Polaris 2003 Frontier Manual do Utilizador

2003Owner's ManualforVehicle MaintenanceandSafety

8SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these word

98MAINTENANCEGeneral MaintenanceNOTE: Do not touch a halogen bulb with bare fingers. Oil from skinleaves a residue, causing a hot spot that will short

99MAINTENANCEGeneral MaintenanceClutch SystemPeriodically inspect the clutch sheaves for damage, wear , or beltresidue. To maintain optimum performanc

100MAINTENANCEGeneral MaintenanceClutch Alignment and OffsetClutch center distance and alignment (A) arecrucial to maintaining optimum performance.See

101MAINTENANCEFrontier Classic Clutching ChartAltitudeMeters (Feet)ShiftWeightDriveClutchSpringDrivenClutchSpringDrivenHelixChaincaseGearing0-900(0-30

102MAINTENANCEGeneral MaintenancePeriodically check the condition and tension of the drive belt, andalways carry a spare belt. For improved drive-away

103MAINTENANCEGeneral MaintenanceDrive Belt Installation1. Drop the drive belt over thedrive clutch and pull back theslack (A). NOTE: To ensuresatisfa

104MAINTENANCEGeneral MaintenanceDrive Belt DeflectionMeasure belt deflection with bothclutches at rest and in their fullneutral position.Place a stra

105MAINTENANCEGeneral MaintenanceReverse Kit Main t en an ceAlways maintain track tension as specified on pages 46 and 50 when asnowmobile is equipped

106MAINTENANCEGeneral MaintenanceTool KitA tool kit is included with each machine foremergency and routine maintenance.1. Phillips Screwdriver2. Tubul

107MAINTENANCEGeneral MaintenanceEmergency SuppliesFor added protection, carry the following items on your snowmobile atall times:SSpare Drive Belt SE

9SAFETYOperator SafetyWARNINGDriving a snowmobile requires your full attention. DO NOTdrink alcohol or use drugs or medications before or whiledriving

108MAINTENANCETrack AlignmentPeriodically check that the track iscentered and running evenly on theslide rails. Misalignment will causeexcessive wear

109MAINTENANCETrack MaintenanceTrack Insp ectio nUsing a hoist, safely lift and support therear of the snowmobile off the ground.Rotate the track by h

110MAINTENANCESteering SystemSteering Inspectio n and AdjustmentEach week, or before a long ride, check fasteners and tighten if needed.Specific faste

111MAINTENANCESteering SystemSki AlignmentWith the handlebars i n a straight ahead position, and with vehicleweight compressing the suspension, measur

112MAINTENANCESteering SystemSki SkagsCheck skags weekly to maintain positive steering characteristics. Skagsmust be replaced when worn to half their

113MAINTENANCESuspension MaintenanceHi-Fax WearReplace Hi-fax when a thickness of5/16″ (.8 cm) is reached. CheckHi-fax wear by measuring thethickness

114MAINTENANCESuspension MaintenanceLoose nuts and bolts can reduce your snowmobile’s reliability andcause needless repairs and down time. Before begi

115MAINTENANCEExtended StorageBearingsGrease the jackshaft and drive shaft clutch side bearings with PolarisPremium All-Season Grease or a similar hig

116MAINTENANCEExtended StorageEngine ProtectionProper preparation of the engine and fuel system is vital to t heprevention of rust and corrosion on pr

117MAINTENANCEExtended StorageTrack and SuspensionModerate track tension should be maintainedduring summer storage. The machine shouldbe supported off

10SAFETYOperator SafetyStay Away F rom Movin g PartsBe alert when riding, and remain properly seated to stay clear of thetrack. Your snowmobile is pro

118MAINTENANCEBatteryBattery ConnectionsKeep battery terminals and connections free of corrosion. Whencleaning is necessary, remove the corrosion with

119MAINTENANCEBatteryWhen 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 i

120SPECIFICATIONSFrontier ClassicCapacities and DimensionsBody Style EdgeRiders 1Coolant 5.9 qts./5.6 lChaincase Oil 12 oz./.34 kgEngine Oil 2qts./1.9

121SPECIFICATIONSFrontier TouringCapacities and DimensionsBody Style EdgeRiders 2Coolant 6qts./5.7lChaincase Oil 12 oz./.34 kgEngine Oil 2qts./1.9lDry

122TROUBLESHOOTINGM10 Suspension TroubleshootingProblem Solution (perform only one change at a time)Rear suspensionbottoms too easily- Increase FRA po

123TROUBLESHOOTINGEdge Touring Suspension TroubleshootingProblem Solution (perform only one change at a time)Rear suspensionbottoms too easily- Adjust

124TROUBLESHOOTINGBelt TroubleshootingBelt Wear/BurnBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM Drive at higher RPMs. Gear the machine

125TROUBLESHOOTINGEngine TroubleshootingCAUTION: All engine service and repair should be performed by aqualified Polaris dealer with training in EFI e

126TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drivesystemBroken drive clutchcomponentsBearing failure/chaincase, jac

127TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turnsbut fails to startFaulty ignitionNo fuel to engineAir in fuel lineP

11SAFETYOperator SafetyRiding PositionOperating a snowmobile requires skill and balance for proper control.Rider positions may vary from person to per

128POLARIS RECOMMENDED PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 Engine Oil (

129WARRANTYService And W arranty InformationPolaris Anti-Theft SystemThe Polaris anti-theft system (PATS) monitoring program is designedto aid owners

130WARRANTYLimited WarrantyPolaris Industries Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEARLIMITED WARRANTY on all components of the Po

131WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND F

132WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if app

133WARRANTYPolaris Second Y ear Engine Service ContractSecond Year Engine Service Contract is standard on all eligible newand unused snowmobiles that

134WARRANTYPolaris Second Y ear Engine Service ContractCoverageS Failure due to unauthorized service.S Failures due to lack of service as required i n

135INDEXAAccessories 53-55...Airbox 23...BBattery 115-119...Battery Connections 118...Battery

136INDEXHHandlebar Adjustments 52...Headlight Adjustment 97...Headlights 98...Hi-Fax Wear 113...High Tem

137INDEXSSpark Plugs 84-85...SPECIFICATIONS 120-121...Speed 13...Spring Rates 38...Spring Tensi

12SAFETYOperator SafetyCargo OverloadToo much weight on the rear of the machine may reduce your ability tosteer. Do not exceed carrier and rack weight

Part No. 9918415PRINTED IN THE USA

13SAFETYOperator SafetyExcessive SpeedObserve all state and local laws governing snowmobile operation.They’ve been established for your protection.Alw

14SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles,posts, or other obstacles. Be especiallyalert if you’re snowmobiling after

15SAFETYOperator SafetyIce and Snow Build -upBefore driving, manually turn the skis to the left and right to be sureice and snow are not interfering w

16SAFETYOperator SafetyDriving in Hilly TerrainOperating i n hilly terrain requires extreme caution to maintain balanceand avoid roll-over. If climbin

17SAFETYOperator SafetyDriving DownhillWhen riding downhill, shift your weight to the rear of the machine andreduce your speed to a minimum. Apply jus

Read, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the safety precau

18SAFETYOperator SafetyIntake SilencerDamage to the engine may occur if the intake silencer or filter areremoved.ClutchesDo not attempt to service the

19SAFETYOperator SafetyPowder Snow OperationSince snow provides t he only lubrication for the power slidesuspension and cooling for the engine, adequa

20SAFETYOperator SafetyYour Polaris snowmobile is a well-engineered and well-constructedrecreational vehicle. Follow the recommended maintenance progr

21SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docileconditions may become dangerous if operators d

22SAFETYOperator SafetyWindchill/Temperature ChartsThe following charts will help you determine when t emperaturesbecome dangerous for riding.WIND CHI

23SAFETYSafety Decals and LocationsNOTE: Warning decals have been placed on the vehicle for yourprotection. Read and follow the instructions on each d

24SAFETYSafety Decals And LocationsTrack Warning DecalThe track warning decal is located on therear of the taillight housing:Stay clear of track. Do n

25SAFETYSafety Decals And LocationsOperation Warning DecalAn operation warning decal ispresent on t he console of the PolarisFrontier snowmobiles in b

26SAFETYSafety Decals And LocationsReverse Warning DecalThe reverse warning decal (PN 7170112) is located on the centerconsole:Reverse operation, even

27FEATURES AND CONTROLS1. Fuel Filler Cap2. Ignition Switch3. Brake Lever4. Electronic Fuel Gauge5. Speedometer6. Headlight High Beam Light7. Low Oil

1What’s the hottest thing on snow?Our new web site. And it’s designed just for YOU!S Technical tipsS New product introductionsS Event schedulesS Parts

28FEATURES AND CONTROLS1. Hood2. Headlight3. Windshield4. Handlebar5. Seat6. Passenger Seat (Touring)7. Cargo Box8. Taillights9. Snow Flap10. Suspensi

29FEATURES AND CONTROLSMalfunction Indicator Lamp (MIL)The Frontier is equipped with amalfunction indicator lamp (CHECKENGINE light) to assist your Po

30FEATURES AND CONTROLSCheck Engine LightYour EFI system has an Electronic Control Unit (ECU), which ispre-coded for any potential problems your EFI s

31FEATURES AND CONTROLSBlock HeaterTo improve cold-weather starting, a block heater has been installed onthe engine of your snowmobile. When connected

32THE PERFECT FITFront Suspension AdjustmentsBefore fine-tuning adjustments are made, break in the suspension forapproximately 150 miles (240 km) and

33THE PERFECT FITFront Suspension AdjustmentsThe tension at which the shock coil spring i s set is called springpreload. For the best ride, the spring

34THE PERFECT FITFront Suspension AdjustmentsAdjusting Front Shock Spring PreloadIncreasing spring preload will increaseski-to-ground pressure. Decrea

35THE PERFECT FITFront Suspension AdjustmentsIndy Select IFS ShockThe Frontier Touring model is equipped with Indy Select IFS shocks,which allows you

36THE PERFECT FITRear Suspension AdjustmentsRider weight, riding style, trail conditions, and vehicle speed all affectsuspension action.Each rear susp

37THE PERFECT FITM10 SuspensionBefore proceeding with the tuning of your M10 suspension, you shouldfamiliarize yourself with the following terms:M10 F

2All information in this manual is based on the latest product data and specificationsavailable at the time of printing. Polaris Industries Inc. reser

38THE PERFECT FITM10 SuspensionM10 F eaturesNOTE: The M10 has been designed to be very sensitive to riderweight. Changes in rider weight of 25 lbs. or

39THE PERFECT FITM10 SuspensionM10 F eaturesOptional Sp ring Rates - Optional springs have been designed to allowadaptation of the M10 t o t he varied

40THE PERFECT FITM10 SuspensionM10 F eaturesSAG SETTINGS - Describes the difference in height of the rearbumper from the sleds fully extended position

41THE PERFECT FITM10 SuspensionInitial Setup and CalibrationYour M10 is a precision instrument which MUST be optimized foryour specific needs and ridi

42THE PERFECT FITM10 SuspensionINITIAL SETUP REFERENCE CHARTThis chart is a guideline to be used for initial suspension setups.Your setup may vary bas

43THE PERFECT FITM10 SuspensionRear Compression Spring Preload - Dimension B1. Using the spannerwrenches in your tool kit,rotate the x-over tubeassemb

44THE PERFECT FITM10 SuspensionLimiter/Ski PressureYour M10 rearsuspension has comefrom the factory set upto delivery the optimumbalance between ridea

45THE PERFECT FITM10 SuspensionSag/Ride Height Settings1. To check if the FRA settings are close before riding, check theSAG settings. Raise the rear

46THE PERFECT FITM10 SuspensionTrack TensionTrack adjustment is criticalfor proper handling. Alwaysmaintain correct tension andalignment.Tension adjus

47THE PERFECT FITEdge Touring SuspensionBefore proceeding with the tuning of your Edge Touring Suspension(ETS), you should familiarize yourself with t

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

48THE PERFECT FITEdge Touring SuspensionEdge Touring FeaturesTorsion Springs - Two torsion springs are used on the rear arm of theETS. Preload adjustm

49THE PERFECT FITEdge Touring SuspensionInitial Setup and CalibrationThe following information has been compiled to assist you in tuningyour ETS to it

50THE PERFECT FITEdge Touring SuspensionTrack TensionTrack adjustment iscritical for properhandling. Alwaysmaintain correct tensionand alignment.Tensi

51THE PERFECT FITEdge Touring SuspensionTorsion Spring TensionTo adjust rear torsion spring tension, rotate the two-position cam usingthe engine spark

52THE PERFECT FITHandlebar AdjustmentsFollow these steps to adjust the handlebars for a personal fit.1. Remove the handlebar cover toexpose the handle

53THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile. Frommap light to saddlebags, Polaris has the accessories t

54THE PERFECT FITAccessoriesTraction ProductsTrack studding will enhance braking control on hard-packed snow orice, but extreme caution is still requi

55THE PERFECT FITAccessoriesWear StripsTo avoid excessive tunnel wear, tunnel wear strips must be installedwhenever track studding is used. Several we

56PRE-RIDE INSPECTIONBefore starting the engine, always check all of the items outlined onthe following pages.Read and Understand Your Owner’s ManualR

57PRE-RIDE INSPECTIONHydraulic BrakesProperly functioning brakesare critical to your safety.Always check the followingitems to assure properoperation

4TABLE OF CONTENTSWELCOME 3...TABLE OF CONTENTS 4...INTRODUCTION 5...

58PRE-RIDE INSPECTIONPark Brake Lever LockYour snowmobile has a park brake lever lock located over the brakelever. Use the brake lever lock when you w

59PRE-RIDE INSPECTIONSteering SystemManually turn the skis completely to the right and to the left. If anydifficulty is encountered, check for ice and

60PRE-RIDE INSPECTIONThe following items must be checked before each use of the vehicle.Check these items after starting the engine (see page 61), but

61OPERATIONStarting the EngineDo not depress the throttle until the engine starts.1. Pull the kill switch (shut-off switch) up to the RUN position.2.

62OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-freemachine life as proper break-in of a new or rebuilt engin

63OPERATIONEngine Break-InLubricationAlways check the oil level when refueling. Oil must be maintainedbetween the SAFE and ADD marks on the dipstick.

64OPERATIONTrack Warm-UpFollow these steps to ensure proper warm-upof the engine, drive train and track.1. Use an appropriate stand to securelysupport

65OPERATIONFuelGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasoline.S Alway

66OPERATIONFuelThe fuel used in your Polaris engine is as important to engine life andperformance as the lubricant. Your Polaris engine is designed to

67OPERATIONOilOil L evelAlways check the oil level on the dipstick before each ride and whenrefueling. The dipstick i s l ocated on the lower left sid

5INTRODUCTIONImportant Notes for Owners and Driversn After reading this manual, store it i n t he snowmobile forconvenient reference. It should remain

68OPERATIONEngine Stop SwitchPush down on the engine stopswitch (A) to stop the engine in anemergency. This will ground outthe ignition and bring the

69OPERATIONThrottle LeverIf the engine stops abruptly when the throttle lever is released:1. Turn the ignition switch to OFF.2. Visually inspect the t

70OPERATIONEmergency StoppingThe following chart lists methods for stopping the snowmobile in theevent of an emergency. Refer to page 68 for more i nf

71OPERATIONReverse OperationMake sure the shift lever is shifted completely into forward or reverseposition. Do not force the shift lever into reverse

72OPERATIONDaily StorageAt the end of each ride, park the snowmobileon a level surface and support it at the rearwith an appropriate track stand. The

73OPERATIONTowingFor your safety, do not attempt to use the t ow hitch until you’ve readthe following warnings and understand the proper hitch functio

74-NOTES-

75MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, followrecommended regular maintenance

76MAINTENANCEMaintenance ChartThe following chart is a guide based on average riding conditions. Youmay need to increase frequency based on riding con

77MAINTENANCEMaintenance ChartItem Weekly orbeforelong trip150 M.(240 km)1000 M.(1600 km)2000 M.(3200 km)SeePageTighten idler adjust bolt jam nuts X 1

6INTRODUCTIONPreservation of the EnvironmentPolaris is committed to supporting an environmental educationcampaign. We encourage state and provincial g

78MAINTENANCEMaintenance LogPresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future

79MAINTENANCEMaintenance LogAdditional Services PerformedAuthorized Polaris Servicing DealerServicing TechnicianDate MileageType of ServiceAdditional

80MAINTENANCELubricationLubricate the suspension and steering components with PolarisPremium 4 all season grease annually or about every 1000 miles(16

81MAINTENANCELubricationThe suspension pivot shafts should be lubricated with Polaris P remiumAll Season Grease at 500 miles (800 km) initially, every

82MAINTENANCELubricationJackshaft BearingLoosen the driven clutch retaining bolt and pullthe clutch outward to expose the bearing andgrease fitting. I

83MAINTENANCELubricationChaincase OilCheck the chaincase oil level weekly and before any long trips.Place the machine on a level surface.Remove the di

84MAINTENANCEGeneral MaintenanceSpark PlugsS Use Champion RC7YC spark plugs.S Proper electrode gap is .035” (.9 mm)S Spark plug torque is 18-22 ft. lb

85MAINTENANCEGeneral MaintenanceSpark PlugsSpark plug condition is indicative of engine operation. The spark plugfiring end condition should be read a

86MAINTENANCEGeneral MaintenanceIntake FilterThe intake foam filters limit snow ingestioninto the intake system. When operating inloose powder snow, c

87MAINTENANCEGeneral MaintenanceOil and Filter ChangeThe F rontier does not have a crankcase drain. The oil in the crankcasemust be drawn out through

7INTRODUCTIONVehicle Identification NumbersThe tunnel vehicle identification number (VIN) and engine serialnumber are important for model identificati

88MAINTENANCEGeneral MaintenanceExhaust SystemCheck the exhaust system for wear or damage at approximately 2000miles (3200 km). To inspect, allow the

89MAINTENANCEGeneral MaintenanceCoolant MixtureThe coolant supplied in the system is a 50/50 mixture ofethylene-glycol and distilled water. This mixtu

90MAINTENANCEGeneral MaintenanceCoolant LevelThe coolant level in the coolant bottle mustbe maintained at the FULL COLD mark (A)to prevent overheating

91MAINTENANCEGeneral MaintenanceBleeding the Cooling SystemIf the pressure cap needs replacement, contact your dealer for thecorrect part. Use of a no

92MAINTENANCEGeneral MaintenanceDrive Chain TensionTo obtain correct chain tension:1. Rotate the driven clutchcounterclockwise to move all chainslack

93MAINTENANCEGeneral MaintenanceHydraulic Brake InspectionFrequently inspect the brakelever reserve. Firmlydepress the brake lever andmeasure the clea

94MAINTENANCEGeneral MaintenanceBrake Components1. Brake Caliper2. Chaincase3. Brake Disc4. Backing Plate5. Brake Pad Material (Replace when thickness

95MAINTENANCEGeneral MaintenanceBrake FluidAll DOT 3 brake fluid is not the same. We recommend the use of onlyPolaris DOT 3 high temperature brake flu

96MAINTENANCEGeneral MaintenanceBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action.Bleed the sy

97MAINTENANCEGeneral MaintenanceHeadlight AdjustmentThe headlight may be adjusted forvertical aim using the followingprocedure:1. Place the snowmobile