Polaris Frontier Classic User manual

2004
Frontier Classic
Frontier Touring
2004
Frontier Classic
Frontier Touring
Owner's Manual
for Vehicle Maintenance
and Safety
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 defects 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.

1
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

2
Copyright 2003 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited. Printed in U.S.A.

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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.

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TABLE OF CONTENTS
Introduction 5...............................
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety 8.....................................
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features and Controls 28.....................
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit 33............................
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Pre-Ride Inspections 53......................
This section explains procedures that must be performed before riding.
Operation 58.................................
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance 71..............................
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Specifications 116............................
Troubleshooting 118.........................
This section is a quick reference guide to solving problems.
Polaris Products 124.........................
Warranty 125................................
Index 131....................................

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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.

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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.

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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:

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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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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. Make sure your snowmobile is in
excellent operating condition at all times. We strongly
recommend that the operator check major and vital safety
components before every ride.
All Polaris snowmobiles are designed and tested to provide
safe operation when used as directed. Failure of critical
machine components may result from operation with any
modifications, especially those that increase speed or power.
DO NOT MODIFY YOUR MACHINE. The snowmobile may
become aerodynamically unstable at speeds higher than those
for which it is designed. Loss of control may occur at higher
speeds. Modifications may also create a safety hazard and
lead to bodily injury.
The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the snowmobile.

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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.
Never attempt adjustments with the engine running. Turn off the
ignition, raise the hood, make the adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.
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.
WARNING
If fingers or clothing contact the moving parts of an engine,
serious injury can result. Always stop the engine before
attempting adjustments.
WARNING

11
SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary from person to person as each becomes more
skilled; but under most conditions, the proper position is to be seated
with feet on the running boards, and comfortably positioned for proper
throttle, brake, and steering control.
Survival Equipment
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone.
If it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the
conditions you may encounter. Such equipment may include, but is
not limited to: extra clothing, a sleeping bag, a flashlight, food and
water, a signaling mirror, a means of building a fire, and a two-way
radio or cellular telephone.
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.
WARNING
Use of a backrest may hinder your weight shifting ability. This
could affect your ability to control this rider-active vehicle in
certain extreme driving situations.
WARNING

12
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.
Riding Apparel
Be aware of the weather forecast,
especially the wind chill. A wind chill
table is provided on page 22 for your
reference. To better enjoy your ride, be
prepared, be warm and be comfortable.
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have
an increased risk of loss of control, which could result in serious injury
or death.
Control becomes more difficult with two people on board. More
space is required to make turns, and longer distances are needed
for stopping. Make sure the passenger remains seated behind the
driver, facing forward, with both feet placed firmly on the running
boards. Slow down and avoid “jumping” your snowmobile.
WARNING
Loose clothing or long scarves may easily become entangled in
moving parts and cause serious personal injury. Avoid wearing
loose clothing and long scarves while riding a snowmobile. Always
wear an approved helmet and eye protection.
WARNING

13
SAFETY
Operator Safety
Excessive Speed
Observe all state and local laws governing snowmobile operation.
They’ve been established for your protection.
Always be alert and pay attention to the trail ahead. Multiplying speed
(MPH) by 1.5 will equal the approximate number of feet per second
your machine travels. If your speed is 40 MPH, your machine is
traveling about 60 feet per second. If you look back for only two
seconds, your machine will travel about 120 feet. If your speed is 60
MPH, your machine will travel about 180 feet.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t “over drive” your headlight
beam. Always be able to bring your machine to a stop in the distance
illuminated by the headlight.
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.
WARNING

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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. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or
highways. Steep embankments may also
hide your view. Always leave yourself a
way out.
Variances in snow depth and/or water
currents may result in uneven ice
thickness. Always check with local
residents or authorities for general information on conditions when
traveling on lakes and streams that are strange to you. Before riding
your machine on a frozen body of water, be sure the ice is thick enough
to support the machine and its operator, as well as the force created by
a moving vehicle. You may drown if you and the snowmobile break
through the ice.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.

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SAFETY
Operator Safety
Ice and Snow Build-up
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. Snow screens and bib kits are
available through your dealer to help reduce snow and ice build-up.
Driving on Slippery Surfaces
Excessive shifting of operator body weight when turning on
hard-packed snow or ice may lead to loss of vehicle control and result
in serious injury or death. Slow down to maintain control under these
conditions.
It’s dangerous to drive on ice or other slippery surfaces. If it’s
unavoidable, use extreme caution and operate at speeds no faster than a
walk. Never attempt an abrupt change of direction. The chance of
“spin-out” increases under these conditions.
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.
WARNING
Driving on ice or hard-packed snow reduces steering and braking
control, which may result in serious injury or death. Slow down
and use caution.
WARNING

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SAFETY
Operator Safety
Driving in Hilly Terrain
Operating in hilly terrain requires extreme caution to maintain balance
and avoid roll-over. If climbing a hill is unavoidable, keep all your
weight low and forward.
If you must cross the face of a slope, keep your weight on the uphill
side of the machine to maintain proper balance and avoid possible
roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops, or other people or vehicles that may be on the
other side of the hill.
If you’re unable to continue up a hill, turn the machine downhill before
it loses momentum. If this isn’t possible, spin the track just enough to
dig in to prevent it from rolling back down the hill. Stop the engine
and set the parking brake (if equipped). Keeping away from the
downhill side of the machine, pull the rear of the snowmobile around
and point the front end and skis downhill. Remount the machine,
restart the engine, release the parking brake, and descend the hill
carefully.
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.
WARNING

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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.
Do Not Operate Engine With Clutch Guard Removed
The clutch guard is designed to protect the operator from metal parts if
the clutch should fail. Although the chance of failure is extremely
remote, don’t defeat the purpose of the guard by removing it. It’s
provided for your safety.
Do Not Operate Engine With Drive Belt Removed
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in personal injury or damage to the engine.
When driving on long downhill stretches, pump the brakes. Riding
the brakes may cause the brake system to overheat, which may
result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.
WARNING

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SAFETY
Operator Safety
Intake Silencer
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is
dynamically balanced before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the machine into motion, but always operate
within safety limits.
Maneuverability
Control and maneuverability comes not only through the steering and
skis, maximum control is achieved by shifting of body weight.
Maneuverability will change for lighter operators or machines designed
to carry a load or a passenger.