Polaris Frontier User manual

2003

Owner's Manual

for

Vehicle Maintenance

and

Safety

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.

WARNING

The engine exhaust from this

product contains chemicals

known to cause cancer, birth de-

fects or other reproductive harm.

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

What’s the hottest thing on snow?

Our new web site. And it’s designed just for YOU!

STechnical tips

SNew product introductions

SEvent schedules

SParts and Service Manual information

SExciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

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.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our

world-wide family of Polaris owners. We proudly produce an exciting

line of utility and recreational products.

Polaris Recreational Vehicles

SSnowmobiles

SAll-terrain vehicles (ATVs)

SPersonal watercraft

SRANGER utility vehicles

SVictory motorcycles

Polaris Professional Series Workmobilest

SUtility Task Vehiclest(UTVs)

SPersonal Task Vehiclest(PTVs)

SAll-Surface Loaders (ASLs)

We believe Polaris sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your Polaris vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)

products, available through our online store at www.purepolaris.com.

Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered

trademarks of Polaris Industries Inc.

TABLE OF CONTENTS

WELCOME 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 8..........................................

The safety section outlines practices for safe vehicle operation and

identifies warning decals and their locations.

FEATURES AND CONTROLS 27......................

The features and controls of your snowmobile are identified in this

section.

THE PERFECT FIT 32................................

Learn how to tailor the suspension and other features for an optimum

riding experience.

PRE-RIDE INSPECTION 56...........................

Always perform these procedures and inspections before riding.

OPERATION 61.....................................

Learn how to properly break in your new snowmobile, how to operate

the controls and features, and how to drive

MAINTENANCE 75..................................

The maintenance section outlines service procedures that must be

performed by you or your dealer to keep the snowmobile operating at

peak performance.

SPECIFICATIONS 120...............................

TROUBLESHOOTING 122............................

POLARIS RECOMMENDED PRODUCTS 128...........

WARRANTY 129....................................

INDEX 135..........................................

INTRODUCTION

Important Notes for Owners and Drivers

nAfter reading this manual, store it in the snowmobile for

convenient reference. It should remain with the snowmobile when

sold.

nThe illustrations and photos used in this manual may be general

representations. Your model may differ.

nFollow 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.

nYou and your dealer must complete the registration form included

with your snowmobile and forward it to us. This completed form

is necessary to ensure warranty coverage.

nProtect and preserve your right to ride by joining your local trail

riding clubs.

INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education

campaign. We encourage state and provincial governments across the

snowbelt to adopt rigorous safety training programs that encourage

protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to

protect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

Noise Level

One of the most publicized issues about snowmobiles is noise. The

Society of Automotive Engineers (SAE), the standard-setting body for

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE

standards. Our muffler systems are designed to reduce noise levels and

must not be altered or removed. The sound of your snowmobile may

not be welcome to non-snowmobilers, so you have a responsibility to

operate your snowmobile with concern for others. We do our part by

manufacturing quieter machines; we ask your help to further reduce the

impact of noise by operating your snowmobile safely and responsibly.

INTRODUCTION

Vehicle Identification Numbers

The tunnel vehicle identification number (VIN) and engine serial

number are important for model identification when registering your

snowmobile, when obtaining insurance, and when ordering

replacement parts. In the event your snowmobile is stolen, these

numbers are essential to its recovery and identification.

Remove the spare key and store it in a safe place. Your key can be

duplicated only by mating a Polaris key blank with one of your

existing keys. If both keys are lost, the ignition switch must be

replaced. See your Polaris dealer.

NOTE: Record your snowmobile’s ID numbers and key number in the

spaces provided.

Tunnel VIN (lower right side of the tunnel) :

Engine Serial Number (right side of engine cylinder head):

Vehicle Model Number:

Key Number:

SAFETY

Operator Safety

The following signal words and symbols appear throughout this

manual and on your vehicle. Your safety is involved when these words

and symbols are used. Become familiar with their meanings before

reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts

you to the potential for personal injury.

The safety alert warning indicates a potential hazard that may result

in serious injury or death.

The safety alert caution indicates a potential hazard that may result

in minor personal injury or damage to the vehicle.

CAUTION

NOTE:

Anote will alert you to important information or instructions.

Acaution indicates a situation that may result in damage to the

vehicle.

CAUTION

WARNING

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