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Xerox 420 All in One Printer User Manual

1. G General Maintenance 76 98 H Handlebar Adjustments 45 Headlight Adjustment 89 Headlights 90 Hi Fax Wear 0 105 High Temperature Indicator Light 81 Hood Latches 0 50 l Ice and Snow Build up 15 TBS 38 ceca essen kieane toekan tates At osha 33 Independent Front Suspension 33 Intake Filter 0 0 000 78 Intake Silencer 0 0 18 INTRODUCTION 5 7 J Jackshaft Bearing 74 L Tights sa e aa st a dts 51 Lubrication 54 72 75 M MAINTENANCE 67 111 Maintenance Chart 68 69 Maintenance Log 70 71 Maintenance Program 67 Malfunction Indicator Lamp 30 Maneuverability 18 Mirrors eane ayuda ees oe be ee 51 Moving Parts 10 N NOISES ee eee do oe Rise Pate 6 O Oilarra EE E EE T 54 59 Oil Change ereenn eera aa ees 79 Oil Filter Change 79 Oil Level 0 50 59 97 Oil Pressure Light 31 Operating Area 51 126 O OPERATION 52 65 Operator Safety 0 8 22 P Park Brake Lever Lock 49 Passenger 0 0 00000 25 Powder Snow Operation 19 PRE RIDE INSPECTION 47 51 Pressure Cap 0 0000 23 R Rear Spring Tension 39 Rear Suspension 38 44 Re
2. Inspect and adjust SEE YOUR DEALER SEE YOUR DEALER SEE YOUR DEALER Seizure is a result of poor lubrication broken parts or improper cooling Recharge battery or replace with new 117 TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Engine lacks power Engine continually backfires Engine crank time has increased 118 Probable Cause Faulty ignition No fuel to engine Air in fuel line Poor engine compression Fuel filter loss of high RPM power Incorrect clutching Fuel pump Faulty plug s Improperly set TPS Poor gasoline or not enough fuel getting to engine Solution Check for spark if no spark SEE DEALER Check tank level and fill with correct fuel Ice in fuel line filter or pump SEE DEALER for fuel line bleeding SEE DEALER This indicates a major en gine problem that must be repaired before engine is run SEE DEALER SEE DEALER There s no adjustment to change power out put SEE DEALER Change plug s SEE DEALER Replace with fresh winter fuel WARRANTY Service And Warranty Information Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 Polaris snowmobile owner reports theft A In addition to notifying the proper law enforcement offi cials the owner must
3. 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 AWARNING 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 60 OPERATION Throttle Lever AWARNING 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 en
4. 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 WELCOME sitchen te Siw barre eae ee ees 3 TABLE OF CONTENTS 0 cceeeeerenenenene 4 INTRODUCTION foie iiaet craw tein ene ee 5 The introduction contains helpful information for owners and drivers including the location of important identification numbers that should be recorded in your owner s manual SAFETY scri ei ceili ata eddie eeu ia wate cide ts 8 The safety section outlines practices for safe vehicle operation and identifies warning decals and their locations FEATURES AND CONTROLS 00eeeeeee 28 The features and controls of your snowmobile are identified in this section THE PERFECT FUP sisese ti iredia ni rasan sair ian 33 Learn how to tailor the suspension and other features for an optimum riding experience PRE RIDE INSPECTION 200eceeeeeeeeees 47 Always perform these procedures and inspections before riding OPERATION aah aa aa aE aos a a a 52 Learn how to properly break in your new snowmobile how to operate the controls and features and how to drive MAINTENANCE in aici ete ccrein eae an aed wee cee ees 67 The maintenance section outlines service procedures that must be performed by you or your dealer to keep the snowmobile oper
5. POLARIS The Way Out PAU IY Frontier Owner s Manual for Vehicle Maintenance and Safety AWARNING 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 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 ZAWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm What s the hottest thing on snow Our new web site And it s designed just for YOU Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com owner POLARIS The Way Out All information in this manual is based on the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2
6. 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 82 MAINTENANCE General Maintenance Bleeding the Cooling System AWARNING 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 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 CAUTION 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 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
7. 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 trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or punc turing of upholstery material corrosion or defects in parts components or the snowmo bile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEG LIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 120 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDI
8. on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm Use the illustration or the decal found under the hood for reference The ideal amount of Sag for the EDGE rear suspension is four inches X Y 4 If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment optional torsion springs softer or stiffer respectively may be required This is only an initial set up and final spring preload may vary based on rider preference and riding conditions 40 THE PERFECT FIT Rear Suspension Adjustments Indy Select Rear Shock The Indy Select rear shock allows for adjustments to the compression valving Locate the adjustment screw A near the base of the shock In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the ride There are approximately three full turns of adjustment available If bottoming continues after the screw has been turned fully clockwise the torsion spring should be ad
9. your dealer as the camber adjustment may also be affected The tension at which the shock coil spring is set is called spring preload For the best ride the spring preload should be set as low as possible to use the full travel of the ski shock with occasional light bottoming To determine if your machine is using full travel of the ski shock push the jounce bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will be seated at the top of the shock Shock Absorber Components g 1 Retainer 2 Shock Rod 4 2 3 Jounce Bumper a 3 4 Body m 5 Threaded Spring Preload Adjuster Nut sgi 4 5 ny 34 THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease ski to ground pressure When adjusting be sure springs on both the left and right sides of the machine are at 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 l preload In the illustrations at right B B indicates high preload and C indicates low preload O Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of th
10. Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks open flames cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper 1 and lower 2 level marks 109 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion When cleaning is necessary remove the corrosion with a stiff wire brush Wash terminals and connections with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry with clean shop towels Coat the terminals with dielectric grease or petroleum jelly CAUTION 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 Battery Removal AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Disconnect the battery hold down straps Remove the batt
11. Cover S l 4 Fluid Level Indicator 1 SNY RN S AWARNING 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 49 PRE RIDE INSPECTION Steering System Manually turn the skis completely to the right and to the left If any difficulty is encountered check for ice and snow build up that may be obstructing the steering linkage Make sure all greasable components are properly lubricated Track Condition Driving 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 AWARNING 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 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 s
12. Oil Fuel Deicer Winter Survival Kit Trail Map eOwner s Manual First 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 Polaris dealer 98 MAINTENANCE Track Maintenance AWARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine running 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 Track Tension Data Measurement Measurement Location Edge 136 10 lbs 4 54 kg 16 ahead of rear 3 8 1 2 1 1 3 cm i
13. Pinch the ends of the spring 1 together and lift until it releases from the spring retainer 2 the outside of the housing 3 With the wire harness attached to 1 the bulb 3 withdraw the bulb from the housing 4 Grasp the bulb by the metal base and carefully separate it from the goo 2 Lift the spring carefully around R Z the wire harness 2 and flip to A 3 harness Installing the Bulb 1 Hold the bulb by the metal base Po 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 90 MAINTENANCE General Maintenance Clutch System AWARNING 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 modificat
14. accessories Never permit a guest to operate this vehicle unless the guest has read the Owner s Manual and warnings 26 SAFETY Safety Decals And Locations Standard Reverse Warning Decal The reverse warning decal PN 7079002 is located above the instrument housing CAUTION Do not attempt to shift until machine has come to a complete stop or chaincase damage may occur WARNING VEHICLE CAPABLE OF EXCESSIVE REVERSE SPEED Reverse operation may be dangerous even at low speeds Steering control becomes difficult in reverse Misuse of reverse may result in injury Avoid turning at sharp angles in reverse Transmission may not always be in the gear indicated by the shift lever Always apply throttle slowly On machines with reverse it is especially important to maintain track tension as specified in the Owner s Manual If specified track tension is not maintained severe damage to the machine may occur which may result in loss of vehicle control Loss of vehicle control may result in severe personal injury or death For more information See Operator s Safety and Maintenance Manual supplied with reverse kit 27 FEATURES AND CONTROLS Fuel Filler Cap Ignition Switch Brake Lever Electronic Fuel Gauge Speedometer Headlight High Beam Light Low Oil Pressure Light Brake Light Check Engine Light 10 Reverse Indicator Light 11 Temperature Light 12 Tachometer 13 Engine Stop Switch 14 Throttle Co
15. been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing your speed Your snowmobile is equipped with a high out put headlamp system that may cause discomfort to operators of on coming vehicles when on high beam 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 Remove the key from the ignition when leaving the snowmobile un attended 21 SAFETY Operator Safety Windchill Temperature Charts The following charts will help you determine when temperatures become dangerous for riding WIND CHILL CHART F Estimated Wind Speed Actual Thermometer Reading F MMRR 50 40 30 20 10 O 10 20 30 40 50 60 Equivalent Temperature F Calm 50 40 30 20 10 O 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 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 O 15 29 44 59 74 88 104 118 133 30 28 13 2 18 33 48 63 7
16. damaged or kinked replace it promptly 78 MAINTENANCE General Maintenance Oil and Filter Change The Frontier does not have a crankcase drain The oil in the crankcase must be drawn out through the dipstick hole using a Polaris oil vacuum pump PN PU 46219 or similar tool from another manufacturer This type of tool is commonly used in the marine industry 1 Position the vehicle on a level surface and run the engine for 2 3 minutes to slightly warm the oil NOTE Running the engine any longer may cause engine overheating It may also cause the oil to become too hot for safe removal with the oil vacuum pump 2 Remove the dipstick and draw out the oil following the instructions provided with the oil vacuum pump Fish the vacuum tube around in the crankcase to remove as much oil as possible 3 Place shop towels beneath the oil filter to catch spills Using an appropriate oil filter wrench such as Polaris PN PV 43527 turn the filter counterclockwise to remove Dispose of the used oil and filter properly 4 Clean the filter sealing surface on the crankcase with a clean dry cloth 5 Lubricate the o ring on the new filter with a film of new engine oil Check to make sure the o ring is in good condition 6 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn an additional half turn 7 Add 2 quarts 1 9 Itr of Polaris Premium 4 synthetic oil through the dipstick hole Reinstall
17. 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 63 OPERATION Daily Storage At the end of each ride park the snowmobile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 20 cm off the ground Remove the key and cover the machine NOTE Polaris has accessory covers and track stands available to fit all mod els See your dealer for more information 64 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 AWARNING 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 o
18. may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque to 18 ft Ibs 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 74 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 See page 113 for the part numbers of Polaris recommended products Flush the chaincase after the first 500 miles then every 1000 miles or seasonally Clean the magnetic plug B whenever checking or changing lubricant 75 MAINTENANCE General Maintenance Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs e Use Champion RC7YC spark plugs e Proper electrode gap is 035 9 mm Spark plug torque is 18 22 ft Ibs 24 30 Nm Change spark plugs annually and whenever inspection reveals fouled or damaged plugs Always use the rec
19. movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop RRSS Attributes Moving the RRSS to a higher position or forward hole will have the following effects on the suspension Reduced weight transfer Improved chatter bump ride Improved cornering performance 43 THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration Rear Rear Scissor Stop RRSS The preferred method for controlling weight i transfer during acceleration of the EDGE rear suspension is by adjusting the RRSS The ROTATE RRSS is located in the best overall trail riding position when delivered from the factory 0 To decrease weight transfer under acceleration for improved cornering rotate the RRSS to a higher position with the scissor stop tool 1 located in your tool kit To increase weight transfer or ski lift during acceleration move the RRSS to the rearward hole on high position The RRSS may also be rotated to a lower position for even more weight transfer if desired A Stock Position This setting is most desirable for trail riding B Medium
20. or High Position standard hole location This setting will decrease weight transfer C Rearward Upper Position optional hole location This setting will increase weight transfer NOTE Your dealer can help you with initial set up and additional set up in structions to help you achieve your op timum ride 44 THE PERFECT FIT Handlebar Adjustments AWARNING 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 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 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 4 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 Torque the handlebar adjuster block bolts to 11 13 ft Ibs 15 18 Nm Replace the handlebar cover 45 THE P
21. 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 77 MAINTENANCE General Maintenance Intake Filter The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow check the filters periodically to remove any accumulation of snow 1 Airbox foam filter 2 Air intake box 3 Hood foam filters CAUTION 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 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 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
22. 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 17 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 18 SAFETY Operator Safety Powder Snow Operation AWARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible tr
23. the dipstick 8 Start the engine and allow it to idle for one to two minutes Stop the engine and inspect for leaks 9 Check the oil level on the dipstick and add oil as needed to bring the level to the SAFE mark on the dipstick 79 MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles 3200 km To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets AWARNING 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 Engine Cooling The cooling system on liquid cooled models consists of the following major components e Coolant bottle e Water pump e Cylinders e Heads e Inlet and outlet manifolds e Pressure cap e Heat exchangers 80 MAINTENANCE General Maintenance Coolant Mixture The coolant supplied in the system is a 50 50 mixture of ethylene glycol and distilled water This mixture provides protection against freezing at temperatures to 34 F 37 C If greater protection is required the percentage of antifreeze to water may be increased Use Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water See page 113 for the part numbers of Pola
24. the outer clutch sheave B Work the belt to the outer edge of the sheave Close the clutch guard and reinstall the retaining pin Close and secure the hood and release the parking brake MAINTENANCE General Maintenance Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt A and apply downward pressure while measuring at point B This measurement should be 1 1 4 Drive Belt Adjustment Belt deflection can be adjusted without removing the clutch from the jackshaft 1 Pull the belt into the driven clutch to slightly open the sheaves 2 Loosen the three bolts on the adjustment cam and turn the cam counterclockwise to reduce the distance between the sheaves Do not rotate past the 1 position 3 Torque the bolts to 4 6 ft Ibs 5 5 8 Nm Clutch Center Distance See the specifications section on page 112 for recommended center distance for your machine If adjustment is necessary see your dealer Due to tolerances in belt length it may be necessary for your dealer to make minor adjustments in the driven clutch to achieve correct belt tension 95 MAINTENANCE General Maintenance Reverse Kit Maintenance Always maintain track tension as specified on page 99 when a snowmobile is equipped with reverse AWARNING Improper track tension can cause serious damage to the snowmobile which can result in loss of vehicle cont
25. the pressure cap and carefully lower the front end of the machine 83 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 84 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 AWARNING 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 85
26. 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 model identification when registering your snowmobile when obtaining insurance and when ordering replacement parts In the event your snowmobile is stolen these numbers are essential to its recovery and identification Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris deal
27. 002 Polaris Industries Inc All Rights Reserved Printed in the U S A 2 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 e Snowmobiles e All terrain vehicles ATVs e Personal watercraft e RANGER utility vehicles e Victory motorcycles Polaris Professional Series Workmobiles e Utility Task Vehicles UTVs e Personal Task Vehicles PTVs e 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 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 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
28. 075351 is found under the hood Do not operate above 40 mph with hood to airbox foam removed or engine failure will result Pressure Cap Warning Decal The water bottle cap warning decal PN 7170063 is found on the water bottle pressure cap WARNING DO NOT OPEN HOT Test or replace when changing coolant Press down and turn to release cap 13 PSI 23 SAFETY Safety Decals And Locations Track Warning Decal The track warning decal PN 7076360 is located on the rear tunnel Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death Cargo Carrier Warning Decal The cargo carrier warning decals PN 7072225 English and PN 7072266 French is located on the side of the rear rack Do not sit in or on cargo area Cargo load should not exceed 40 Ibs 18 kg Cargo load affects machine steering and response Never allow person s to use carrier as a means of hand support skiing skidding or dragging Severe injury may result due to track entanglement falling off or loss of steering control if warnings are not followed 24 Safety Decals And Locations Passenger Warning The Frontier snowmobile is designed for the operator and one passenger The passenger warning decal PN 7075439 is located on the right side of the console For more information on operating capacities see page 20 This vehicle is designed for operator an
29. 106 Coolant 0 00 00 0008 81 Coolant Level 0 82 Cooling Sites Miaka as 80 Cooling System 82 D Disabled Operators 12 Drive Belt 0 0004 17 Drive Belt Adjustment 95 Drive Belt Deflection 95 Drive Belt Installation 94 Drive Belt Removal 93 Drive Chain Tension 84 Drive System 0 107 Driver Awareness 14 Driveshaft Bearing 74 Driving Downhill 17 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 15 Driving Responsibly 21 E EFI System 0 004 67 Electrical Connections 107 Emergency Starting 62 Emergency Stopping 62 Emergency Supplies 98 Engine Break In 53 54 Engine Cooling 80 Engine Protection 108 Engine Service Contract 123 124 Engine Stop Switch 51 60 Engine Troubleshooting 116 118 Environment 0 6 Exhaust System 0 80 F Fall Tune Up 000 98 FEATURES AND CONTROLS 28 32 Flushing the Cooling System 82 Front Suspension 33 37 Front To Rear Coupling 42 FRSS Apie etae a e ie 42 Bue EEE EE E A EA 56 58 Fuel Filter 0 0 0 0 ee 78 Fuel Eines oe ches ees Res eed 78 Fuel System Deicers 58 125 INDEX
30. 9 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 Little Danger Increasing Great Than 40 MPH Have For Properly Danger Danger Little Added Effect WIND CHILL CHART C Estimated Wind Speed Clothed Person Danger From Freezing of Exposed Flesh Actual Thermometer Reading C in KPH 10 15 20 25 Equivalent Temperature C Wind Speeds Greater Than 70 KPH Have Little Added Effect 22 Little Danger For Properly Clothed Person Increasing Danger Danger From Freezing of Exposed Flesh SAFETY Safety Decals and Locations NOTE Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully If any safety decal becomes illegible or comes off contact your Polaris dealer for a free replacement The part number is printed on the decal Clutch Cover Warning Decal The clutch cover warning decal PN 7075350 is found under the hood on the clutch cover Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with this guard open Never run engine with drive belt removed Never service clutches yourself see your dealer Airbox Warning Decal The airbox warning decal PN 7
31. Drive System Remove the drive belt and store in a cool dry location Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant See page 113 for part numbers Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer Electrical Connections CAUTION Tampering with the EFI connections could result in damage to the vehicle Do not remove the engine EFI connections See your Polaris dealer for all EFl system service 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 from sharp edges steering linkage moving parts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 111 107 MAINTENANCE Extended Storage Engine Protection Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the can See page 113 Always add Premium Carbon Clean or a fuel conditioner stabili
32. ERFECT 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 e Non compliance with government industry requirements e Voiding of warranty e Personal injury to self or others This applies to but is not limited to brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use ap proved Polaris parts Please see your Polaris dealer for service Traction Products CAUTION Use of traction products such as studs ice growsers etc will damage the rear close off cooler of the Frontier Never install traction products on your Frontier snowmobile 46 PRE RIDE INSPECTION Before starting the engine always check all of the items outlined on the following pages AWARNING 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 Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often We ve attempted to provide as much information as possi
33. MAINTENANCE General Maintenance Brake Components INES mint CY fT Lem iii Ei 1 Brake Caliper 2 Chaincase 3 Brake Disc 4 Backing Plate 5 Brake Pad Material Replace when thickness is less than 1 16 Excessive Brake Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 85 the machine should be returned to an authorized Polaris dealer for inspection and adjustment 86 MAINTENANCE General Maintenance Brake Fluid AWARNING 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 AWARNING 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 CAUTION Brake fluid will damage decals paint and some plastics Always wipe up spills immediately All DOT 3 brake fluid is not the same We recommend the use of only Polaris DOT 3 high temperature brake fluid See page 113 for the part numbers of Polaris recommended products The brake fluid level can be seen through a pla
34. NG 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 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 62 OPERATION Reverse Operation AWARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death e Always look behind the vehicle before and while backing e Always avoid sharp turns e Shift to or from reverse only when stopped e Always apply throttle slowly 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
35. NG BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles When requesting warranty 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 personnel at Polaris if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recomm
36. ack damage and lead to serious personal injury 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 may then mount the machine and continue riding ACAUTION 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 19 SAFETY Operator Safety Your Polaris snowmobile is a well engineered and well constructed recreational vehicle Follow the recommended maintenance program beginning on page 67 to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals Rider Capacities The Polaris Frontier snowmobile is designed for two riders A decal on the console indicates that the vehicle is designed for one operator and one passenger only See page 25
37. ar To Front Coupling 43 IRECOM sarrio ext steed a De Seay a s 62 RECOMMENDED PRODUCTS 113 Revene odo ov odds ee 27 Reverse Kit Maintenance 96 Reverse Operation 63 Rider Capacities 0 20 Riding Apparel 12 Riding Position 11 RRSS 25 eetan bien e ooh 43 44 S SAFET Y croccan eie eseas 8 27 Safety Decals and Locations 23 27 Scissor Stop 0 000005 42 44 Service Contract 123 124 SHOCK yerine ewes eek be ele nce 34 Shock Spring Preload 35 Shock Valving 004 36 Shock Front 35 Shock Indy Select IFS 37 Shock Indy Select Rear 41 Skag Replacement 104 SKAGS Fe feed eile Lae E 104 Ski Alignment 103 Ski Skags 000 104 Spark Plugs 00 76 77 SPECIFICATIONS 112 Speeds eid sek See whe wea oe 13 S Spring Preload 40 Spring Tension Rear 39 Starting 0 0 2 0 eee ee 62 Starting the Engine 52 Steering Adjustment 102 Steering Inspection 102 Steering System 50 102 104 Stop Switch 0 00 51 60 Stopping 0 0004 62 Storage 000 64 106 109 Survival Equipment 11 Suspension 00 109 Suspension Adjustments 33 44 Suspension Coupling 42 Suspension Maint
38. arts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage The gearcase and transmission are excluded from coverage 124 A ACCESSOTIES oiii ee ee eee 46 AITbO goliere udne dekh ox 23 B Battery ss ccncc e Vin oe ges Ye 107 111 Battery Connections 110 Battery Fluid 109 Battery Installation 111 Battery Removal 110 Belt Troubleshooting 115 Bleeding the Cooling System 83 Bleeding the Hydraulic Brake System 88 Brake Components 86 Brake FIG 606 s 5 cc eee see ees 87 Brake Inspection 85 Brake Lever Feel 48 Brake Lever Travel 48 86 Brake System 00 88 Brake Park 00005 49 Brakes is jce ethene A Bod seks 48 Break In sasies sarii eretats 53 54 Cc Cargo Carrier 00 24 Cargo Overload 12 Chain Tension 97 Chaincase Oil 0 75 Check Engine Light 31 Cleanin amp skeneros huer aaas 106 Clutch Alignment and Offset 92 Clutch Center Distance 95 Clutch Cover 04 23 Clutch Guard 04 17 Clutch System 91 107 Clutches csc bee eens amp ew sete 18 Clutching Chart 92 Coil Springs 04 42 Cold Weather Drive Away 18 Controls and Linkage
39. ating at peak performance SPECIFICATIONS ai ci iai ee eral a hae ees 112 POLARIS RECOMMENDED PRODUCTS 113 TROUBLESHOOTING wiedcceee cteetieweianener enn 114 WARRANTY wiccae ee civeta vei beri weet eaa eles 119 INDEX ree ee ee eer ee ene E E eee 125 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient reference It should remain with the snowmobile when sold i The illustrations and photos used in this manual may be general representations Your model may differ 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 i 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 i 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 Please support their efforts and operate your snowmobile
40. ble to ensure a safe and enjoyable snowmobiling experience Throttle Lever The throttle is one of the primary controls of your snowmobile If it should malfunction loss of control could result Make sure the 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 operated See page 60 47 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 88 Brake Lever Feel A hydraulic system multiplies the force of your hand squeezing the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever feels spongy when squeezed check the level and condition of the fluid Also check for the presence of air in the fluid system Refer to page 88 for more information or see your dealer f
41. call the Polaris warranty department United States 763 542 0500 Canada 204 925 7100 B Owners must provide their name address telephone num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovered Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual Contact your Polaris dealer for replacement parts service or warranty Your dealer receives frequent updates on changes modifications and tips on snowmobile maintenance which may supersede information contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 5 Details of trouble experienced 2 Model number 6 Length of time and conditions of operation 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 119 WARRANTY Limited Warranty Polaris Industries Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIMITED WARRANTY on all components of the Polari
42. ching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your machine on a frozen body of water be sure the ice is thick enough to support 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 14 SAFETY Operator Safety Ice and Snow Build up AWARNING 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 Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered check for ice and snow build up that may be obstructing the steering linkag
43. condition When the low oil pressure indicator light is on visually check the oil level on the dipstick If the oil level is below the SAFE mark continued operation will cause serious engine damage Add the recommended oil before further operation of the snowmobile See page 113 for the part numbers of Polaris recommended products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic OW 40 engine oil for your snowmobile Never mix brands 31 FEATURES AND CONTROLS Block Heater To improve cold weather starting a block heater has been installed on the engine of your snowmobile When connected to a 110V electrical outlet the block heater warms the engine making it easier to start in subzero temperatures We recommend the use of this block heater whenever temperatures drop below 20 F 30 C Open the hood to access the block heater plug in see page 29 for location 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 CAUTION 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 32 THE PERFECT FIT Front Suspension Adjustments Before fi
44. d ONE passenger only Caution Decal A caution decal PN 7078363 is located on the center console of the snowmobile BEFORE STARTING ENGINE Check throttle and brake for proper operation Check to see that hood is securely latched Check surroundings to verify clear operation area Determine that steering is free and functional BRAKE LEVER LOCK May relax when used for long periods Do not leave brake engaged for more than five minutes ALWAYS Be seated and in position to control vehicle Stop engine before attempting adjustments Know the limitations of the vehicle and your skills as a driver Understand your Owner s Manual Wear clothing designed for snowmobiling Stops from high speed may cause fading or unexpected loss of braking ability OIL INJECTION SYSTEM Unmixed fuel only Check oil level when refueling If Owner s Manual is missing contact a Polaris dealer for a replacement 25 SAFETY Safety Decals And Locations Operation Warning Decal An operation warning decal is present on the console of the Polaris Frontier snowmobile in both English PN 7078056 and French PN 7078057 Read and understand warnings and the Owner s Manual before operation Severe injury or death can result from not heeding the warnings Never consume alcohol or drugs before or while operating this ve hicle Night riding limited visibility or excessive speeds may cause over driving of headlights resulting in insuf
45. d operating on ice hard packed surfaces or roads AWARNING 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 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 Start the engine and allow it to warm up two to three minutes 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 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 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 The engine drive system and track are now properly warmed up and the machine may be driven following normal safety practices 55 OPERATION Fuel 56 AWARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handli
46. d stream free of air bubbles AWARNING 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 After bleeding is complete refill the reservoir to the recommended level See page 87 Reinstall the gasket and cover General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure 1 Place the snowmobile on a level surface with the headlight approximately 25 feet 7 6m from a wall 2 Measure the distance from the floor to the center of the 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 MAINTENANCE Lamp Center Height 2 5 1 cm 89 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
47. dard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date free of charge through any Polaris snowmobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty registration form This form is your proof of warranty Consumer Exclusions e Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible e The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 calendar years from date of purchase which ever comes first Tampering with the odometer shall void all war ranties service contracts No extensions to coverage under this engine service contract can be given Used snowmobiles are not eli gible under this program e Snowmobiles used for commercial purposes or for racing are ex cluded from coverage Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visi
48. dler shaft If the track needs adjustment 5 Loosen rear idler shaft bolt D 6 Loosen locknuts A 7 Tighten or loosen the track adjusting screws B as necessary to provide equal adjustment on both sides of the track C Track 99 MAINTENANCE Track Maintenance If the track needs adjustment continued 8 Repeat the measurement on the other side of the track NOTE Check more frequently when machine is new 9 Start the machine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check the track alignment and adjust as necessary 11 Tighten the locknuts A 12 Tighten the idler shaft bolts D and torque to 35 ft Ibs 47 Nm Track Alignment Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five 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 tig
49. e Snow screens and bib kits are available through your dealer to help reduce snow and ice build up Driving on Slippery Surfaces AWARNING 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 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 15 SAFETY Operator Safety Driving in Hilly Terrain AWARNING 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 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 t
50. e RPM Avoid riding in high ambient RPM 10 MPH temperatures Ice and snow build up Warm the engine at least five minutes Take the drive belt off between track and the machine in extremely cold weather and warm it up tunnel Break machine loose from the snow Poor engine Check for fouled plugs and water ice or dirt in gas tank or performance fuel line Loading machines onto Skis may gouge into trailers and prevent the drivetrain from trailers spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch en Use fast aggressive throttle to engage clutch gagement 115 TROUBLESHOOTING Engine Troubleshooting CAUTION All engine service and repair should be performed by a qualified Polaris dealer with training in EFI engines Problem Erratic engine operating RPM during accelera tion or load variations Harsh drive clutch engagement Drive belt turns over Machine fails to move 116 Probable Cause Drive clutch bind ing Driven clutch malfunction Drive belt worn or too narrow Excessive belt sheave clearance Wrong belt for application Clutch alignment out of spec Engine mount bro ken or loose Transmission in neutral Clutch jammed Track jammed Chaincase sprocket or chain jammed or broken Solution Disassemble d
51. e 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 AWARNING Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause lt serious personal injury or death We recommend having your dealer perform track service and alignment procedures 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 AWARNING If fingers or clothing c
52. e rear suspension Decreasing the spring preload too much may allow the upper spring retainer to fall off Always leave at least one thread showing above the nut A ACAUTION 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 35 THE PERFECT FIT Front Suspension Adjustments If the spring preload is at its maximum and you want more adjustment e Remove the existing spring and install the next highest rate spring or e Increase compression damping on Indy Select shocks PE 52 See your dealer for details 36 THE PERFECT FIT Front Suspension Adjustments Indy Select IFS Shock Some snowmobiles are equipped with Indy Select IFS shocks which allow you to make adjustments to the compression valving of the front shocks by turning adjustment screws A located near the base of the shocks By turning the screw clockwise the compression of the shock increases stiffening the ride By turning counterclockwise the compression decreases softening the ride The factory setting is in the softest position screw all the way out counterclockwise If bottoming occurs the Indy Select feature should be used to achieve the desired ride effect One half turn will affect the ride considerably There are about three turns of adjustment available If experimenting with this adjustment feature turn the screw only 1 4 t
53. e 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 101 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 102 MAINTENANCE Steering System Ski Alignment AWARNING 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 Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 greater than at point Y NOTE Ifthe skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected 103 MAINTENANCE Steering System Ski Skags AWARNING 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 carbide skags than the original e
54. enance 105 106 Suspension Performance Tips 38 Suspension Troubleshooting 114 T TABLE OF CONTENTS 4 Temperature Chart 22 Tether Switch 0 08 51 THE PERFECT FIT 33 46 Throttle Cable 0 74 Throttle Lever 47 61 Throttle Position Sensor 59 Throttle Safety Switch 47 60 T Tool Kat eid tts Seek See eh 97 Tool Pouch Clip 97 OOS ice 2s ses Red aoe se et 98 TOWING e eiie oe apenas ein 65 TPS vipat casdece shbvadecen A oi a agers 59 TACK ik 28t0k Se tenth t Roe et 24 109 Track Alignment 100 Track Condition 50 Track Inspection 101 Track Lubrication 101 Track Maintenance 99 101 Track Tension 0005 99 Track Warm Up 55 Traction Products 46 Transmission 00005 51 TROUBLESHOOTING 114 118 Tune Up 0 000004 98 V Vehicle Identification Numbers 7 W WARRANTY 119 124 Water Bottle Cap 0 23 Weight Transfer During Acceleration 44 WELCOME 005 3 Windchill Chart 22 127 POLARIS The Way Out Part No 9918414 PRINTED IN THE USA
55. ended lubricants may not be covered by warranty 121 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a Polaris Dealer if applicable Failure of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of re quired periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Tires Slide Rails Suspension components Clutches and components Drive Belts Steering components Hydraulic components Batteries Circuit Breakers Fuses Light bulbs Sealed beam lamps Electronic components Finished and unfinished surfaces Wheels Brake components Throttle body components Seat components Engine components Warranty applies to the product only and does not allow fo
56. enings 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 1000 miles 1600 km See page 79 53 OPERATION Engine Break In Lubrication CAUTION 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 Always check the oil level when refueling Oil must be maintained between the SAFE and ADD marks on the dipstick See page 59 CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic OW 40 engine oil for your snowmobile Never mix brands We highly recommend the use of only Polaris products for your snowmobile We re continuously testing lubricants and provide the highest performance products available for your snowmobile s engine See page 113 for the part numbers of Polaris recommended products 54 OPERATION CAUTION 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 Avoi
57. ensor 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 3 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 System too rich Short term adaption at upper or lower limit 34 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 End of sequence message 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 Ifa problem with your EFI system occurs a code is triggered and the CHECK ENGINE light will come on If the light comes on take your Frontier to a qualified Polaris dealer for diagnostic service Low Oil Pressure Light 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 A low oil pressure indicator light will alert you to a low oil
58. er NOTE Record your snowmobile s ID numbers and key number in the spaces provided Tunnel VIN lower right side of the tunnel Vehicle Model Number Engine Serial Number right side of engine cylinder head 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 AWARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety AWARNING 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 ensur
59. er 2 20 41 0 3000 e R 11 900 1800 10 62 Yellow Silver 2 R 11 20 41 3000 6000 1800 2700 10 58 Yellow Silver 2 R 11 19 44 6000 9000 2700 3700 10 58 Yellow Silver 2 R 11 19 41 9000 12000 92 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 93 MAINTENANCE General Maintenance Drive Belt Installation 1 94 Drop the drive belt over the drive clutch and pull back the slack A NOTE To ensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves Hold the belt down between the sheaves and roll the bottom portion over
60. ery vent tube from the battery 3 Disconnect the black negative battery cable first then disconnect the red positive battery 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 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 110 MAINTENANCE Battery When your snowmobile is placed in storage for one month or more e Remove the battery e Charge it to the proper level e Store it in a cool dry place e Check and or charge monthly Before using the battery take it to your dealer for testing and recharging Batteries may freeze if not fully charged resulting in cell damage Charge Condition Will Freeze At 100 75 F 59 C ZEEN FECSO FCO 0 18 F 8 C Battery Installation AWARNING Batteries contain gases that can explode If the battery vent tube is pinched or kinked battery gases could accumulate Whenever removing or installing the battery disconnect the negative black cable first and reinstall the negative cable last to avoid the possibility of explosion Battery electrolyte contains acid Avoid skin contact with electrolyte as severe burns may result 1 Place the battery in its holder Attach the battery box cover Install the battery vent line It must be free
61. ety Excessive Speed AWARNING 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 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 13 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 approa
62. f 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 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 CAUTION 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 65 66 NOTES MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and service checks outlined in this manual The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 1000 miles 1600 km and 2000 miles 3200 km These inspections should be performed by a qualified service technician For co
63. ficient time to react to terrain changes or avoid unexpected obstacles This vehicle is capable of high speeds Buried objects or uneven ter rain can cause loss of control Exercise extreme caution when oper ating in unfamiliar terrain This vehicle is designed for adult use only The vehicle size speed capabilities and control requirement prohibit operation by children Operating this vehicle with a passenger on approved models only reduces your ability to control the vehicle due to the added weight and change in weight distribution Reduce vehicle speeds and allow extra space for maneuvering since steering control may be reduced Always wear an approved helmet eye protection and adequate clothing while operating this vehicle The Auxiliary Shut Off Switch is the primary means of stopping this vehicle in case of an emergency and is located on the top of the throttle control assembly Depress the switch to stop the engine and vehicle Routinely check this switch for proper function with the en gine idling Steering and braking ability are greatly reduced when operating on hard packed snow ice or when crossing roads Reduced speed and extra care are required to maintain vehicle control Carbide skags and studs enhance vehicle control on ice or hard packed surfaces Care must be taken to maintain a proper balance of ski carbides to track studs to maintain proper vehicle control See the Owner s Manual for proper use of traction
64. for decal location Machines designed for two riders should never be operated with more than two people on board When traveling with a passenger it s 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 20 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 A snowmobile depends on the rider s body position for proper bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience Before allowing someone else use your snowmobile know the ex tent of their operating skills Check to see if they ve taken a 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 Don t jump your snowmobile Jumping may injure your back be cause of spinal compression The seat and suspension of your snow mobile have
65. 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 111 SPECIFICATIONS Capacities and Dimensions Body Style Ee ape eres Suspension Engine and Cooling C res Features Standard 112 POLARIS RECOMMENDED PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 Engine Oil 4 Cycle qt Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz 2871372 2871322 2871423 2871329 Dielectric Grease Nyogel 2871323 Antifreeze 60 40 Premix gal 2871534 Antifreeze 60 40 Premix qt 113 TROUBLESHOOTING Suspension Troubleshooting Problem Solution perform only one change at a time Rear suspension Increase torsion spring preload bottoms too easily Increase rear shock compression damping by turning screw clockwise Increase torsion spring wire diameter see your dealer Rides too stiff in Check for binding suspension shafts and grease all pivot points rear Decrease torsion spring preload adjustments Decrease rear shock compression valving by turning screw counterclockwise if equipped with optional Indy Select shock Change to lighte
66. gine 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 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe 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 61 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency Refer to page 60 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION AWARNI
67. gs Inspect exhaust pipe for cracks or damage Inspect clutch sheaves for damage wear belt residue 69 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 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 3000 Mile 4800 km Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 4000 Mile 6400 km Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 70 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 71 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium 4 all season grease annually or about every 1000 miles 1600 km See page 113 for the part numbers of Polaris recommended pr
68. hat 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 16 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 AWARNING 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 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
69. hould 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 59 50 PRE RIDE INSPECTION The following items must be checked before each use of the vehicle Check these items after starting the engine see page 52 but before putting the machine into motion Transmission Make sure the reverse is not engaged before squeezing the throttle Engine Stop Switch Check the auxiliary shut off switch for proper operation Push down to stop the engine Pull up to release and start the engine See page 60 Tether Switch If your machine has a tether switch make sure the engine shuts off when the tether is removed from the switch See page 60 Lights Check the headlight high and low beam taillight and brake light for normal operation Mirrors If equipped adjust your mirrors so they can be used to their full advantage Operating Area Make sure you have a clear area all around your snowmobile including an area clear of bystanders There s always the possibility of some sideways vehicle movement of applying a little more throttle than intended or of debris being thrown by the track If the surrounding area is clear you before you start you can devote your full attention to operating
70. hten the right adjusting bolt 4 After adjustments are complete tighten the locknuts and torque the idler shaft bolts to 35 ft lbs 47 Nm 5 Repeat steps 2 and 3 to verify proper alignment 100 MAINTENANCE Track Maintenance Track Inspection AWARNING Broken track rods can cause a rotating track to come off the machine which could result in serious injury or death Never operate with a damaged track Never rotate a damaged track under power Using a hoist safely lift and support the 21 3 12 rear of the snowmobile off the ground Rotate the track by hand to check for possible damage Carefully examine the track along the entire length of each rod bending the track and inspecting for breakage The three most common damage areas are shown in the illustration Replace the track if any rod damage is found Track Lubrication AWARNING Operating with insufficient lubrication between the Hi fax and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new Hi fax can cause faster heat build up in limited lubrication resulting in excessive wear NOTE If excessive Hi fax wear occurs du
71. ions to clutches such as adding or removing weights will void the warranty CAUTION 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 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 91 MAINTENANCE General Maintenance Clutch Alignment and Offset Clutch center distance and alignment A are crucial to maintaining optimum performance See the specifications section on page 112 for the recommended offset between the drive and driven clutches with the belt removed MENI The drive belt is a very important part of the drive A e system Belt width and length must match the center distance of the clutches and sheave width of J the drive clutch For this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can l 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 Al ways carry a spare belt in case of an emergency Clutching Chart Altitude Shift Driven Driven Chaincase Meters Feet Weight Clutch Helix Gearing Spring 0 900 10 62 Yellow Silv
72. 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 113 for the part numbers of Polaris recommended products If you use oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives are not required and should not be used CAUTION Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel 58 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 aS E O eT SONA T Throttle Position Sensor TPS 4 CAUTION 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 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 59
73. justed see page 39 Return the screw to its original starting position after the torsion spring has been tightened 41 THE PERFECT FIT Rear Suspension Adjustments Optional Coil Springs Different rate coil springs are available for some shocks if a firmer ride is desired Contact your dealer for more information Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of suspension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and eliminating kickback Your FRSS is preset at the factory 42 THE PERFECT FIT Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop couples the
74. ne tuning adjustments are made break in the suspension for approximately 150 miles 240 km and re grease all suspension parts Settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved Adjustments should be made to one area at a time in order to properly evaluate the change All snowmobile suspensions have a front and a rear suspension each of which has adjustment options Independent Front Suspension IFS The IFS is made up of the skis 1 front shocks and springs 2 and the components that connect these parts to both the steering such as the tie rods 3 and to the machine itself such as the trailing arms 4 Front suspension adjustments include shocks springs toe and camber IFS Adjustment Options e Front shock spring preload e Optional springs e Optional valving if equipped with Fox RYDE FX or Walker Evans shocks e Indy Select if equipped 33 THE PERFECT FIT Front Suspension Adjustments AWARNING Always verify ski alignment before making adjustments to the IFS See page 103 to check alignment If the skis are misaligned see
75. ng gasoline e Always refuel with the engine stopped and outdoors or ina well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e 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 AWARNING 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 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 CAUTION 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 57 OPERATION Fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of
76. ntinued optimum performance and component life continue maintenance checks at 1000 mile 1600 km intervals Have your dealer perform a throttle body adjustment at 4000 miles 3200 km All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or adjust your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable performing these tasks yourself contact an authorized Polaris dealer for service EFI System There are no maintenance adjustments required for the EFI system Any service to the EFI system must be performed by an authorized Polaris dealer with training in EFI systems 67 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 Weekly or 150 M 1000 M 2000 M See before 240 km 1600 km 3200 km Page long trip Check brake operation and Daily 48 85 adjustment e
77. ntrol 15 Reverse Lever 16 Headlight Dimmer Switch 17 Park Brake 18 Handlebar Grip Warmer Switch 19 Thumbwarmer Switch SO 90 AON Ge No te 28 ONDARON Hood Headlight Windshield Handlebar Seat Storage Rear Taillights Cargo Carrier FEATURES AND CONTROLS Snow Flap Suspension Track Trailing Arm Block Heater under hood Nosepan Front Bumper Skis 29 FEATURES AND CONTROLS Malfunction Indicator Lamp MIL The Frontier is equipped with a malfunction indicator lamp CHECK ENGINE light to assist your Polaris dealer in diagnosing problems The MIL codes are for reference only Full diagnostics must be performed by a Polaris dealer trained to 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 CAUTION 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 MIL Diagnostic Code Summary CODE 21 Yes Lost synchronization Synchronization of crankshaft position lost 22 Yes Throttle position s
78. oducts The illustration shows the location of suspension and steering components A indicates a grease point or fitting Grease the left and right spindles Raise the front end of the ma chine to permit better grease entry into the spindle area Lubricate both of the front ski pivots at the fittings as shown Grease the jackshaft and driveshaft clutch side bearings Use an aerosol lubricant on the steering post support bracket Grease the center steering arms Grease the steering post lower pivot Grease the rear suspension pivot shafts raise the rear of unit A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles See page 113 72 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 x 73 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
79. ommended 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 76 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 AWARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or use of non recommended injection oil Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool
80. ontact the moving parts of an engine serious injury can result Always stop the engine before attempting adjustments Never attempt adjustments with the engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation 10 SAFETY Operator Safety Riding Position AWARNING 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 Operating a snowmobile requires skill and balance for proper control Rider positions may vary from person to person as each becomes more skilled but under most conditions the proper position is to be seated with feet on the running boards and comfortably positioned for proper throttle brake and steering control AWARNING 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 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 ext
81. or service 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 113 for the part numbers of Polaris recommended products AWARNING 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 48 PRE RIDE INSPECTION Park Brake Lever Lock Your snowmobile has a park brake lever lock located over the brake lever Use the brake lever lock when you want the machine to remain stationary for example when parked on an incline for a period of five minutes or less To apply the lock squeeze the brake handle and push forward on the brake lever lock Hold the lock forward and release the brake handle If the brake handle is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break To release the lock squeeze and release the brake lever The lever will return to the unlocked position The brake light on the console will light up when the park brake lever is locked and the engine is running It will also be lit when the service brake is in use If the brake light does not come on when the park brake or service brake is in use have it serviced by your dealer 1 Brake Lever 2 Park Brake Lever Lock 3 4 3 Master Cylinder Reservoir 2 S
82. quipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags weekly to maintain positive steering characteristics Skags must be replaced when worn to half their original diameter NOTE Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 2 3 Raise and support the front of the machine so the skis are approximately 6 15 2 cm from the ground Remove the attaching nuts and pry the skag A downward Remove the forward portion of the skag first then remove the entire skag Reverse this procedure for new skag installation 104 MAINTENANCE Suspension Maintenance Hi Fax Wear Replace Hi fax when a thickness of 5 16 8 cm is reached Check Hi fax wear by 5 16 8 cm measuring the thickness at several points along the rail A Take the machine to your dealer for Hi fax replacement Minimum Thickness 105 MAINTENANCE Suspension Maintenance Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the following items on a weekly basis or before any long trip Check rear idler wheel bolts for tightness Check rear idler adjusting bolt locknuts for tightness Check front
83. r 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 Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper en gine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjust ment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of after mar ket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been dam aged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 122 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is stan
84. r valving if if equipped with Fox shocks Check for proper track tension Machine darts from Make sure skis are aligned properly side to side Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check Hi fax and replace if worn Reduce ski pressure Reduce IFS spring preload Reduce rear torsion spring preload Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Increase IFS spring preload by adjusting cam or threaded ad juster Decrease front limiter strap length Steering is heavy Check ski alignment Check skags and skis for damage Reduce ski pressure Increase front track spring preload Reduce IFS spring preload by adjusting cam Reduce rear torsion spring preload Setting up for deep Change worn Hi fax snow operation Move front track shock assembly to upper position 114 TROUBLESHOOTING Belt Troubleshooting Belt Wear Burn Belt Wear Burn Diagnosis Driving at low RPM Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up 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 Towing at low RPM Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM Lower the gear ratio Remove windage plates from the and slow speed 8000 clutch Reduc
85. ra 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 11 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 AWARNING 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 Riding Apparel AWARNING 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 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 12 SAFETY Operator Saf
86. rformance Bogie wheel kits are available from your dealer e 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 Maintenance on pages 105 106 38 THE PERFECT FIT Rear Suspension Adjustments Rear Spring Tension To adjust rear torsion spring tension rotate the three position cam using the engine spark plug tool Different rate torsion springs are available if a firmer ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style 1 Turn screw clockwise to stiffen compression 2a Low tension 2b Medium tension 2c High tension 39 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the EDGE rear suspension torsion spring preload measure the distance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension NOTE The rear bumper may need to be lifted upward slightly to fully extend the rear suspension Next have the rider drop down hard
87. ris recommended products Never exceed a 60 antifreeze 40 water mixture Contact you dealer if greater protection is required NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Coolant High Temperature Indicator Light The high temperature indicator light is controlled by 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 81 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 CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended The engine coolant level is controlled by the recovery system The recovery system components are e Coolant bottle e Engine filler neck e Pressure cap e 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
88. rive clutch to inspect shift weights for wear and free operation SEE YOUR DEALER Clean and polish stationary shaft hub Replace ramp buttons and rollers SEE YOUR DEALER Inspect movable sheaves for excessive bush ing clearance and replace if necessary SEE YOUR DEALER Replace drive belt SEE YOUR DEALER Replace drive belt Adjust alignment offset Inspect and adjust or replace SEE YOUR DEALER Shift out of neutral Belt twisted spring broken weights stuck lubricated SEE YOUR DEALER Foreign object caught or Hi fax melted to track clips due to lack of lubrication Machine may be frozen to ground Track may be iced up Chain is loose or broken chain tightener is loose SEE YOUR DEALER TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Poor low RPM performance Engine doesn t start electric start models Engine doesn t turn over Probable Cause Broken drive clutch components Bearing failure chaincase jack shaft or front drive shaft Drive belt surface flat spots Drive chain loose or worn sprocket teeth broken Worn drive belt Excessive belt sheave clearance Loose torque stop Sticky clutch Wire connections Seized engine Dead battery Solution SEE YOUR DEALER SEE YOUR DEALER Inspect and replace if necessary Inspect and adjust or replace Inspect and replace if necessary SEE YOUR DEALER
89. rol and serious injury or death Always maintain the track tension as specified Allow the engine to reach idle speed before attempting to shift into or out of reverse CAUTION Damage will occur to the chaincase or transmission if shifting is attempted before the machine has come to a complete stop Make sure the snowmobile has completely stopped and the engine has returned to idle speed before shifting gears 96 MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for amp gz emergency and routine maintenance T gt 1 Phillips Screwdriver ee 1 2 Tubular Socket a i 3 Tubular Socket Handle Se J 4 Wrench ye 3 5 Shielded Screwdriver 6 Scissor Stop Wrench me SS 7 Box End Wrench lt Ox 6 NOTE Always keep the tool kit with the 5 k 2 snowmobile If necessary a replacement tool kit may be purchased from your Polaris dealer Tool Pouch Clip A tool pouch clip A is located inside the flap on the back of the seat Use this clip to secure the tools and keep them from bouncing around during snowmobile use Chain Tension Maintain the proper chain tension as outlined on page 84 Oil Level Maintain the oil level between the SAFE and ADD marks on the oil dipstick See page 59 97 MAINTENANCE General Maintenance Emergency Supplies For added protection carry the following items on your snowmobile at all times Spare Drive Belt Extra Set of Spark Plugs Tow Rope eExtra
90. s snowmobile against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferrable to another consumer during the war ranty period through a Polaris dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures 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
91. senee sopien bay _ 31 Presteersmap Pay _ _ chook wack condition Day o Tes onne satey switch Daly check toe ver operon Day _ __ ig taillight brakelight cheek park brake tacion pay _ _ 9 CA a id creek cootattevet pay _ Check vackaligame _ __ ___ 100 Stcoingarmand erodes x __ _ m_ check thrwte cate condition x _ _ _ oreck mackiension x _ _ creck chsineaseoirever x _ _ 5 creck gsurense eve x _ _ 5 check drive cameron x _ Creek drive condition x _ 3 __ ee ae a suspension mounting bolts th de he Check front limiter strap eas ee ae ee ee a ed worn to half original diameter o ec Check Hi fax thickness have HHH dealer replace when worn Tighten rear idler wheel bolts X X X X X 68 MAINTENANCE Maintenance Chart Weekly or 150 M 1000 M 2000 M See before 240 km 1600 km 3200 km Page long trip Check spark plug condition re X 77 place annually Inspect coolant filter replace if X X X 83 necessary ews ee Lubricate steering post support bracket and pivot oo Grease driveshaft bearing X X 74 always perform before storage Grease rear suspension pivot 500 mi X X 73 shafts Grease jackshaft bearing X X 72 always perform before storage mensem o o e specific Say peaosa OO e a Inspect exhaust system for weak or missing retaining sprin
92. stic 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 87 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 AWARNING 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 During the bleeding procedure keep the brake handle as level as possible The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 2 88 Remove the brake master cylinder reservoir cover and gasket 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 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air Close the bleeder valve and release the brake lever Repeat steps 4 and 5 until fluid flows from the bleeder valve in a soli
93. t Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes e Damage due to accident fire explosion theft or other causes be yond Polaris control e Damage caused by the failure of other components of the snowmo bile e Failures caused by improper fuel or oil e Piston seizures unless caused by a defective engine component e Failures caused due to improper adjustments 123 WARRANTY Polaris Second Year Engine Service Contract Coverage Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gas kets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered Throttle body ad justments are excluded from coverage The fuel pump is covered Clutches and related clutch p
94. the snowmobile 51 OPERATION Starting the Engine AWARNING Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without checking all components to be sure of proper operation See Pre Ride Inspection section beginning on page 47 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 The Frontier is equipped with a recoil for emergency starting See page 62 52 OPERATION Engine Break In No single action on your part is as important to long trouble free machine life as proper break in of a new or rebuilt engine During the first three hours of operation operate the snowmobile as outlined in the Engine Break In section 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 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 op
95. torque arm limiter strap condition Check slide rail Hi fax condition have your dealer replace when worn to minimum thickness Check track tension beginning on page 99 YY WYXX YX Lubricate grease all suspension components beginning on page 72 Check ski runner skag condition Extended Storage 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 previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Controls and Linkage All bushings spindle shafts tie rod ends and cables should receive a light coat of oil or grease 106 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All Season Grease or a similar high quality grease to prevent corrosion See page 113 for part numbers Clutch and
96. urn at a time And always adjust both shocks equally 37 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 set up options is located on the clutch cover It provides a guideline for initial suspension set up Additional adjustments can be made from this point Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer Suspension Performance Tips e Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride e In deep snow a new Hi fax will offer improved performance over worn Hi fax It can also improve top speed e When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s pe
97. zer to the fuel tank Follow the instructions on the can running the engine for five minutes to get additives through the entire 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 the machine is elevated and the engine is tilted rearward 3 Remove the spark plugs 4 Rotate the engine slowly watching the pistons until they re at bottom dead center BDC the lowest position in the cylinder 5 Pour approximately one ounce of engine oil into each spark plug hole 6 Repeat step 4 then replace the spark plugs and lower the machine to the floor 108 MAINTENANCE Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely See illustration Battery AWARNING 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

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