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.
What’s the hottest thing on snow? Our new web site. And it’s designed just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.
All information in this manual is based on the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements that may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc. Copyright 2002 Polaris Industries Inc. All Rights Reserved 2 Printed in the U.S.A.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.
TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 The introduction contains helpful information for owners and drivers, including the location of important identification numbers that should be recorded in your owner’s manual. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual may be general representations. Your model may differ. n Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.
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.
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.
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. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs. Polaris produces high performance snowmobiles capable of traveling at high speeds. Extra caution must be observed to ensure operator safety.
SAFETY Operator Safety Stay Away From Moving Parts WARNING Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death. We recommend having your dealer perform track service and alignment procedures. 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.
SAFETY Operator Safety Riding Position WARNING 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.
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. WARNING 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.
SAFETY Operator Safety Excessive Speed WARNING 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.
SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to distinguish. Make sure the way is clear before crossing railroads and other roads and highways. The noise of your machine will drown out the sound of approaching vehicles.
SAFETY Operator Safety Ice and Snow Build-up WARNING 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 linkage.
SAFETY Operator Safety Driving in Hilly Terrain WARNING 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.
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. WARNING 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.
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.
SAFETY Operator Safety Powder Snow Operation WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track 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.
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.
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.
SAFETY Operator Safety Windchill/Temperature Charts The following charts will help you determine when temperatures become dangerous for riding.
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.
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 lbs. (18 kg).
SAFETY Safety Decals And Locations Passenger Warning The Frontier snowmobile is designed for the operator and one passenger. The passenger warning decal (PN 7075439) is located on the right side of the console. For more information on operating capacities, see page 20. + This vehicle is designed for operator and ONE passenger only. Caution Decal A caution decal (PN 7078363) is located on the center console of the snowmobile: BEFORE STARTING ENGINE: Check throttle and brake for + proper operation.
SAFETY Safety Decals And Locations Operation Warning Decal An operation warning decal is present on the console of the Polaris Frontier snowmobile in both English (PN 7078056) and French (PN 7078057): S Read and understand warnings and the Owner’s Manual before + operation. Severe injury or death can result from not heeding the warnings. S Never consume alcohol or drugs before or while operating this vehicle.
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.
FEATURES AND CONTROLS 5 6 7 8 9 10 11 12 4 3 13 15 14 2 1 1. Fuel Filler Cap 2. Ignition Switch 3. Brake Lever 4. Electronic Fuel Gauge 5. Speedometer 6. Headlight High Beam Light 7. Low Oil Pressure Light 8. Brake Light 9. Check Engine Light 10. Reverse Indicator Light 11. Temperature Light 12. Tachometer 13. Engine Stop Switch 14. Throttle Control 15. Reverse Lever 16. Headlight Dimmer Switch 17. Park Brake 18. Handlebar Grip Warmer Switch 19.
FEATURES AND CONTROLS 6 4 3 7 8 5 2 1 9 10 16 11 15 1. 2. 3. 4. 5. 6. 7. 8. Hood Headlight Windshield Handlebar Seat Storage/Rear Taillights Cargo Carrier 14 12 13 9. 10. 11. 12. 13. 14. 15. 16.
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.
FEATURES AND CONTROLS Check Engine Light Your EFI system has an Electronic Control Unit (ECU), which is pre-coded for any potential problems your EFI system will have. If a problem with your EFI system occurs, a code is triggered and the CHECK ENGINE light will come on. If the light comes on, take your Frontier to a qualified Polaris dealer for diagnostic service. Low Oil Pressure Light CAUTION Operating the snowmobile without proper engine lubrication can result in serious engine damage.
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).
THE PERFECT FIT Front Suspension Adjustments Before fine-tuning adjustments are made, break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 103 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. 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.
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 A left and right sides of the machine are at the same adjustment. To increase front shock spring preload, grasp the spring and turn it to the right. Turn it to the left to decrease preload.
THE PERFECT FIT Front Suspension Adjustments If the spring preload is at its maximum and you want more adjustment: S Remove the existing spring and install the next highest rate spring, or S Increase compression damping on Indy Select shocks (PE 52) See your dealer for details.
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 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.
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.
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 X full extension. NOTE: The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.
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.
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.
THE PERFECT FIT Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm. Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance.
THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration Rear Rear Scissor Stop (RRSS) 1 The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the RRSS. The RRSS is located in the best overall trail riding position when delivered from the factory. To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position with the scissor stop tool (1) located in your tool kit.
THE PERFECT FIT Handlebar Adjustments WARNING 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.
THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to saddlebags, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories. NOTE: The accessory tether switch is available for all models. Order PN 2870668. Use only Polaris parts and accessories on your Polaris snowmobile.
PRE-RIDE INSPECTION Before starting the engine, always check all of the items outlined on the following pages. WARNING 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.
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. A 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.
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.
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.
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.
OPERATION Starting the Engine WARNING 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.
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.
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.
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. Avoid operating on ice, hard-packed surfaces or roads. WARNING 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.
OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck.
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.
OPERATION Fuel Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. See page 113 for the part numbers of Polaris-recommended products.
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.
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. A Throttle Safety Switch B Test the throttle safety switch system daily before operation.
OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. 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.
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.
OPERATION Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. S S S S Always look behind the vehicle before and while backing. Always avoid sharp turns. Shift to or from reverse only when stopped. 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.
OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (20 cm) off the ground. Remove the key and cover the machine. NOTE: Polaris has accessory covers and track stands available to fit all models. See your dealer for more information.
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. WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used.
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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.
MAINTENANCE Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item Weekly or before long trip 150 M. (240 km) 1000 M. (1600 km) 2000 M.
MAINTENANCE Maintenance Chart Item Weekly or before long trip 150 M. (240 km) 1000 M. (1600 km) 2000 M.
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.
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 products. The illustration shows the location of suspension and steering components. A + indicates a grease point or fitting. S Grease the left and right spindles. Raise the front end of the machine to permit better grease entry into the spindle area.
MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension. For detailed information about suspension lubrication and adjustments, see your Polaris dealer. NOTE: Lubrication points are indicated by a L.
MAINTENANCE Lubrication Jackshaft Bearing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps). Push the clutch back onto the shaft and replace the clutch retaining bolt. Torque to 18 ft. lbs. (24 Nm).
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.
MAINTENANCE General Maintenance Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. S S S Use Champion RC7YC spark plugs. Proper electrode gap is .035” (.9 mm) Spark plug torque is 18-22 ft. lbs. (24-30 Nm). Change spark plugs annually and whenever inspection reveals fouled or damaged plugs. Always use the recommended spark plugs for your machine. A spark plug with a heat range too high will cause engine damage.
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. WARNING 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.
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 1 2 3 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.
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.
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. WARNING 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.
General Maintenance 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 Polaris-recommended products.
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. A 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.
MAINTENANCE General Maintenance Bleeding the Cooling System WARNING 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.
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.
MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and A 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.
MAINTENANCE General Maintenance Brake Components 1 2 5 4 3 1. 2. 3. 4. 5. Brake Caliper Chaincase Brake Disc Backing Plate 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.
MAINTENANCE General Maintenance Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. WARNING Keep the master cylinder cover free of dirt and debris.
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. WARNING 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.
MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of 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.
MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlights Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases 2 from the spring retainer. 2. Lift the spring carefully around the wire harness (2) and flip to 3 the outside of the housing. 3.
MAINTENANCE General Maintenance Clutch System WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.
MAINTENANCE General Maintenance Clutch Alignment and Offset Clutch center distance and alignment (A) are crucial to maintaining optimum performance. See the specifications section on page 112 for the recommended offset between the drive and driven clutches with the belt removed. The drive belt is a very important part of the drive system. Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M.
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.
MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the A 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 B sheaves as outlined in the belt removal procedures. 2. Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves. 3.
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”. A B 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.
MAINTENANCE General Maintenance Reverse Kit Maintenance Always maintain track tension as specified on page 99 when a snowmobile is equipped with reverse. WARNING Improper track tension can cause serious damage to the snowmobile, which can result in loss of vehicle control and serious injury or death. Always maintain the track tension as specified. Allow the engine to reach idle speed before attempting to shift into or out of reverse.
MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance. 1. Phillips Screwdriver 2. Tubular Socket 3. Tubular Socket Handle 4. Wrench 4 5. Shielded Screwdriver 6. Scissor Stop Wrench 7. Box End Wrench NOTE: Always keep the tool kit with the 5 snowmobile. If necessary, a replacement tool kit may be purchased from your Polaris dealer. 1 2 3 6 7 Tool Pouch Clip A tool pouch clip (A) is located inside the flap on the back of the seat.
MAINTENANCE General Maintenance Emergency Supplies For added protection, carry the following items on your snowmobile at all times: SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner’s Manual SFirst Aid Kit Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technicians will keep your machine in peak operating condition.
MAINTENANCE Track Maintenance WARNING 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.
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. lbs. (47 Nm).
MAINTENANCE Track Maintenance Track Inspection WARNING 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 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.
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 +.
MAINTENANCE Steering System Ski Alignment WARNING 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.
MAINTENANCE Steering System Ski Skags WARNING 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 equipment, 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.
MAINTENANCE Suspension Maintenance Hi-Fax Wear Replace Hi-fax when a thickness of 5/16″ (.8 cm) is reached. Check Hi-fax wear by measuring the thickness at several points along the rail (A). Take the machine to your dealer for Hi-fax replacement. A 5/16″ (.
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: n Check rear idler wheel bolts for tightness. n Check rear idler adjusting bolt locknuts for tightness. n Check front torque arm limiter strap condition.
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 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.
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/stabilizer to the fuel tank.
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 WARNING 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.
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.
MAINTENANCE Battery When your snowmobile is placed in storage for one month or more: S Remove the battery. S Charge it to the proper level. S Store it in a cool dry place. S 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.
SPECIFICATIONS Capacities and Dimensions Body Style Rider Capacity Dry Weight (Est.) Fuel Tank capacity Height Length Oil Capacity (Quarts) Ski Center Distance (in.) Width (in.) Brake Type Drive Clutch Center Distance Clutch Type Track Length Track Width Drive Chain Length Sprocket Ratio EDGE 2 581 lbs/264 kg 11.8 gal/44.7 ltr 48.5 in/23 cm 127.0 in/322.6 cm 2 qts/1.9 ltr 42.5 in/108 cm 47 in/119.4 cm Hydraulic 10 in/25.4 cm P-85 136 in/345.
POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz.
TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily -Increase torsion spring preload -Increase rear shock compression damping by turning screw clockwise -Increase torsion spring wire diameter (see your dealer) Rides too stiff in rear -Check for binding suspension shafts and grease all pivot points -Decrease torsion spring preload adjustments -Decrease rear shock compression valving by turning screw counterclockwise (if equip
TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn Belt Wear/Burn Diagnosis Causes Solutions 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.
TROUBLESHOOTING Engine Troubleshooting CAUTION: All engine service and repair should be performed by a qualified Polaris dealer with training in EFI engines. Problem Probable Cause Solution Erratic engine operating RPM during acceleration or load variations Drive clutch binding -Disassemble drive clutch to inspect shift weights for wear and free operation. SEE YOUR DEALER. -Clean and polish stationary shaft hub. Driven clutch malfunction -Replace ramp buttons and rollers. SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Solution Broken drive clutch -SEE YOUR DEALER. components Bearing failure/ chaincase, jackshaft, or front drive shaft -SEE YOUR DEALER. Drive belt surface flat spots -Inspect and replace if necessary. Drive chain loose or worn, sprocket teeth broken -Inspect and adjust or replace. Worn drive belt -Inspect and replace if necessary. Excessive belt/ sheave clearance -SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable Cause Solution Faulty ignition -Check for spark; if no spark SEE DEALER. No fuel to engine -Check tank level and fill with correct fuel. -Ice in fuel line, filter, or pump. Air in fuel line -SEE DEALER for fuel line bleeding. Poor engine compression -SEE DEALER. This indicates a major engine problem that must be repaired before engine is run. Fuel filter (loss of high RPM power) -SEE DEALER.
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 officials, the owner must call the Polaris warranty department: United States #763-542-0500 Canada #204-925-7100 B.
WARRANTY Limited Warranty Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris 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 warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES 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.
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 required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard 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.
WARRANTY Polaris Second Year Engine Service Contract Coverage S Failure due to unauthorized service. S 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. S Failure due to use of unauthorized parts or modifications. S Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls, and recoil ropes are excluded from coverage.
INDEX A Accessories . . . . . . . . . . . . . . . . . . . 46 Airbox . . . . . . . . . . . . . . . . . . . . . . 23 B Battery . . . . . . . . . . . . . . . . . . 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 . . .
INDEX G O General Maintenance . . . . . . . . . 76-98 OPERATION . . . . . . . . . . . . . . . 52-65 Operator Safety . . . . . . . . . . . . . . . 8-22 H Handlebar Adjustments . . . . . . . . . . Headlight Adjustment . . . . . . . . . . . Headlights . . . . . . . . . . . . . . . . . . . . Hi-Fax Wear . . . . . . . . . . . . . . . . . High Temperature Indicator Light . . Hood Latches . . . . . . . . . . . . . . . . . 45 89 90 105 81 50 I Ice and Snow Build-up . . . . . . . . . . IFS . . . . . . . . . .
INDEX S T Spring Preload . . . . . . . . . . . . . . . . 40 Spring Tension, Rear . . . . . . . . . . . . 39 Starting . . . . . . . . . . . . . . . . . . . . . . 62 Starting the Engine . . . . . . . . . . . . . 52 Steering Adjustment . . . . . . . . . . . 102 Steering Inspection . . . . . . . . . . . . 102 Steering System . . . . . . . . 50, 102-104 Stop Switch . . . . . . . . . . . . . . . . 51, 60 Stopping . . . . . . . . . . . . . . . . . . . . . 62 Storage . . . . . . . . . . . . . . .
