2003 Polaris Frontier Problems and Repair Information
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Popular 2003 Polaris Frontier Manual Pages
Owners Manual - Page 2
... this manual and on which contain chemicals known to cause cancer and birth defects or other reproductive harm.
Read, understand, and follow the safety precautions could result in this engine properly tuned and avoid unnecessary idling and spillage during fueling. PROPOSITION 65 WARNING
Snowmobile engines discharge fuel and exhaust, which they operate. WARNING
The engine exhaust...
Owners Manual - Page 5
Many years of experience have gone into the engineering, design, and development of Polaris Industries Inc.
3
Have your accessories and clothing delivered right to our world-wide family of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Be sure to return to follow the instructions and recommendations in our Parts Apparel...
Owners Manual - Page 12
... operation. WARNING
If fingers or clothing contact the moving parts of the track. We recommend having your dealer perform track service and alignment procedures.
Always stop the engine before attempting adjustments. Never attempt adjustments with the engine running. Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert...
Owners Manual - Page 27
... ability to control the vehicle. See Owner's Manual for you should have a proper balance of the throttle control assembly, to track studs. Use unmixed fuel only. S This vehicle is latched. S Never... or to stop the engine. S When operating with limited visibility, can cause loss of braking ability. Then pull the brake lever to stop . S To maintain vehicle control on hard-packed...
Owners Manual - Page 28
...to return to or from reverse only when stopped. S Shift to forward. S NOTE: For more information, see Owner's Manual. S Apply throttle slowly. S Avoid sharp turns. Flashing light on LH control to set. Let go of button at ...Look behind before and while backing up. If electric reverse:
+
S Machine stopped and engine at idle, push yellow button on dash indicates reverse operation.
Owners Manual - Page 31
...indicate the type of failure. Full diagnostics must be performed by a Polaris dealer trained to service EFI systems. When enabled, the CHECK ENGINE light will blink in , electrical drainage will occur... CONTROLS
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 10 seconds to clear the code....
Owners Manual - Page 32
... mark, continued operation will cause serious engine damage. Low Oil Pressure Light
CAUTION
Operating the snowmobile without proper engine lubrication can result in serious engine damage. See page 128 for your ...marks on , take your EFI system occurs, a code is pre-coded for diagnostic service. If a problem with your Frontier to a low oil condition. Always check the oil level on the...
Owners Manual - Page 56
... studs or skags may be reduced on hard-packed snow or ice. Extended-wear brake pad kits are used , the longer the carbide on the skags should be.
WARNING
Loss of carbide ... THE PERFECT FIT
Accessories
Traction Products
Track studding will result from outside edge of carbide skags is a replaceable bar attached to the underside of the spec to obtain proper vehicle control on the skis...
Owners Manual - Page 58
Have the throttle serviced immediately. Read and Understand Your Owner's Manual
Read the Owner's Manual completely and refer to it should immediately return to...of your snowmobile. If the throttle does not function smoothly, DO NOT start the engine. PRE-RIDE INSPECTION
Before starting the engine, check all of the items outlined on the following pages. Throttle Lever
The throttle ...
Owners Manual - Page 61
..., check for damage before each ride and when refueling. If any difficulty is not covered by warranty. WARNING
Always inspect the track for ice and snow build-up that may be operated with ...RIDE INSPECTION
Manually turn the skis completely to the right and to the left side of the engine.
Maintain the oil level between the SAFE and ADD marks on the dipstick before using the vehicle. Track...
Owners Manual - Page 62
Push down to stop the engine. See page 68. There's always the possibility of some sideways vehicle movement, of applying a little more throttle than intended, or of bystanders.
Lights
Check ... be used to their full advantage.
Check these items after starting the engine (see page 61), but before each use of the vehicle. Transmission
Make sure the reverse is removed from the switch.
Owners Manual - Page 64
... hours of the owner's manual could result in the Engine Break-In section of operation will damage close-fitted engine parts. Avoid Heat Build-Up
Excessive heat build-up during the first 100 miles (160 km)of the machine. CAUTION
Failure to break in the Engine Break-In section. Perform Fluid Checks
Perform regular checks on all...
Owners Manual - Page 69
... adjust the TPS without proper tools and training WILL result in deteriorated engine performance and could result in SEVERE engine damage. Any service must be performed by a Polaris dealer trained to the engine. of the engine.
Always have been preset at the factory for adequate fuel supply at all altitudes. No adjustment is located on the TPS. When...
Owners Manual - Page 92
... to protect the engine, the system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be maintained at the FULL COLD mark (A) to check the coolant when he performs the fall tune-up on your snowmobile.
90
This service must be...
Owners Manual - Page 118
....
116 If you prefer to an approved fuel container using a siphon pump. Whenever the machine is stored for five minutes to drain the fuel system. Follow the engine fogging instructions provided on the can . Transfer unused fuel from the fuel tank to drain the fuel tank, use fuel after storage. 2. Rotate the engine slowly, watching the pistons until they...
Owners Manual - Page 127
...-Shift out of spec Engine mount broken or loose... Hi-fax melted to track clips due to ground. Engine Troubleshooting
TROUBLESHOOTING
CAUTION: All engine service and repair should be performed by a qualified Polaris dealer with training in neutral Clutch...clearance and replace if necessary. Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Drive clutch binding...
Owners Manual - Page 129
Engine Troubleshooting
Problem Engine turns but fails to start Probable Cause Faulty ignition No fuel to engine Air in fuel line, filter, or pump. -SEE DEALER for spark; This indicates a major engine problem that must be repaired before engine is run. -SEE DEALER.
-SEE DEALER. -There's no spark SEE DEALER. -Check tank level and fill with fresh winter fuel.
127 if no adjustment...
Owners Manual - Page 131
.... Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Previous correspondence 4. Service And Warranty Information
Polaris Anti-Theft System
WARRANTY
The Polaris anti-theft system (PATS) monitoring program is designed to record the identification numbers of your snowmobile and its...
Owners Manual - Page 133
... personnel at Polaris if additional assistance is YOUR responsibility). This warranty gives you specific legal rights, and you must present your copy of the Warranty Registration form to the dealer. (The cost of transportation to and from state to perform warranty service. When requesting warranty service you if inconsistent with your original selling dealer; Your dealer will...
Owners Manual - Page 136
... and sensors. The fuel pump is limited to the water pump assembly and components, ...transmission are covered. S Failure due to unauthorized service. S Electrical coverage is covered. This includes off-season storage as listed in the owner's manual or Polaris updates. S Non wear related throttle body parts are excluded from coverage. WARRANTY
Polaris Second Year Engine Service...
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