the belt to the outer edge of the sheave 4 Close the clutch guard and reinstall ...

Page 102: ... the belt into the driven clutch to slightly open the sheaves 2 Loosen the three bolts on the adjustment cam and turn the cam counterclockwise to reduce the distance between the sheaves Do not rotate past the 1 position 3 Torque the bolts to 4 6 ft lbs 5 5 8 Nm Clutch Center Distance See the specifications section on pages 116 117 for recommended center distance for your machine If adjustment is n...

Page 103: ...erse Improper track tension can cause serious damage to the snowmobile which can result in loss of vehicle control and serious injury or death Always maintain the track tension as specified WARNING Damage will occur to the chaincase or transmission if shifting is attempted before the machine has come to a complete stop Make sure the snowmobile has completely stopped and the engine has returned to ...

Page 104: ...nt tool kit may be purchased from your Polaris dealer Tool Pouch The Frontier Classic has a seat compartment bag for tool storage Touring models have a tool pouch clip A which is located under the hood It s connected to the steering hoop in front of the left footrest Use this clip to secure the tools and keep them from bouncing around during snowmobile use Chain Tension Maintain the proper chain t...

Page 105: ...r SWinter Survival Kit STrail Map SOwner s Manual SFirst Aid Kit Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service technicians will keep your machine in peak operating condition Maintenance Tools The tools and maintenance items mentioned in this book as well as other Polaris accessories are available through your Po...

Page 106: ...ve complete revolutions Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails A are evenly spaced on each side If the track runs to the left loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the right locknut and tighten the right adjusting bolt 4 Afte...

Page 107: ...ulting in excessive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty Broken track rods can cause a rotating track to come off the machine which could result in serious injury or ...

Page 108: ...106 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check fasteners and tighten if needed Specific fasteners that should be checked are marked with a ...

Page 109: ...he measurement between the skis at point X should be 1 8 to 1 4 greater than at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski alignment or camber adjustment See your P...

Page 110: ... 2 Remove the attaching nuts and pry the skag A downward 3 Remove the forward portion of the skag first then remove the entire skag Reverse this procedure for new skag installation Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive ca...

Page 111: ...tenance Hi Fax Wear Replace Hi fax when a thickness of 7 16 1 1 cm is reached Check Hi fax wear by measuring the thickness at several points along the rail A Take the machine to your dealer for Hi fax replacement 7 16 1 1 cm A A A A ...

Page 112: ...ge Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components Cleaning and Preservation of Hood Chassis and Trim Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previou...

Page 113: ...ushing as outlined in the Master Repair Manual See your dealer Electrical Connections Separate the electrical connector blocks and clean any corrosive build up from the connectors Lubricate or pack the connector blocks with dielectric grease and re connect NOTE Do not grease the TPS connector Replace worn or frayed electrical wire and connectors Be sure the wiring harness is properly secured away ...

Page 114: ...ntire fuel system Top off with fresh fuel Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the following procedure 1 Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump Do not re use fuel after storage 2 Securely support the front of the snowmobile with a jackstand so th...

Page 115: ...and lower 2 level marks Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing If contact occurs seek immediate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batt...

Page 116: ...ttery cable 4 Remove the battery box cover and tip the box forward 5 Carefully lift the battery out of the snowmobile Do not tip it sideways or spill electrolyte Tap water contains minerals that will damage a battery and shorten its life Use only distilled water to refill your battery Never allow cleaning solution or tap water to enter the battery CAUTION Improperly connecting or disconnecting bat...

Page 117: ...x cover 2 Install the battery vent line It must be free from obstructions and securely installed Route the vent line properly to prevent kinks and to allow for proper drainage 3 Connect and tighten the red positive cable first then connect and tighten the black negative cable 4 Verify that cables and vent hose are properly routed Batteries contain gases that can explode If the battery vent tube is...

Page 118: ...dard Front Suspension Type Edge IFS Shock Type Nitrex Rear Suspension Type M10 M10 Ace Elec Front Track Shock Fox IFP Rear Track Shock Fox IFP w Res Engine Model Number S2466 7868 PR7D Alternator Output 416 watt Bore x Stroke 80 x 78 mm Displacement 784 Carburetor Model EFI Idle RPM 1300 200 Cooling Liquid Cylinders 2 Ignition Timing _BTDC RPM 15_ w diagnostic tool Ignition Type Digital Spark Plug...

Page 119: ...nsmission Standard Front Suspension Type Edge IFS Shock Type Nitrex Rear Suspension Type Edge Touring Front Track Shock Ryde AFX Rear Track Shock High Pressure Gas Engine Model Number S2466 7868 PR7D Alternator Output 416 watt Bore x Stroke 80 x 78 mm Displacement 784 Carburetor Model EFI Idle RPM 1300 200 Cooling Liquid Cylinders 2 Ignition Timing _BTDC RPM 15_ w diagnostic tool Ignition Type Dig...

Page 120: ...n see setup decal under hood Decrease rear track shock coil spring preload Change to optional soft rear track shock compression spring see your dealer Revalve rear track shock compression damping see your dealer Check track tension Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components turn freely Make sure skags are straight on skis Incr...

Page 121: ...ivot points Adjust RCA rearward see setup decal under hood Decrease spring preload adjustments Decrease front track compression damping by turning screw counter clockwise factory position full soft Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make sure skags are straight on skis Ensure use of Accu Trakt dual ska...

Page 122: ...e plates from the clutch Reduce RPM Avoid riding in high ambient temperatures Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for fouled plugs and water ice or dirt in gas tank or fuel line Loading machines onto trailers S...

Page 123: ... if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave clearance Replace drive belt SEE YOUR DEALER Drive belt turns over Wrong belt for application Clutch alignment out of spec Engine mount bro ken or loose Replace drive belt Adjust alignment offset Inspect and adjust or replace SEE YOUR DEALER Machine fails to move Transmission in neutral ...

Page 124: ...ect and replace if necessary Inspect and adjust or replace Poor low RPM performance Worn drive belt Excessive belt sheave clearance Loose torque stop Sticky clutch Inspect and replace if necessary SEE YOUR DEALER Inspect and adjust SEE YOUR DEALER Engine doesn t start electric start models Wire connections SEE YOUR DEALER Engine doesn t turn over Seized engine Dead battery SEE YOUR DEALER Seizure ...

Page 125: ...ump SEE DEALER for fuel line bleeding SEE DEALER This indicates a major en gine problem that must be repaired before engine is run Engine lacks power Fuel filter loss of high RPM power Incorrect clutching Fuel pump SEE DEALER SEE DEALER There s no adjustment to change power out put SEE DEALER Engine continually backfires Faulty plug s Improperly set TPS Change plug s SEE DEALER Engine crank time h...

Page 126: ...12 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogelt Coolant 2871323 Antifreeze 60 40 Premix gal 2871534 Antifreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2870990 DOT3 Brake Fluid 12 oz 2872893 Engine Degreaser 12 o...

Page 127: ...n 3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 763 417 8650 Canada 1 204 925 7100 Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles ...

Page 128: ... not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that oc cur during tra...

Page 129: ...ty service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate pe...

Page 130: ...els Brake components Throttle body components Seat components Engine components Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs...

Page 131: ...tomatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes S Damage due to accident fire explosion theft or other causes beyond Polaris control S Damage caused by the failure of other com...

Page 132: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 133: ...Linkage 110 Coolant 85 Coolant Level 86 Cooling 84 Cooling System 86 D Disabled Operators 12 Drive Belt 17 Drive Belt Adjustment 100 Drive Belt Deflection 100 Drive Belt Installation 99 Drive Belt Removal 98 Drive Chain Tension 88 Drive System 111 Driver Awareness 14 Driveshaft Bearing 78 Driving Downhill 17 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 15 Driving Responsibly 21 E EFI S...

Page 134: ...ke Lever Lock 55 Passenger 24 POLARIS PRODUCTS 124 Powder Snow Operation 19 PRE RIDE INSPECTION 53 57 Pressure Cap 23 R Rear Spring Preload M10 39 Rear Spring Preload M10 ACE 45 Recoil 67 Reverse 25 Reverse Kit Maintenance 101 Reverse Operation 68 Ride Control Adjuster ETS 48 Rider Capacities 20 Riding Apparel 12 Riding Position 11 S SAFETY 8 27 Safety Decals and Locations 23 27 Sag Ride Height M1...

Page 135: ... FIT 33 50 Throttle Cable 78 Throttle Lever 53 66 Throttle Position Sensor 64 Throttle Safety Switch 53 65 Tool Kit 102 Tool Pouch 102 Tools 103 Torsion Springs ETS 47 Towing 70 T TPS 64 Track 24 113 Track Alignment 104 Track Condition 56 Track Inspection 105 Track Lubrication 105 Track Maintenance 105 Track Tension Data 42 Track Tension ETS 48 Track Tension M10 42 Track Tension M10 ACE 45 Track W...

Page 136: ...r your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9918289 Rev 02 Printed in USA ...

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Polaris Frontier Classic, Owner'S Manual

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