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.

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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

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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