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Introduction
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Market Position
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Target Audience:
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Polaris Frontier Touring snowmobile owners, DIY mechanics, parts departments, service technicians
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Value Proposition:
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Provides essential information for identifying and sourcing OEM replacement parts, enabling cost savings and facilitating DIY repairs
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Competitive Analysis
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Competitors:
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Other online parts catalogs, dealer service departments, unofficial repair manuals
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Key Features
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Illustrations:
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Exploded parts diagrams for visual part identification
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Part Numbers:
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Includes specific Polaris OEM part numbers
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Accessibility:
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Instant PDF download, printable
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Ease Of Use:
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Clear and easy to follow for various skill levels
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Manual Coverage
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Systems Covered
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Engine:
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Engine components (pistons, rings, valves, crankshaft, camshaft, oil pump, gaskets, etc.), cooling system components
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Drivetrain:
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Primary drive clutch, secondary clutch, drive belt, chaincase, gears, driveshaft, track components
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Suspension:
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Front suspension (spindles, control arms, shocks, springs), rear suspension (skis, idler wheels, bogies, shocks, springs, rails)
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Electrical:
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Ignition system components, lighting, battery, wiring harness sections, starter motor, stator
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Body Chassis:
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Chassis components, seat, handlebars, controls, body panels, windshield, tunnel, bumper
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Fuel System:
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Carburetor components (if applicable), fuel pump, fuel lines, fuel tank, oil injection system components (if applicable)
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Braking System:
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Brake caliper, brake disc, brake lever, brake cable/line
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Procedures Included
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Identification Of Parts:
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Detailed visual identification of all replaceable components via exploded diagrams
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Part Ordering:
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Provides OEM part numbers for accurate ordering
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Disassembly And Assembly:
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Illustrations are designed to assist with correct disassembly and reassembly sequences
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Technical Depth
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Level Of Detail:
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Comprehensive for parts identification and procurement
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Diagnostic Capability:
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Limited to component identification; does not provide diagnostic procedures
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Repair Guidance:
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Illustrative guidance for assembly, but not step-by-step repair instructions
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Engine Specifications
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Primary Engine
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Engine Type:
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Two-stroke, liquid-cooled (common for Polaris 2004 models, specific engine may vary by Frontier Touring sub-model)
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Displacement:
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Likely in the 500cc to 700cc range, depending on specific Frontier Touring variant (e.g., 550, 600, 700cc models were common)
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Cooling System:
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Liquid-cooled (radiator, fan, coolant hoses, thermostat)
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Performance
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Horsepower:
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Typically 80-120 HP depending on engine size and tuning for this era
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Torque:
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Sufficient for snowmobile applications, specific figures vary by engine
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Fuel System
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Fuel Delivery:
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Carbureted (likely Mikuni VM series or similar) or potentially early fuel injection on some variants; oil injection system common
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Oil Type:
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2-stroke synthetic oil, specific grade recommended by Polaris (e.g., API-TC rated)
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Engine Components
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Cylinder Design:
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Aluminum alloy with nickel-silicon carbide bore (typical for Polaris)
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Spark Plugs:
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Specific NGK or Champion part numbers will be listed
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Dimensions
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Exterior
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Length:
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Varies by specific model configuration, typically around 110-120 inches
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Width:
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Varies, typically 40-50 inches
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Height:
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Varies, typically 45-55 inches
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Weights
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Dry Weight:
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Typically 450-550 lbs (dry)
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Payload Capacity:
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Designed for 1-2 riders plus minimal gear
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Cargo
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Cargo Capacity:
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Typically includes under-seat storage and potential for rack attachments
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Track
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Track Length:
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Commonly 136 inches for touring models
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Track Width:
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Standard 15 inches
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Lug Height:
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Typically 1.00 to 1.25 inches for trail and touring use
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Maintenance
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Service Intervals
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Clutch Inspection:
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Inspect primary and secondary clutches at the beginning of each season or every 1,000 miles for wear and alignment.
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Track Tension Adjustment:
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Check and adjust track tension periodically as per owner's manual recommendations.
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Chaincase Oil Change:
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Change chaincase oil annually or as specified by Polaris service bulletins.
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Coolant Flush:
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Flush and replace coolant every two years or as recommended.
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Spark Plug Replacement:
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Replace spark plugs at recommended intervals, typically every 2,000-3,000 miles or annually.
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Fluid Specifications
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Engine Oil Type:
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High-quality 2-stroke synthetic oil, API-TC rated, Polaris-branded or equivalent.
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Coolant Type:
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Ethylene glycol-based antifreeze, typically 50/50 mix with distilled water. Polaris recommends specific coolant part numbers.
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Chaincase Oil Viscosity:
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SAE 80W-90 or equivalent gear oil.
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Known Issues
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Clutch Wear:
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Clutch buttons and rollers can wear out, leading to poor performance and belt slippage. Regular inspection and replacement are key.
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Suspension Bushings:
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A-arm and shock bushings can degrade over time, affecting ride quality and handling.
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Track Ice Buildup:
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Ice and snow buildup in the track and tunnel can affect performance and potentially damage components. Ice scratchers can mitigate this.
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Carburetor Cleaning:
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Carburetors can become clogged with fuel deposits, especially after storage. Regular cleaning and proper fuel stabilizer use are important.
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Vehicle History
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Brand Heritage
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Polarishistory:
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Polaris Industries is a long-standing American manufacturer of powersports vehicles, founded in 1954, known for pioneering snowmobile technology.
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Model Evolution
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Frontier Series:
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The Frontier series was Polaris's lineup of utility and touring snowmobiles, emphasizing comfort, cargo capacity, and reliable performance for extended rides and work.
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2004 Model Year:
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2004 models represented a mature iteration of Polaris's snowmobile technology, featuring refinements in engine performance, suspension, and rider comfort.
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Production
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Manufacturing Location:
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Polaris snowmobiles are typically manufactured in the United States.
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