2005 Polaris Frontier Touring Owners Manual

2005 Polaris Frontier Touring Manual

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2005 Polaris Frontier Touring manual content summary:

  • 2005 Polaris Frontier Touring | Owners Manual - Page 1
  • 2005 Polaris Frontier Touring | Owners Manual - Page 2
  • 2005 Polaris Frontier Touring | Owners Manual - Page 3
    WARNING 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 WARNING Snowmobile engines discharge fuel
  • 2005 Polaris Frontier Touring | Owners Manual - Page 4
  • 2005 Polaris Frontier Touring | Owners Manual - Page 5
    reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2005 Frontier Touring Owner's Manual P/N 9919111 2
  • 2005 Polaris Frontier Touring | Owners Manual - Page 6
    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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 7
    4
  • 2005 Polaris Frontier Touring | Owners Manual - Page 8
    identification numbers that should be recorded in the owner's manual. This section describes safe vehicle operation and identifies warning Maintenance ...64 Specifications ...109 Troubleshooting ...110 This section is a quick reference guide to solving problems. Polaris Products ...115 Warranty
  • 2005 Polaris Frontier Touring | Owners Manual - Page 9
    6
  • 2005 Polaris Frontier Touring | Owners Manual - Page 10
    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. Preventive maintenance ensures that critical components of the snowmobile are inspected by your
  • 2005 Polaris Frontier Touring | Owners Manual - Page 11
    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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 12
    Vehicle Identification Numbers INTRODUCTION 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 13
    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. WARNING The damage to the vehicle. NOTE: A note will alert you to important information or instructions. 10
  • 2005 Polaris Frontier Touring | Owners Manual - Page 14
    Operator Safety 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 15
    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. Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving
  • 2005 Polaris Frontier Touring | Owners Manual - Page 16
    your snowmobile at all times: SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner's Manual SFirst Aid Kit Riding Apparel Be aware of the weather forecast and especially the wind chill. A wind chill table is provided on page 24 for
  • 2005 Polaris Frontier Touring | Owners Manual - Page 17
    SAFETY Operator Safety 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. Cargo Overload Too much
  • 2005 Polaris Frontier Touring | Owners Manual - Page 18
    Operator Safety Excessive Speed SAFETY WARNING High speed driving, especially at night, could result in serious personal injury or death. Always reduce speed when driving at night or in inclement weather. Observe all state and local laws governing snowmobile operation. They've been established
  • 2005 Polaris Frontier Touring | Owners Manual - Page 19
    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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 20
    and avalanche conditions, contact local law enforcement in your area, or visit either the American Avalanche Association online at www.americanavalanceassociation.org or the U.S. Forest Service National Avalanche Center at www.avalanche.org. 17
  • 2005 Polaris Frontier Touring | Owners Manual - Page 21
    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. If difficulty
  • 2005 Polaris Frontier Touring | Owners Manual - Page 22
    Operator Safety SAFETY Driving in Hilly Terrain WARNING 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 23
    purpose of the guard by removing it. It's provided for your safety. Drive Belt Do not operate the engine with the 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 24
    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 recommended maintenance program outlined beginning on page 65 of this manual to ensure that all critical components on the snowmobile
  • 2005 Polaris Frontier Touring | Owners Manual - Page 25
    SAFETY Operator Safety Inadequate Snow Conditions WARNING 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 26
    Operator Safety 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.
  • 2005 Polaris Frontier Touring | Owners Manual - Page 27
    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 p in MPH Actual Thermometer Reading (°F) 50 50 48 40 36 32 30 28 27 26 40 40 37 28 22 18 16 13 11 10 30 30 27
  • 2005 Polaris Frontier Touring | Owners Manual - Page 28
    the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile this guard open. Never run engine with drive belt removed. Never service clutches yourself - see your dealer. Pressure Cap Warning This warning decal
  • 2005 Polaris Frontier Touring | Owners Manual - Page 29
    SAFETY Safety Decals And Locations Track Warning Passenger Warning Your snowmobile is designed for the operator and no more than one passenger. For more information on operating capacities, see page 14. + 26
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    Safety Decals and Locations Electronic Reverse Warning SAFETY + WARNING AVERTISSEMENT 27
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    SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English. WARNING 28
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    Safety Decals and Locations Operation Warning AVERTISSEMENT SAFETY 29
  • 2005 Polaris Frontier Touring | Owners Manual - Page 33
    FEATURES AND CONTROLS 7 10 5 4 3 6 8 9 11 12 13 15 14 2 1 1. Fuel Filler Cap 2. Ignition Switch 3. Brake Lever 17 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. Temperature
  • 2005 Polaris Frontier Touring | Owners Manual - Page 34
    FEATURES AND CONTROLS 6 3 2 1 9 16 12 11 10 4 5 8 7 15 14 13 1. 2. 3. 4. 5. 6. 7. 8. Hood Headlight Windshield Handlebar Seat Passenger Seat Cargo Box Taillights 9. 10. 11. 12. 13. 14. 15. 16. Snow Flap Suspension Track Trailing Arm Block Heater (under hood) Nosepan Front Bumper Skis 31
  • 2005 Polaris Frontier Touring | Owners Manual - Page 35
    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. When enabled, the CHECK ENGINE light will blink in numerical sequences
  • 2005 Polaris Frontier Touring | Owners Manual - Page 36
    your EFI system will have. If a problem with your 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 CAUTION Operating the snowmobile without proper
  • 2005 Polaris Frontier Touring | Owners Manual - Page 37
    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. We recommend the use of this
  • 2005 Polaris Frontier Touring | Owners Manual - Page 38
    Front Suspension Adjustments THE PERFECT FIT Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail
  • 2005 Polaris Frontier Touring | Owners Manual - Page 39
    THE PERFECT FIT WARNING Front Suspension Adjustments Always verify ski alignment before making adjustments to the IFS. See page 100 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. For the best ride, the suspension should be adjusted
  • 2005 Polaris Frontier Touring | Owners Manual - Page 40
    Front Suspension Adjustments THE PERFECT FIT 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 the springs on both the left and right sides of the machine are
  • 2005 Polaris Frontier Touring | Owners Manual - Page 41
    THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs
  • 2005 Polaris Frontier Touring | Owners Manual - Page 42
    Edge Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. The firm torsion spring should be used if frequent bottoming is encountered during two up
  • 2005 Polaris Frontier Touring | Owners Manual - Page 43
    THE PERFECT FIT Edge Touring Suspension (ETS) Adjustments Initial Setup and Calibration The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of
  • 2005 Polaris Frontier Touring | Owners Manual - Page 44
    resulting in loss of control and possible serious personal injury or death. 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 A expose the handlebar and the four adjuster
  • 2005 Polaris Frontier Touring | Owners Manual - Page 45
    , clutches, fuel systems and exhaust systems. NOTE: Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 42
  • 2005 Polaris Frontier Touring | Owners Manual - Page 46
    Accessories THE PERFECT FIT Traction Products See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. Use only Polaris traction products on your snowmobile. Track warranties are void
  • 2005 Polaris Frontier Touring | Owners Manual - Page 47
    THE PERFECT FIT Accessories Traction Products Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice. A skag is a replaceable bar attached to the underside of the ski
  • 2005 Polaris Frontier Touring | Owners Manual - Page 48
    Accessories Wear Strips THE PERFECT FIT To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. Several wear strips are available. See your dealer for more information. Components as viewed from the
  • 2005 Polaris Frontier Touring | Owners Manual - Page 49
    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item Drive Belt
  • 2005 Polaris Frontier Touring | Owners Manual - Page 50
    be sure of proper operation. Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. We've attempted to provide lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. The need for a properly functioning brake is critical. Check
  • 2005 Polaris Frontier Touring | Owners Manual - Page 51
    the fluid. Also check for the presence of air in the fluid system. Refer to page 86 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. Use only Polaris
  • 2005 Polaris Frontier Touring | Owners Manual - Page 52
    brake is in use. If the brake light does not come on when the park brake or service brake is in use, have it serviced by your dealer. 1. Brake Lever 4 3 2. Park Brake Lever Lock 3. Master Cylinder Reservoir 1 and Cover 4. Fluid Level Indicator 2 WARNING If the park brake lever lock is
  • 2005 Polaris Frontier Touring | Owners Manual - Page 53
    PRE-RIDE INSPECTIONS Before Starting the Engine n Check for Proper Operation of 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 54
    Start the Engine and Check 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. n Transmission: Make sure the reverse is not engaged before starting your
  • 2005 Polaris Frontier Touring | Owners Manual - Page 55
    OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 47. Do not
  • 2005 Polaris Frontier Touring | Owners Manual - Page 56
    No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or 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. Follow all procedures as outlined. Avoid
  • 2005 Polaris Frontier Touring | Owners Manual - Page 57
    OPERATION Lubrication Engine Break-In CAUTION Serious engine damage can occur without the proper lubrication. Check the oil level often during the first tankful of fuel. Maintain the oil level between the SAFE and ADD marks on the dipstick. Always check the oil level when refueling. Oil must be
  • 2005 Polaris Frontier Touring | Owners Manual - Page 58
    it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable. CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds
  • 2005 Polaris Frontier Touring | Owners Manual - Page 59
    OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not overfill the tank. Do not fill the tank neck. S Do
  • 2005 Polaris Frontier Touring | Owners Manual - Page 60
    Fuel OPERATION 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 61
    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. No adjustment is required. Any
  • 2005 Polaris Frontier Touring | Owners Manual - Page 62
    n 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. OPERATION A n Throttle Safety Switch B Test the
  • 2005 Polaris Frontier Touring | Owners Manual - Page 63
    ignition switch on and go through normal starting procedures. 5. If the engine doesn't start, take the snowmobile to an authorized Polaris dealer for service. Excessive free play in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, see
  • 2005 Polaris Frontier Touring | Owners Manual - Page 64
    Emergency Stopping OPERATION The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 59 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether
  • 2005 Polaris Frontier Touring | Owners Manual - Page 65
    OPERATION Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. S Always look behind the vehicle before and while backing. S Always avoid sharp turns. S Shift to or from reverse only when stopped. S Always apply
  • 2005 Polaris Frontier Touring | Owners Manual - Page 66
    Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover
  • 2005 Polaris Frontier Touring | Owners Manual - Page 67
    a throttle body adjustment at 4000 miles. Specifications and adjustments for engine tune-ups are located in the Service Manual available to your qualified service technician. Reverse must not be engaged during engine tune-ups. Owner's Responsibilities Please read the Snowmobile Engine Emissions
  • 2005 Polaris Frontier Touring | Owners Manual - Page 68
    Maintenance Program MAINTENANCE To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles
  • 2005 Polaris Frontier Touring | Owners Manual - Page 69
    MAINTENANCE 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 70
    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 (annually) Grease driveshaft bearing (always perform before storage) Flush
  • 2005 Polaris Frontier Touring | Owners Manual - Page 71
    MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced. 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 72
    Maintenance Log MAINTENANCE Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Mileage Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Mileage 69
  • 2005 Polaris Frontier Touring | Owners Manual - Page 73
    ski pivots at the fittings as shown. S Grease the jackshaft and driveshaft clutch side bearings. S Use an aerosol lubricant on the steering post support bracket. S Grease the center steering arms. S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of
  • 2005 Polaris Frontier Touring | Owners Manual - Page 74
    Lubrication MAINTENANCE 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 75
    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). Push
  • 2005 Polaris Frontier Touring | Owners Manual - Page 76
    Lubrication MAINTENANCE Chaincase Oil Check the chaincase oil level weekly and before any long trips. 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 77
    MAINTENANCE Spark Plugs General Maintenance CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Use Champion RC7YC spark plugs. Proper electrode gap is .035" (.9 mm) Spark plug torque is 18-22 ft. lbs. (24-30 Nm). Change spark
  • 2005 Polaris Frontier Touring | Owners Manual - Page 78
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or a faulty EFI system. Wet
  • 2005 Polaris Frontier Touring | Owners Manual - Page 79
    MAINTENANCE Intake Filter General Maintenance 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. Hood foam filters 3 1 2 CAUTION
  • 2005 Polaris Frontier Touring | Owners Manual - Page 80
    cause the oil to become too hot for safe removal with the oil vacuum pump. 2. Remove the dipstick and draw out the oil, following the instructions provided with the oil vacuum pump. Fish the vacuum tube around in the crankcase to remove as much oil as possible. 3. Place shop towels beneath
  • 2005 Polaris Frontier Touring | Owners Manual - Page 81
    cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure
  • 2005 Polaris Frontier Touring | Owners Manual - Page 82
    General Maintenance Coolant Mixture MAINTENANCE The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to
  • 2005 Polaris Frontier Touring | Owners Manual - Page 83
    system should be completely drained every two years and a fresh 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 84
    General Maintenance MAINTENANCE Bleeding the Cooling System WARNING 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 85
    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. Loosen the adjuster bolt jam nut (A). 3.
  • 2005 Polaris Frontier Touring | Owners Manual - Page 86
    General Maintenance n Hydraulic Brake Inspection MAINTENANCE Frequently inspect the brake lever reserve. Firmly depress the brake lever and A 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 87
    MAINTENANCE Brake Components General Maintenance 1 2 3 5 4 1. 2. 3. 4. 5. Brake Caliper Chaincase Brake Disc Backing Plate 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 88
    General Maintenance n Brake Fluid MAINTENANCE WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the
  • 2005 Polaris Frontier Touring | Owners Manual - Page 89
    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. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an
  • 2005 Polaris Frontier Touring | Owners Manual - Page 90
    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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 91
    MAINTENANCE NOTE: General Maintenance 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 92
    General Maintenance Clutch System MAINTENANCE WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by
  • 2005 Polaris Frontier Touring | Owners Manual - Page 93
    be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance. See your dealer for service and adjustments. NOTE: A worn belt will continue to function, but will not deliver maximum performance. Always carry a spare belt in case of an
  • 2005 Polaris Frontier Touring | Owners Manual - Page 94
    General Maintenance n Drive Belt Condition MAINTENANCE Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions
  • 2005 Polaris Frontier Touring | Owners Manual - Page 95
    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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 96
    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". MAINTENANCE A B Drive Belt Adjustment
  • 2005 Polaris Frontier Touring | Owners Manual - Page 97
    MAINTENANCE General Maintenance Reverse Kit Maintenance If your snowmobile is equipped with reverse, or if you have a reverse kit installed, it's especially important to maintain track tension as specified on page 97. WARNING Improper track tension can cause serious damage to the snowmobile,
  • 2005 Polaris Frontier Touring | Owners Manual - Page 98
    marks on the oil dipstick. See page 58. 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 99
    rotate a damaged track under power. 21 3 Using a hoist, safely lift and support the 1 2 rear of the snowmobile off the ground. Rotate the track by WARNING Operating with insufficient lubrication between the slider and track guide clips can cause track failure, loss of vehicle control and
  • 2005 Polaris Frontier Touring | Owners Manual - Page 100
    adjustments should be made only after the track is warmed up and limber. 1. Turn the machine off. 2. Lift the rear of the C D machine and safely support it off the ground. 3. Place the recommended weight or downward pressure on the track at the specified distance ahead of the center of the rear
  • 2005 Polaris Frontier Touring | Owners Manual - Page 101
    check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly
  • 2005 Polaris Frontier Touring | Owners Manual - Page 102
    Steering System MAINTENANCE 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 +. + + + + + + + 99
  • 2005 Polaris Frontier Touring | Owners Manual - Page 103
    MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead
  • 2005 Polaris Frontier Touring | Owners Manual - Page 104
    weekly to maintain positive steering characteristics. Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the machine so the skis are approximately 6″ (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag
  • 2005 Polaris Frontier Touring | Owners Manual - Page 105
    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. See page 97
  • 2005 Polaris Frontier Touring | Owners Manual - Page 106
    Extended Storage MAINTENANCE Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and
  • 2005 Polaris Frontier Touring | Owners Manual - Page 107
    except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Electrical Connections CAUTION Tampering with the EFI EFI connections. See your Polaris dealer for all EFI system service. Separate the electrical connector blocks and clean any corrosive build
  • 2005 Polaris Frontier Touring | Owners Manual - Page 108
    Clean or a fuel conditioner/stabilizer to the fuel tank. Follow the instructions on the can, running the engine for five minutes to get additives using a siphon pump. Do not re-use fuel after storage. 2. Securely support the front of the snowmobile with a jackstand so the machine is elevated and
  • 2005 Polaris Frontier Touring | Owners Manual - Page 109
    MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of
  • 2005 Polaris Frontier Touring | Owners Manual - Page 110
    Battery MAINTENANCE 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 111
    MAINTENANCE Battery Battery Installation WARNING Batteries contain gases that can explode. If the battery vent tube is pinched or kinked, battery gases could accumulate. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the negative cable last to
  • 2005 Polaris Frontier Touring | Owners Manual - Page 112
    SPECIFICATIONS 2005 Frontier Touring Body Style Riders Coolant Chaincase Oil Engine Oil Dry Weight (est.) Fuel Tank Height Length Ski Center Distance Width Brake Type Drive Clutch Center Distance Drive Belt P/N Clutch Type Track Length Track Width Reverse Transmission Front Suspension Type IFS Shock
  • 2005 Polaris Frontier Touring | Owners Manual - Page 113
    TROUBLESHOOTING Problem Rear suspension bottoms too easily ETS Suspension Troubleshooting Solution (perform only one change at a time) - Adjust RCA forward (see setup decal under hood). - Adjust coil over spring on front track shock to increase
  • 2005 Polaris Frontier Touring | Owners Manual - Page 114
    Belt Wear/Burn Causes Driving at low RPM Insufficient warm-up TROUBLESHOOTING Belt Wear/Burn Diagnosis Solutions Drive at higher RPMs. Gear the machine down. Check belt deflection. Warm the engine at least five minutes. Take the
  • 2005 Polaris Frontier Touring | Owners Manual - Page 115
    TROUBLESHOOTING Engine Troubleshooting Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Drive clutch binding CAUTION: All engine service and repair should be performed by a qualified Polaris dealer with training in EFI engines. Solution -Disassemble drive
  • 2005 Polaris Frontier Touring | Owners Manual - Page 116
    Engine Troubleshooting Problem Noise in drive system Probable Cause TROUBLESHOOTING Solution Broken drive clutch -SEE YOUR DEALER. components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose or
  • 2005 Polaris Frontier Touring | Owners Manual - Page 117
    TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable , filter, or pump. -SEE DEALER for fuel line bleeding. -SEE DEALER. This indicates a major engine problem that must be repaired before engine is run. -SEE DEALER. -SEE DEALER. -There's no adjustment to change
  • 2005 Polaris Frontier Touring | Owners Manual - Page 118
    POLARIS PRODUCTS Part No. 2870791 2871281 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2870990 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Chaincase Lubricants
  • 2005 Polaris Frontier Touring | Owners Manual - Page 119
    information contained in this manual. Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1. Serial number 5. Details of trouble experienced 2. Model number
  • 2005 Polaris Frontier Touring | Owners Manual - Page 120
    preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to
  • 2005 Polaris Frontier Touring | Owners Manual - Page 121
    dealer is YOUR responsibility). Polaris recommends that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Your dealer will contact the appropriate personnel at Polaris if
  • 2005 Polaris Frontier Touring | Owners Manual - Page 122
    dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty
  • 2005 Polaris Frontier Touring | Owners Manual - Page 123
    oil. S Piston seizures, unless caused by a defective engine component. S Failures caused due to improper adjustments. 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
  • 2005 Polaris Frontier Touring | Owners Manual - Page 124
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2005 Polaris Frontier Touring | Owners Manual - Page 125
    for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary. It is a potential violation of the Clean Air
  • 2005 Polaris Frontier Touring | Owners Manual - Page 126
    ...107 Battery Fluid ...106 Battery Installation ...108 Battery Removal ...107 Battery Storage ...108 Before Starting the Engine ...47-50 Belt Troubleshooting ...111 Bleeding the Cooling System ...81 Bleeding the Brake System ...86 Brake Components ...84 Brake Fluid ...85 Brake Inspection ...83
  • 2005 Polaris Frontier Touring | Owners Manual - Page 127
    Indicator Lamp ...32 Maneuverability ...21 Mirror Adjustment ...51 Moving Parts ...12 S SAFETY ...10-29 Safety Decals and Locations ...25-29 Service Contract ...120 Shock Absorber Components ...36 Shock Spring Preload, Front ...37 Skag Replacement ...101 Ski Alignment ...100 Ski Skags ...101
  • 2005 Polaris Frontier Touring | Owners Manual - Page 128
    96 Track Maintenance ...96-98 Track Tension ...97 Track Tension Data ...98 Track Warm-Up ...55 Traction Products ...43, 44 Transmission ...51 TROUBLESHOOTING ...110-114 Tune-Up ...95 T TABLE OF CONTENTS ...5 Temperature Chart ...24 Tether Switch ...51 THE PERFECT FIT ...35-43 Throttle Cable ...72
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