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Polaris Frontier Owner's Manual

Polaris 2002 snowmobile owner's manual
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  • Page 2 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 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...
  • Page 3 What’s the hottest thing on snow? Our new web site. And it’s designed just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
  • Page 4 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.

  • Page 5: Welcome

    S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...

  • Page 6: Table Of Contents

    SPECIFICATIONS POLARIS RECOMMENDED PRODUCTS TROUBLESHOOTING WARRANTY ........

  • Page 7: 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.

  • Page 8: Welcome

    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.

  • Page 9: Vehicle Identification Numbers

    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.

  • Page 10: Safety

    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.
  • Page 11 We strongly recommend that the operator check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
  • Page 12 SAFETY Operator Safety Stay Away From Moving Parts Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track.

  • Page 13: Safety

    Operator Safety Riding Position 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;...

  • Page 14: Cargo Overload

    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. Control becomes more difficult with two people on board.

  • Page 15: Excessive Speed

    Operator Safety Excessive Speed 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.

  • Page 16: Driver Awareness

    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.

  • Page 17: Ice And Snow Build-Up

    Operator Safety Ice and Snow Build-up 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.

  • Page 18: Driving In Hilly Terrain

    SAFETY Operator Safety Driving in Hilly Terrain 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.

  • Page 19: Driving Downhill

    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.

  • Page 20: Intake Silencer

    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.

  • Page 21: Powder Snow Operation

    Operator Safety Powder Snow Operation 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.

  • Page 22: Rider Capacities

    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 for decal location.

  • Page 23: Driving Responsibly

    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.
  • Page 24 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 in MPH in MPH Calm Wind Speeds Greater Than 40 MPH Have Little Added Effect Little Added Effect Clothed Person) Clothed Person)

  • Page 25: 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.
  • Page 26 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.

  • Page 27: Passenger Warning

    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. SAFETY...
  • Page 28 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.
  • Page 29 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!

  • Page 30: Features And Controls

    FEATURES AND CONTROLS 1. Fuel Filler Cap 2. Ignition Switch 3. Brake Lever 4. Electronic Fuel Gauge 5. Speedometer 6. Headlight High Beam Light 7. Low Oil Pressure Light 8. Brake Light 9. Check Engine Light 10. Reverse Indicator Light 11.
  • Page 31 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage/Rear 7. Taillights 8. Cargo Carrier FEATURES AND CONTROLS 9. Snow Flap 10. Suspension 11. Track 12. Trailing Arm 13. Block Heater (under hood) 14. Nosepan 15. Front Bumper 16.
  • Page 32 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.

  • Page 33: Check Engine Light

    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 Operating the snowmobile without proper engine lubrication can result in serious engine damage.
  • Page 34 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.

  • Page 35: The Perfect Fit

    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.

  • Page 36: Shock Absorber Components

    THE PERFECT FIT Front Suspension Adjustments 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.
  • Page 37 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.

  • Page 38: The Perfect Fit

    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, S Increase compression damping on Indy Select shocks (PE 52) See your dealer for details.
  • Page 39 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.

  • Page 40: Suspension Performance Tips

    Bogie wheel kits are available from your dealer. S Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.

  • Page 41: Rear Spring Tension

    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.

  • Page 42: Rear Suspension Adjustments

    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.
  • Page 43 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.

  • Page 44: Suspension Coupling

    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.
  • Page 45 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.

  • Page 46: Weight Transfer During Acceleration

    THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration Rear Rear Scissor Stop (RRSS) 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.

  • Page 47: Handlebar Adjustments

    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).

  • Page 48: Traction Products

    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.

  • Page 49: Pre-Ride Inspection

    Before starting the engine, always check all of the items outlined on the following pages. 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.

  • Page 50: Hydraulic Brakes

    Also check for the presence of air in the fluid system. Refer to page 88 for more information, or see your dealer for 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.

  • Page 51: Park Brake Lever Lock

    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.

  • Page 52: Pre-Ride Inspection

    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...

  • Page 53: Engine Stop Switch

    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.

  • Page 54: Operation

    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. WARNING...
  • Page 55 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. 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.
  • Page 56 We recommend the use of Polaris Premium 4 Synthetic 0W-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.

  • Page 57: Operation

    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.
  • Page 58 OPERATION Fuel Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 59 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.

  • Page 60: Fuel System Deicers

    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.

  • Page 61: Oil Level

    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.
  • Page 62 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.
  • Page 63 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. WARNING OPERATION...

  • Page 64: Emergency Starting

    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 Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (Option) Excessive or repetitive use of brakes for high speed stops will...

  • Page 65: Reverse Operation

    Reverse Operation Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. 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.

  • Page 66: Daily Storage

    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.
  • Page 67 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. 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.
  • Page 68 - NOTES -...

  • Page 69: Maintenance

    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.

  • Page 70: 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 Check brake operation and...
  • Page 71 Maintenance Chart Item Tighten idler adjust bolt jam nuts Check spark plug condition, re- place annually Inspect coolant filter, replace if necessary Grease ski pivots Grease ski spindles Grease center steering arm(s) Lubricate steering post support bracket and pivot (aerosol) Grease lower steering post pivot Change oil and oil filter (annually) Grease driveshaft bearing...

  • Page 72: Maintenance Log

    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 1000 Mile (1600 km) Maintenance Inspection...
  • Page 73 Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service MAINTENANCE Mileage Mileage...
  • Page 74 S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of unit). A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 113.
  • Page 75 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.

  • Page 76: Throttle Cable

    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).

  • Page 77: Chaincase Oil

    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.

  • Page 78: General Maintenance

    General Maintenance Spark Plugs Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. S Use Champion RC7YC spark plugs. S Proper electrode gap is .035” (.9 mm) S Spark plug torque is 18-22 ft. lbs. (24-30 Nm).
  • Page 79 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. A hot exhaust system and engine can cause serious burns.

  • Page 80: Fuel Filter

    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.

  • Page 81: Oil And Filter Change

    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.

  • Page 82: Exhaust System

    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.
  • Page 83 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. Never exceed a 60% antifreeze/40% water mixture. Contact you dealer if greater protection is required.

  • Page 84: Coolant Level

    50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile. CAUTION...

  • Page 85: Bleeding The Cooling System

    General Maintenance Bleeding the Cooling System 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.

  • Page 86: Drive Chain Tension

    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.

  • Page 87: Hydraulic Brake Inspection

    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″).

  • Page 88: Brake Components

    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.

  • Page 89: Brake Fluid

    All DOT 3 brake fluid is not the same. We recommend the use of only Polaris DOT 3 high temperature brake fluid. See page 113 for the part numbers of Polaris-recommended products. The brake fluid level can be seen through a plastic sight glass in the brake reservoir.

  • Page 90: Bleeding The Hydraulic Brake System

    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. 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.

  • Page 91: Headlight Adjustment

    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.
  • Page 92 MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlights Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.

  • Page 93: Clutch System

    Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. 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.

  • Page 94: Specifications

    The drive belt is a very important part of the drive system. Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance.

  • Page 95: Drive Belt Removal

    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.

  • Page 96: Drive Belt Installation

    MAINTENANCE General Maintenance Drive Belt Installation 1. 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.

  • Page 97: Drive Belt Adjustment

    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.

  • Page 98: Reverse Kit Maintenance

    MAINTENANCE General Maintenance Reverse Kit Maintenance Always maintain track tension as specified on page 99 when a snowmobile is equipped with reverse. Improper track tension can cause serious damage to the snowmobile, which can result in loss of vehicle control and serious injury or death.

  • Page 99: Tool Kit

    7. Box End Wrench NOTE: Always keep the tool kit with the 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.

  • Page 100: Emergency Supplies

    SFirst Aid Kit Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technicians will keep your machine in peak operating condition. Maintenance Tools The tools and maintenance items mentioned in this book, as well as other Polaris accessories, are available through your Polaris dealer.

  • Page 101: Track Tension

    Track Maintenance 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.

  • Page 102: Track Alignment

    MAINTENANCE Track Maintenance f 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.

  • Page 103: Track Inspection

    Track Maintenance Track Inspection 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.

  • Page 104: Steering System

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

  • Page 105: Ski Alignment

    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.

  • Page 106: Ski Skags

    MAINTENANCE Steering System Ski Skags 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.

  • Page 107: Suspension Maintenance

    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...

  • Page 108: Controls And Linkage

    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.

  • Page 109: Electrical Connections

    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.

  • Page 110: Engine Protection

    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.

  • Page 111: Battery Fluid

    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 Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing.

  • Page 112: Battery Removal

    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.

  • Page 113: Battery Installation

    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.

  • Page 114: Specifications

    SPECIFICATIONS 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 Front Type IFS Shock Type Rear Type Front Track Shock...

  • Page 115: Polaris Recommended Products

    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.)

  • Page 116: Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension -Increase torsion spring preload -Increase rear shock compression damping by turning screw bottoms too easily 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...

  • Page 117: Belt Troubleshooting

    Belt Troubleshooting Belt Wear/Burn Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch en- gagement...
  • Page 118 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 Erratic engine Drive clutch bind- operating RPM during accelera- tion or load variations Driven clutch...

  • Page 119: Troubleshooting

    Engine Troubleshooting Problem Probable Cause Noise in drive Broken drive clutch components system Bearing failure/ chaincase, jack- shaft, or front drive shaft Drive belt surface flat spots Drive chain loose or worn, sprocket teeth broken Poor low RPM Worn drive belt performance Excessive belt/ sheave clearance...
  • Page 120 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Engine turns Faulty ignition but fails to start No fuel to engine Air in fuel line Poor engine compression Engine lacks Fuel filter (loss of power high RPM power) Incorrect clutching Fuel pump Engine Faulty plug(s) continually Improperly set TPS...

  • Page 121: Warranty

    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.

  • Page 122: Limited Warranty

    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.

  • Page 123: Engine Oil

    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).

  • Page 124: Warranty

    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.
  • Page 125 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.
  • Page 126 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.

  • Page 127: Index

    Accessories ....Airbox ..... . Battery .
  • Page 128 INDEX General Maintenance ..Handlebar Adjustments ..Headlight Adjustment ... Headlights ....Hi-Fax Wear .
  • Page 129 Spring Preload ....Spring Tension, Rear ... . Starting ..... . Starting the Engine .

This manual is also suitable for:

Frontier 2002

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