Polaris Offroad Vehicle 120 Pro X User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.

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

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.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

2005 120 PRO X Owner’s Manual P/N 9919072

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS

Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Important Notes for Owners and Drivers . . . . . . . . . . . 6

Preservation of the Environment . . . . . . . . . . . . . . . . . . 7

Vehicle Identification Numbers . . . . . . . . . . . . . . . . . . . . 9

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

YOUTH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Know Your Snowmobile . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pre-Ride Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Riding Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ADULT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pre-Ride Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operation Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 42

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Download from Www.Somanuals.com. All Manuals Search And Download.

WELCOME

Dear Parents:

We believe your children should have the opportunity to enjoy The

Way Out experience along with you. We’ve provided this owner’s

manual to assist you and your children in learning about the safe

operation and care of your new Polaris snowmobile. Please review the

information in this manual with any child who may operate the

snowmobile. Help your children learn to operate the snowmobile with

safety as a top priority. Help them also learn to show respect for our

environment and for the rights of others while operating the

snowmobile. Since the operator will be a newcomer to the exciting

winter sport of snowmobiling, please be sure he/she understands this

information before riding the snowmobile. Never allow a child to

operate the snowmobile without adult supervision.

The preventive maintenance program outlined in this manual is

designed to ensure that all critical components on your child’s

snowmobile are thoroughly inspected at various intervals. For safe and

enjoyable operation of the vehicle, be sure to follow all of the

instructions and recommendations in this manual. A table of

Polaris-recommended products is provided on page 82. If you have

any questions about the snowmobile, contact a Polaris dealer for

assistance.

This Owner’s Manual contains instructions for minor maintenance, but

major repairs are covered in the Polaris Service Manual and should be

performed by a Factory Certified MSD (Master Service Dealer)

Technician.

Dear Children:

Before you ride your new Polaris snowmobile, there are some

important things that you need to know. Your parents and Polaris want

you to enjoy riding your new snowmobile, and that’s why you need to

read and understand the information in your owner’s manual.

Ask your parents to explain anything you don’t understand, and pay

close attention to the warnings and instructions you read. Your safety

and the safety of others is the most important thing to think about at all

times.

As the driver of the snowmobile, you must learn how to keep yourself

and those around you safe while you’re riding. So read your manual,

and then enjoy riding your new Polaris snowmobile!

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

After reading this manual, store it in the snowmobile for convenient

reference. It should remain with the snowmobile when sold.

n This manual contains the latest information at the time of printing.

We reserve the right to make product changes and improvements

without notice.

n The illustrations and photos used in this manual are 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 dealer at specific mileage

intervals.

n A table of Polaris-recommended products for your snowmobile is

provided on page 82.

n You 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.

n Protect and preserve your right to ride by joining your local trail

riding clubs.

IMPORTANT

Parents should sit down with their children and read the Youth

Section with them before allowing them to use this snowmobile.

Parents must also read the Adult Section before allowing their

children to ride this snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Important Notes for Owners and Drivers

PARENTS: Do not allow anyone under the age of six (6) to operate

this machine. Review the information in this manual with any child

who may be operating the snowmobile. It is up to you to teach any

operator the proper and safe way to ride a snowmobile. You must set

boundaries and adhere to them, keeping the operator’s safety foremost

in your mind. Never allow a child to operate this machine without

adult supervision.

These units are not designed for adult use. Serious damage to the

vehicle may occur if the maximum rider weight capacity is exceeded.

The maximum rider weight capacity is 140 lbs. (63.5 kg).

CHILDREN: Before you ride your new Polaris snowmobile, there are

some important things that you need to know. Your safety and the

safety of others is the most important thing to think about at all times.

As the driver of the snowmobile, you must learn how to keep yourself

and those around you safe while you’re riding.

Pay attention when you see this symbol:

This is the safety alert symbol. When you see this

symbol on your snowmobile or in this manual it means

PAY ATTENTION because you could die or be seriously

hurt if you don’t follow the instructions.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Preservation of the Environment

Teach your child to drive their snowmobile with consideration for the

protection and preservation of the environment.

Noise Level

One of the most publicized subjects with regard to snowmobiles is

noise. The Society of Automotive Engineers (SAE), which is the

standard-setting body for snowmobiles, has recommended that

snowmobiles conform to prescribed sound levels. This Polaris

snowmobile has been engineered to conform to these SAE standards.

In order to be meaningful, all regulations require the cooperation of the

snowmobile owner. Muffling systems, designed to reduce noise levels,

should not be altered or removed. Snowmobile drivers must be aware

that they have a public responsibility to operate their snowmobiles with

concern for others. As a snowmobile operator you may not realize the

sound of your snowmobile may annoy non-snowmobilers. We are

attempting to do our part through the manufacture of quieter machines,

and we also ask your help in the effort to further reduce the impact of

noise.

Air Pollution

As a part of Polaris’ plan for the snowmobile’s compatibility within the

environment, our engineers are investigating ways to reduce emission

levels of engines. We expect our efforts to lead to the reduction of

potential air pollution.

The four-stroke engine used in this snowmobile produces less exhaust

emissions and reduces noise, as well.

In addition to technological research, we also suggest that

governmental agencies, manufacturers, distributors, dealers, ecologists,

and other interested parties work together to develop data on

environmental topics. We will continue to participate in this type of

study so that someday we may find the answers to these difficult

issues.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Preservation of the Environment

Environmental Protection

As part of the continuing environmental education campaign, we are

encouraging state and provincial governments across the snowbelt to

adopt rigorous safety training programs which also encourage

protection of our environment, wildlife and vegetation. Snowmobile

clubs and other organizations are working together to protect our

environment. It is very important that we encourage them as well as

become actively involved ourselves. Teach your child the following:

Respect your snowmobile;

respect your environment;

and you will earn

the respect of everyone.

Download from Www.Somanuals.com. All Manuals Search And Download.

INTRODUCTION

Vehicle Identification Numbers

The frame vehicle identification number (VIN) and engine serial

number are important for model identification when registering your

vehicle, when obtaining insurance, and when ordering replacement

parts. In the event your vehicle is stolen, these numbers are essential to

the recovery and identification of your vehicle.

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.

Please record your snowmobile identification numbers below for future

reference:

31XX

1. Tunnel VIN (lower right side of the tunnel)

________________________________________________________________

2. Engine Serial Number (right front side of engine crankcase)

________________________________________________________________

3. Key Number:

________________________________________________________________

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

WARNING

Failure to follow the warnings in this manual can result in severe

injury or death. Read and understand the owner’s manual and all

warnings before operating a Polaris snowmobile. Adults must

thoroughly explain this information to all operators of the

snowmobile.

All operators must be at least six (6) years old and must

understand the risk involved if these important warnings and

cautions are not heeded.

Equipment Modifications

All Polaris snowmobiles have been designed and tested to provide safe

operation when used as directed. Failure of critical machine

components may result from operation with any modification;

especially those that increase speed or power. There’s a significant

possibility of loss of control at higher speeds.

We are concerned for the safety of our customers and for the general

public. Any modifications to the original equipment of the vehicle

create a substantial safety hazard and increase the risk of bodily injury.

Therefore, we strongly recommend that consumers do not install on a

Polaris snowmobile any equipment that may increase the speed or

power of the vehicle, or make any other modifications to the vehicle

for these purposes.

The warranty on your Polaris snowmobile is terminated if any

equipment has been added to the vehicle, or if any modifications have

been made to the vehicle, that increase its speed or power.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Maintenance Program

As with all snowmobiles, caution must be observed to ensure operator

safety. Particular caution must be taken to make sure that the

snowmobile is in excellent operating condition at all times. We

strongly recommend that the operator, as well as an adult, check major

and vital safety components before each use of the vehicle.

We also recommend that you strictly follow the maintenance schedule

outlined in this manual to ensure that all critical components on the

snowmobile are thoroughly inspected by your dealer at various mileage

intervals.

This snowmobile is not a toy. It is a well-engineered and

well-constructed recreational vehicle. The information in this manual

is provided to aid you in its safe operation.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals

Safety and warning decals have been placed on the vehicle for the

operator’s protection. Make sure the operator understands the

information on all decals. If any decal becomes illegible or comes off,

contact your Polaris dealer for a replacement. Any safety decal

needing replacement will be provided by Polaris at no charge. The part

number is printed on the decal.

CAUTION

Improper use of this snowmobile or failure to maintain it in good

operating condition can result in injury. To reduce this possibility,

read the important safety information on the following decal and

make sure all operators and guests are familiar with all warnings,

cautions and safe operating procedures. They must also

understand the consequences and risks if they choose to ignore

or neglect this information.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the

vehicle.

IMPORTANT

IMPORTANT will alert you to important information or

instructions.

NOTE: A note will alert you to key information or instructions.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Know Your Snowmobile

Before you have an adult start the engine for you for the first time, let’s

learn about the controls on your new machine.

1. Engine Stop Switch - When the engine is running, you can push

this button down and the engine will stop. The stop switch must

be in the UP position to start the engine again.

2. Throttle Control - The throttle control makes your snowmobile go

forward when you press it with your thumb. You must always

make sure the throttle control does not stick before you operate

your snowmobile. Read more about it on page 19.

3. Recoil Starter Handle - Pull the recoil starter handle to start your

snowmobile. An adult will help you start it the first time.

4. Choke Knob - You may need to use the choke to help start your

snowmobile if the engine is cold. Read more about it on page 48.

Always have an adult put gas in your snowmobile. Never try to do

it yourself.

5. Gas Cap - The gas cap has to be taken off when an adult puts gas in

your snowmobile. Never take the gas cap off. Always make sure

it’s tightly closed.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Know Your Snowmobile

Always take your thumb off the throttle lever when you squeeze

the brake lever.

6. Brake Lever - Squeeze the brake lever toward the handlebar to

make your snowmobile slow down or stop.

7. Ignition Switch - The ignition switch key must be turned ON

before pulling on the recoil starter handle to start your snowmobile.

You can also use this key to turn off the engine.

Never ride without the tether strap attached to your right wrist and

to your snowmobile. Be careful not to let the cord get tangled

around the handlebars or any part of your body.

8. Tether Strap/Switch - The tether strap must always be attached

snugly to your right wrist and to your snowmobile every time you

drive. If you fall off your snowmobile, the tether strap will pull away

from the switch and the engine will stop.

Always make sure the hood hold-down straps are latched before

you ride.

9. Hood Hold-Down Strap - There are two straps to hold down the

hood of your snowmobile. They must always be latched before you

start your machine.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Know Your Snowmobile

Let’s learn more about the parts of your snowmobile before we talk

about riding.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Know Your Snowmobile

1. Hood - The hood covers the moving and hot parts of the engine

and must be securely latched before you ride the snowmobile.

2. Headlight - The headlight is always on when the engine is

running. It helps others see you when you’re riding during

daylight, but it’s not supposed to be strong enough to help you see

in the dark. Drive your snowmobile only in the daylight.

3. Windshield - Always keep your windshield clean so you can see

where you’re driving.

4. Handlebar - The handlebar is connected to the skis. When you

turn the handlebar, the skis turn in the same direction.

5. Flag - The flag helps other people see where you’re riding. Your

snowmobile is smaller than an adult snowmobile, so it’s harder to

see. Never remove the flag from your snowmobile.

6. Seat and Storage - When the engine isn’t running, you can take

the seat cushion off and put things under the seat in the special

compartment.

7. Taillight - The taillight is always on when the engine is running.

It will help others see you when you’re riding.

8. Snow Flap - The snow flap keeps snow, ice or other things from

flying out behind your snowmobile.

Never get close to a moving track. Never wear clothing that

could get caught in a moving track, like a long scarf or baggy

clothing. Tie up long hair.

9. Track - The engine makes the track turn. The turning track makes

your snowmobile go forward.

10. Skis - The skis turn your snowmobile in the same direction that

you turn the handlebar.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Know Your Snowmobile

Let’s review the three ways to stop your snowmobile:

1. Push the stop switch down.

2. Pull off the tether strap.

3. Turn the key off.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Pre-Ride Check

You’re almost ready to have an adult start your snowmobile. Before

the snowmobile is started for the first time, you must do a PRE-RIDE

CHECK. In fact, every time you ride your snowmobile you must have

an adult help you check these things before starting it. Let’s learn

about these things now.

Never start the engine if you have a sticky throttle. You could get

hurt if you ride with a sticky throttle. Have an adult or your

Polaris dealer fix the throttle before you ride.

n Make sure the throttle doesn’t stick. Push the throttle lever toward

the handlebar and then let it go. The lever should come right back

to where it was before you pushed it. If it comes back slowly or

stays close to the handlebar, you have a sticky throttle. This means

that something is wrong or broken. Don’t start the snowmobile

until an adult fixes the sticky throttle.

Never start the engine if you have sticky brakes. You could get

hurt if you ride with sticky brakes. Have an adult or your Polaris

dealer fix the brakes before you ride.

n Make sure the brakes don’t stick. Squeeze the brake lever toward

the handlebar and then let it go. It should come right back to

where it was before you squeezed it. If it goes back slowly or stays

close to the handlebar, your brakes are sticking.

n If you’ve used the storage area under the seat, make sure the seat

locking tabs are in place.

n Make sure your hood is latched tight before starting your machine.

Never check the track or skis when the engine is running. You

could get hurt. Never stand behind or in front of any snowmobile

when the engine is running.

n Make sure your track and skis are not frozen to the snow. Stand

behind the machine and lift up on the back of the sled. This will

free the track if it is frozen to the ground. Turn the handlebars to

move the skis back and forth to make sure they aren’t frozen. If

any of this is hard to do, have an adult help you.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Pre-Ride Check

Always have an adult put gas in your snowmobile. Never try to do

it yourself.

n Have an adult check the gas level to see if your snowmobile needs

more. Children should never add their own gasoline. This must

always be done by an adult. Before anyone adds gasoline to your

snowmobile they must read the instructions and warnings on page

46 in this Owner’s Manual.

n Have an adult check the engine oil level when the engine is cold.

The engine is very hot after it has been running. It could burn your

skin. Children should never check the oil. Only an adult should

be responsible for keeping the gas and oil levels to the full marks.

n The last check is done with the engine running. Always check to

make sure that ALL THREE WAYS TO STOP THE

SNOWMOBILE are working the way they should. Do you

remember what they are? If you can’t list them, go back to page

18 and review.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Riding Rules

Now you’re ready to learn about driving your Polaris snowmobile.

There are some things you can do and there are some things you must

never do. Rules are very important when you’re driving a snowmobile.

Adults have riding rules, too. The rules help keep us safe when we

ride.

You must be at least six (6) years old before you can ride this

snowmobile. The adult with you is your teacher. Always pay attention

to what your teacher says so you can learn how to always drive safely.

Let’s learn how to ride!

Always follow the safe riding rules found on the next pages. You

or others around you could be seriously hurt or killed if you don’t

follow the safe riding rules.

Your snowmobile is made for one person. Never carry a passenger.

A passenger will make the snowmobile harder to drive. You may

lose control and hurt yourself and your passenger.

Never pull anything behind your snowmobile.

Make sure you know where you’re going to drive when your snow-

mobile is started. Make sure the area is safe all around your snow-

mobile.

Never ride alone. An adult should always be watching you in case

you need help. Always drive within the sight of an adult.

Never ride on public trails.

When you’re a beginner, always stay on level ground.

Don’t ride your snowmobile on roads or over railroad tracks. Your

snowmobile makes noise that will keep you from hearing cars,

trucks or trains that may be coming towards you.

Fences and snowmobiles don’t mix. Make sure you know where all

the fences are before you ride. If you drive into a fence, you could

get hurt.

Don’t ride at night. The headlight on your snowmobile is there only

so others can see you driving during the day.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Riding Rules

Helmet

Face

Shield

Jacket

Gloves

Pants

Boots

Always wear the right kind of clothing when you’re riding your

snowmobile. You’ll need a good helmet with a face shield or

goggles. Wear a warm jacket and snowpants. Make sure your cloth-

ing fits properly. If it’s too small, it could keep you from moving

easily. If it’s too big, it could hang down and get caught in the track

or another moving part. Never, ever wear a long scarf. Wear warm

snowmobile boots and gloves, and make sure your boot laces are

tied. If you have long hair, be sure to tie it up.

Learn where there are lakes, rivers, ponds and ditches in your driv-

ing area. Stay away from them. Never ride on frozen water. You

could get hurt or you could even die. All ice can be dangerous!

Always be alert and pay attention to where you’re driving. Pay

attention to other drivers and be even more careful around them be-

cause you don’t know what they’re going to do.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Riding Rules

Both Hands on

Handlebars

Sit Down

Feet on Running Boards

Always drive your snowmobile while sitting down. Keep both

hands on the handlebars and keep both feet on the running boards.

Never follow another snowmobile too closely. Always allow lots of

time and space to stop your snowmobile.

Ride your snowmobile only

where you know it’s safe to

drive and where you have per-

mission to drive. Be careful of

To Machine

To Wrist

the things around you.

Always be a polite driver. (No

driving through the flower gar-

den or over the little trees you

planted.)

Always attach the tether strap to

your wrist and machine before

riding.

Download from Www.Somanuals.com. All Manuals Search And Download.

YOUTH SECTION

Riding Rules

Learn how to ride safely and correctly. Learn how to use your hands

and arms as signals. Read and understand your Owner’s Manual.

Left Turn

Right Turn

Stop

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Pre-Ride Check

It’s up to you, the adult, to teach your child the proper and safe way to

ride a snowmobile. You must set boundaries and adhere to them,

keeping your child’s safety foremost in your mind. Never allow your

child to operate this machine without adult supervision.

WARNING

Teach the operators to perform the following Pre-Ride Check

before each use of the snowmobile. Serious injury or death could

result if they do not check the machine properly before riding.

n Check the throttle for proper operation.

n Check the brake for proper operation.

n Check for proper operation of steering system.

n Check the throttle safety switch for proper operation.

n Make sure all three ways to stop the engine are functioning.

n Inspect the track.

n Make sure the seat is locked into place.

n Make sure the track and skis are not frozen to the ground.

n An adult should check the gas and oil levels for the rider and add

more if necessary.

n Make sure the hood is latched.

n Make sure headlight and taillight are working properly.

These checks should become automatic for your children before each

ride. It’s up to you, the adult, to instill in your children the importance

of performing this Pre-Ride Check before they operate the

snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Pre-Ride Check

Before Starting The Engine

n Read and Understand Your Owner’s Manual

Read and make sure the operators understand the Owner’s Manual

completely before allowing anyone to operate this snowmobile. It’s

also a good idea to review it periodically to reinforce the information.

It’s very important to familiarize the operator and guests with the

cautions and warnings pertaining to the machine as well as safe

operating procedures. We’ve attempted to provide you with as much

information as possible to alert you to the safety requirements of

snowmobiling.

WARNING

The throttle and brake are the primary controls of the

snowmobile. If either should malfunction, the operator could lose

control, which could lead to serious injury or death. Always check

the throttle and brake levers for proper operation before operating

the vehicle.

n Check throttle for proper operation

When checking the throttle, make sure the control lever compresses

evenly and smoothly. When the lever is released, it should

immediately return to the idle position without binding or hesitation.

If the throttle does not function smoothly, do not attempt to start the

engine. Have the throttle serviced before starting the engine.

n Check brake for proper operation

The need for a properly functioning brake is critical. The brake must

be checked for correct operation before starting the engine. See page

31 for brake lever travel specifications.

n Check for proper operation of steering system

Check for proper operation of the steering system by manually turning

the skis completely to the right and to the left. If difficulty is

encountered, check for ice and snow buildup which may be obstructing

the steering linkage. Make sure all greasable components are properly

lubricated.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Pre-Ride Check

n Check throttle safety switch

Test the throttle safety switch system

on a daily basis before the machine

is used.

While seated in a normal riding

position, and with the engine idling,

hold the throttle lever pin stationary

by exerting pressure on the pivot pin

in the direction shown in the

illustration (A). Apply a slight

amount of throttle opening. A properly functioning switch must shut

down the engine.

The throttle safety switch is designed to stop the engine whenever all

pressure is removed from the throttle lever and the throttle cable or

valve does not return to the normal closed position.

If excessive play develops in the

throttle cable, the safety switch may

be activated and will prevent the

engine from starting. If the engine

doesn’t start and throttle safety switch

malfunction is suspected, return the

machine to an authorized Polaris

dealer for service. If an adult must

.03 in.

start the engine in an emergency situation, the throttle safety switch

and engine stop switch may be disconnected from the wire harness. In

this situation, the ignition key switch must be used to shut off the

engine. Be sure to reconnect the safety switches and have the

snowmobile serviced before operating the vehicle again.

WARNING

Do not continue to operate the machine with the throttle safety

switch disconnected as serious injury or death could result.

Return the machine to an authorized Polaris dealer for service

before operating.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Pre-Ride Check

n Check engine stop switch

Test the engine stop switch before

each use of the snowmobile. To

stop the engine in an emergency,

push down on the stop switch (A).

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.

n Inspect the track

Driving for extended periods of time with marginal lubrication could

severely damage the track. Driving on icy trails or driving when there

is little or no snow are two examples of situations that would provide

marginal lubrication and are not recommended.

WARNING

Operating the snowmobile with a damaged track will increase the

possibility of additional track damage and/or failure. This could

cause loss of control, resulting in severe injury or death. Always

inspect for damage before using the snowmobile.

NOTE: Track damage or failure caused by operation under poor

lubrication conditions will void the track warranty.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

n Do not carry passengers

This snowmobile is designed for a single operator.

n Do not operate with intake silencer removed

CAUTION

If the engine is operated with the intake silencer removed,

damage to the engine may occur. Do not operate the engine with

the intake silencer removed.

n Stay clear of track

WARNING

During warm-up and operation, stand clear of the rotating track.

Entanglement and serious injury or death may result. Use just

enough throttle to rotate the track and warm up the engine.

n Do not operate with drive chain guard removed

WARNING

The drive chain guard is designed to protect the operator from

metal parts in the event of a drive chain failure. Although the

chance of failure is extremely remote, do not defeat the purpose

of the guard by removing it. It is provided for the safety of the

child.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

n Do not touch the engine after it’s been running

WARNING

Hot components can cause serious burns to skin. Do not touch

engine and exhaust parts after the engine has been running.

n Disabled operators

WARNING

Safe operation of this rider-active vehicle requires good

judgement and physical skills. Persons with cognitive or physical

disabilities who operate this vehicle have an increased risk of

overturns and loss of control, which could result in serious injury

or death.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

n Check brake lever travel

Measure the clearance

between the lever and brake

block. Inspection should be

made with the lever

firmly depressed.

Distance A should be no

more than 3/4″ (1.9 cm).

Excessive travel indicates

a need to adjust the brake cable.

Refer to the mechanical brake adjustment information on page 59.

n Make sure the hood is securely latched

The hood of the snowmobile protects the operator from moving and hot

parts as well as aiding in sound emission control and various other func-

tions. Under no circumstances should your snowmobile be operated with

the hood open or removed.

n Test stop switch operation

Start the engine and push the stop switch down to test for proper

operation. The engine should immediately stop running.

n Test tether switch operation

Start the engine and disconnect the tether switch to test for proper

operation. The engine should immediately stop running.

n Remove the ignition key

Don’t tempt someone to steal or ride your snowmobile without

permission by leaving the key in the ignition.

n Check lights

Start the engine and check that both the headlight and taillight are

operating.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

n Check surroundings to verify clear operating area

It’s important to make sure there’s a clear area all around the

snowmobile, including an area clear of bystanders. Some sideways

movement is possible when starting out, and debris may be thrown by

the track. Teach the operator to check the operating area before riding.

n Sit properly on the snowmobile

Improper operator position on the snowmobile can be the source of

serious injury. Operating a snowmobile does require skill and balance

for proper control, and an improper position can seriously reduce the

child’s ability to control the snowmobile. The riding position may

vary as the operator becomes more skilled, but under most conditions

the proper position is to be seated with both feet on the running boards,

in a comfortable position for proper throttle, brake and steering control.

WARNING

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.

This snowmobile is propelled by a revolving track, which must be

partially exposed for proper operation. Serious injuries may be caused

by operator carelessness, resulting in hands, feet, hair or clothing

becoming entangled in the track. Teach your child to respect this

machine and all the moving parts. Stress that being properly seated

keeps the child clear of the track.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

n Stop engine before attempting adjustments

WARNING

The snowmobile engine compartment contains moving parts.

Shields and guards have been provided for safety, but it is still

possible to carelessly get your hands or fingers into a moving

chain or a rotating shaft. For this reason never attempt

adjustments with the engine running. Serious personal injuries

can result. The proper method is to turn off the ignition, raise the

hood, make the adjustment, secure shields and guards, secure

the hood, and then re-start the engine to check its operation. The

same is true of track alignment. If the track must be re-aligned, it

is recommended that this service be performed by your dealer.

n Always wear clothing designed for snowmobiling

Clothing designed for snowmobiling is warm, comfortable and safe.

WARNING

Always make sure the operator is wearing an approved helmet

and eye protection. Do not allow the child to wear loose clothing

or long scarves because they can easily become entangled in

moving parts. If your child has long hair, be sure it is always tied

up securely and tucked into the helmet or jacket.

Extremely cold weather can cause frostbite and/or hypothermia.

Always be aware of weather conditions, especially the wind chill.

See the table on page 36.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

n Know limitations of machine and skills of driver

The operator should be aware that there are state and local laws

governing snowmobile operation and that these laws should be

followed. They have been established for the protection of all

snowmobile riders. Most states offer a snowmobile safety course for

children. Check your state or county agencies for this service.

This vehicle is intended for daylight use only. Check both the

headlight and taillight of the machine to ensure proper operation.

IMPORTANT: The headlight and taillight are intended only to

increase the visibility of the 120 PRO X during daylight operation. Do

not operate the snowmobile in the dark.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

Wire fences are a serious hazard. Teach

your child to always be on the alert for

fences. Single strands are especially

dangerous, since there can be a great

distance between posts. Guy wires on

utility poles are also difficult to

distinguish. Teach your child to

reduce speed when traveling near

poles, posts, or other obstacles.

Teach your child that the sound of the

machine will make it difficult to hear

the sound of approaching vehicles. Do

not allow your child to operate the snowmobile on or near roads and

railroad tracks.

Teach your child what it means to drive defensively. Never tailgate

and always allow ample stopping distances.

Your child must be taught to always be alert and pay attention to the

driving area ahead.

When teaching inexperienced operators to ride, set up a nearby

predetermined course. Establish boundaries and make sure the

operator(s) know and understand them. Make sure they know how to

drive and control the snowmobile before you allow them to make

supervised longer distance runs. Teach them proper snowmobile

courtesy.

It’s a good idea to predetermine some hand signals as a way to

communicate with your child while giving instruction. It may be

difficult for your child to hear your voice over the sound of the

snowmobile and through a helmet.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

Windchill/Temperature Charts

The following information is provided as a guide to determine what

temperatures are dangerous when riding your snowmobile.

WIND CHILL CHART (°F)

Esti-

mated

Wind

Speed

in MPH

Actual Thermometer Reading (°F)

20 10 -10

-20

-3 -4 -5 -6

Equivalent Temperature (°F)

Calm

-10

-15

-33

-45

-53

-59

-63

-67

-69

-20

-26

-46

-58

-67

-74

-79

-82

-85

-3 -4 -5 -6

-5

-3 -4 -- 5 -6

-9

-21

-36

-39

-44

-48

-49

-53

-5 -7 -8 -9

-5

-18

-25

-29

-33

-35

-37

-7 -8 -9 -1

-10

-15

-18

-20

-21

-8 -9 -1 -1

10 24

-8 -1 -1 -1

04 18 33

-2

-4

-6

-9 -1 -1 -1

09 25 40

-9 -1 -1 -1

13 29 45

-1 -1 -1 -1

00 16 32 48

Wind

Speeds

Greater

Than

Little Danger

(For Properly

Clothed Person)

Increasing

Danger

Great

Danger

40 MPH

Have

Little

Danger From Freezing of Exposed Flesh

Added

Effect

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

WIND CHILL CHART (°C)

Esti-

mated

Wind

Speed

in KPH

Actual Thermometer Reading (°C)

-10 -15 -20 -25

Equivalent Temperature (°C)

-5

-30

-35

-40

-5

-10

-16

-23

-28

-32

-34

-35

-36

-15

-22

-29

-35

-39

-41

-43

-44

-20

-27

-36

-42

-47

-49

-51

-52

-25

-33

-42

-48

-53

-57

-59

-60

-30

-38

-48

-55

-61

-64

-66

-68

-35

-45

-54

-63

-69

-73

-75

-76

-40

-50

-61

-69

-76

-80

-82

-84

-4

-11

-17

-21

-24

-26

-27

-28

-4

-9

-7

-13

-16

-18

-19

-20

-9

-11

-12

-13

Wind

Speeds

Greater

Than

Little Danger

(For Properly

Clothed Person)

Increasing

Danger

Great

Danger

70 KPH

Have

Little

Danger From Freezing of Exposed Flesh

Added

Effect

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

Cold Weather Drive-Away

Whenever the machine has been parked for some length of time,

especially overnight, always shake loose the skis and track for the

operator before attempting to put the machine into motion. The

throttle will require some pressure to move the machine. Teach the

operator not to be afraid of applying pressure to the throttle but at the

same time, teach them not to be too forceful with the throttle which

could cause the machine to lurch forward.

Powder Snow Operation

This snowmobile is designed to operate best on snow. Maneuverability

is attained by the steering, skis, and the shifting of the driver’s body

weight. Maximum control will be attained by shifting body weight.

Maneuverability will change for lighter operators.

If the machine becomes stuck in snow, free the running board area and

step down the snow in front of the machine so that when the throttle is

opened the machine will be able to climb out. The operator can then

get back on the machine and continue. It is best to encourage the

operator to stay on established riding areas to avoid the possibility of

getting stuck.

Track Lubrication

Do not operate for prolonged periods in conditions of marginal

lubrication.

CAUTION

It’s essential that this machine be operated under conditions with

adequate snow cover, as snow provides the only lubrication for

the track. Failure to do so will result in excessive wear and

damage to the slide rail and track.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

Snow and Ice Build-Up

Snow and ice buildup in the underhood area can interfere with the

steering.

WARNING

Before allowing your child to drive the machine, be sure that ice

and snow are not interfering with the steering. Manually turn the

skis to the left and right. If difficulty is encountered, check for ice

and snow buildup which may be obstructing the steering linkage.

Hard Packed Snow

Teach your child to reduce speed as required to maintain control in all

driving conditions. If necessary, maximum speed may be regulated by

using the procedure outlined on page 47.

WARNING

Steering and braking control are substantially reduced when

operating on on hard surfaces, hard-packed snow or icy surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

Driving on Ice

It is dangerous to operate on ice or under slippery conditions. If ice or

slippery conditions are unavoidable, use extreme caution and operate at

speeds no faster than a walk. Never attempt an abrupt change of

direction on a slippery surface. The chance of “spin-out” increases

under these conditions. Being able to turn a snowmobile depends

primarily on the skis being in snow. On hard surfaces, such as ice, the

ability to turn is reduced and the machine will not turn very well. In

this situation it may be best to dismount and move either the front or

rear of the machine to point it in the proper direction.

Teach your child to respect the unknown. Children must be taught that

they are not to venture out on their own in unapproved territory. They

must learn that they must never ride a snowmobile on a frozen body of

water. You and the driver of the machine should know and understand

that severe injury or death can result if the snowmobile and its

occupant break through the ice.

Driving in Hilly Terrain

WARNING

Traveling on hilly terrain is not recommended. It takes some

maneuvering of body weight that a child may not be capable of,

which will leave the child at risk. If traveling on hilly terrain is

unavoidable, teach your child to exercise extreme caution as well

as the proper operating procedure as outlined below.

Driving Uphill

Riding uphill requires extreme caution and should be attempted only

by experienced operators. The operator should assume a standing

position with body weight kept low and forward, accelerating before

the start of the climb and then releasing throttle pressure enough to

prevent track slippage.

When reaching the crest of the hill, the operator must slow down and

be prepared to react to obstacles, sharp drops, or other people or

vehicles which may be on the other side of the hill.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation Warnings

Driving Downhill

When riding downhill, the operator must keep the speed at a minimum.

It is important to apply just enough throttle to keep the clutch engaged

while descending the hill. This will allow use of the engine’s

compression to help slow the machine, and keep the snowmobile from

rolling freely downhill.

WARNING

Teach your child to never stand or get off the machine on the

downhill side of the machine. Serious injury or death could result.

Driving Responsibly

It is up to you, the adult, to teach your child the proper and safe way to

ride a snowmobile. You must set boundaries and adhere to them,

keeping your child’s safety foremost in your mind. Never allow your

child to operate this machine without adult supervision.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Component Identification

5,6

1. Hood

2. Headlight

8. Rear Suspension

9. Nosepan

3. Windshield

4. Handlebar

5. Seat

6. Storage (under seat)

7. Taillight

10. Trailing Arm

11. Skis

12. Front Bumper

13. Rear Bumper

14. Snow Flap

15. Track

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Component Identification

1. Stop Switch

2. Tether Strap

3. Throttle Control

4. Recoil Starter Handle

5. Hood Hold-Down

6. Choke Button

7. Gas Cap

8. Ignition Switch

9. Console

10. Brake Lever

11. Tether Switch

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Break-In Period

Engine Break-In

The break-in period for your new snowmobile is defined as the first ten

hours of operation, or the time it takes to use the first two tanks full of

gasoline. No single action on your part is as important as a proper

break-in period. Careful treatment of a new engine will result in more

efficient performance and longer life for the engine. Perform the

following procedures carefully.

1 Drive slowly at first. Select an area that’s open and will allow room

to familiarize yourself with vehicle operation and handling.

2 Vary the throttle positions. Do not operate at sustained idle.

3 Perform regularchecks on fluid levels, controls and all important areas

on the vehicle, as outlined in the maintenance section.

4 Break in the oil. Change the oil after the first 20 hours of operation.

CAUTION

Never mix brands of oil. Serious chemical reactions can cause oil

passage blockage, resulting in severe engine damage and

voiding of engine warranty. The only oil recommended for this

system is Polaris Premium 4 All Season Synthetic oil. This oil

has been specially formulated for all temperatures and has

extreme cold flow characteristics.

Do not operate at prolonged full throttle for the first three hours of

operation. Vary the throttle openings and machine speeds. This

will reduce friction on all close fitting machined parts and allow

them to break in slowly without damage.

Avoid operating on ice or hard-packed surfaces, roads, etc. The

absence of lubrication and cooling by snow will lead to

overheating of the slide rail and track resulting in premature wear

and failure. Reduce speeds and frequently drive into fresh snow

to allow adequate cooling and lubrication of the slide rail and track

surfaces.

Drive with extra caution during the break-in period. Perform

regular checks on fluid levels, lines, and all important areas of the

machine.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Break-In Period

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 All Season Synthetic oil. Never substitute or mix oil

brands.

Checking Engine Oil

Before checking or refilling engine

oil, be sure the engine is stopped and

the vehicle is positioned on a stable,

level surface.

NOTE: Always change the oil if

it’s become contaminated.

1. Remove the dipstick and wipe it

dry with a clean shop towel.

2. Insert the dipstick (A) into the oil

fill hole, then remove it and read

the oil level.

NOTE: Do not thread the dipstick into

the hole to perform the oil check.

3. If the oil level is below the lower

level mark (B) on the dipstick,

add the recommended oil to the

upper mark (C).

NOTE: Always use Polaris Premium 4 All Season Synthetic Oil or

any class SE, SF (API classification) or higher grade oil. If

multi-grade oil is used, oil consumption will increase when

the ambient temperature is high.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation

Fuel

When refueling, use either leaded or unleaded gasoline with a

minimum pump octane number of 87=(R+ M/2) octane.

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

Always exercise extreme caution whenever handling gasoline.

Always refuel with the engine stopped, and outdoors or in a well

ventilated area.

Do not smoke or allow open flames or sparks in or near the area

where refueling is performed or where gasoline is stored.

Do not overfill the tank. Do not fill the tank neck.

If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

If you get gasoline in your eyes or if you swallow gasoline, see

your doctor immediately.

Never start the engine or let it run in an enclosed area. Engine

exhaust fumes are poisonous and can cause loss of

consciousness or death in a short time.

Turn the fuel valve off whenever the vehicle is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation

Speed/Performance Regulation

Adults have the responsibility for teaching children the proper and safe

way to ride a snowmobile. Please set boundaries and adhere to them,

keeping your child’s safety foremost in your mind. Never allow a child

to operate this machine without adult supervision.

Under certain circumstances it may be necessary for an adult to

regulate the speed and acceleration of the snowmobile by moving the

governor lever spring. Use the following procedure to set the

performance level.

CAUTION

Hot engine components can cause serious burns to skin. Always

perform the following procedures when the engine is cool.

For maximum performance,

move governor spring (A) to

hole #3.

For minimum performance

move governor spring to hole

#1.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation

Starting the Engine

Never start the snowmobile without checking all components to be sure

of proper operation. Refer to the Pre-Ride Check beginning on page

25.

Starting a Cold Engine

1. Turn the key to ON.

2. Pull the engine stop switch (shut-off switch) up to the RUN

position.

3. Pull the choke lever completely outward to the FULL ON position.

NOTE: Do not depress the throttle while starting.

4. Grasp the starter handle and pull slowly until the recoil engages,

then pull abruptly to start.

CAUTION

Extending the starter rope too far or allowing it to snap back into

the housing will cause damage to the recoil assembly. Do not

extend the starter rope to its maximum length, and do not drop

the rope handle during starting.

5. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm-up.

6. Apply the brakes and vary the engine RPM slightly with the

throttle to aid in warm-up. When the engine idles smoothly, push

the choke all the way in.

NOTE: To prevent excessive wear on the clutch components, don’t

engage the clutch while performing the warm-up.

Starting a Warm Engine

1. Turn the key to ON.

2. Pull the engine stop switch (shut-off switch) up to RUN.

3. Grasp the starter rope handle and pull slowly until the recoil

engages, then pull abruptly to start.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation

Emergency Stopping Procedures

The following chart lists methods for stopping the engine in the event

of an emergency.

SYSTEM

WHAT IT DOES

THROTTLE

CONDITION

Engine Stop Switch

Ignition Switch

Tether Switch

Throttle Safety Switch

Choke

Interrupts ignition circuit

Floods engine

All

1/2 throttle or less

All

Brake

Slows drive shaft

Daily Storage

Whenever the machine is placed in

overnight or daily storage the

following steps must be taken:

1. Park the snowmobile on a level

surface and support it at the rear

so the track is suspended

approximately 4″ (20 cm) from

the ground.

2. Remove the key and cover the

machine using the Polaris cover

available for your model. See

your dealer for more information.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Operation

Pre-Ride Warm-Up

Always warm up the engine, drive train and track before operating the

snowmobile. With the snowmobile securely supported by the rear

bumper with a minimum clearance of 4″ (10 cm) from the ground, use

the following procedure to properly warm up the snowmobile.

WARNING

A loose track or flying debris could cause serious personal injury

or death. Be sure the rear support is stable. Stand clear of the

front of the machine and the moving track. Never hold the

snowmobile up or stand behind it while performing this procedure.

Do not use too much throttle during warm-up or when the track is

free-hanging.

1. Start the engine and allow it to warm up two to three minutes.

2. Engage the drive system abruptly and allow it to rotate the track

several revolutions.

NOTE: The outside temperature will determine the amount of track

warm-up required.

3. Shut off the engine and remove the rear support.

4. Grasp the skis by their front loops and move from side to side.

This will loosen frozen snow from the ski bottoms, allowing the

machine to move forward more easily.

5. The engine, drive system and track are now properly warmed up

and the machine can be driven following normal safety practices.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Polaris Recommended Maintenance Program

Your Polaris snowmobile has been engineered and manufactured by

skilled Polaris personnel to the highest degree of performance and

reliability possible. In order to maintain this level of quality, your

machine must have regular service and maintenance inspections.

The Polaris Recommended Maintenance Program is intended to assist

you in performing routing maintenance that will ensure trouble-free

enjoyment of your Polaris snowmobile. If the recommended regular

maintenance and service checks are followed, you will be doing your

part in keeping this snowmobile in excellent operating condition at all

times.

The recommended maintenance schedule for your snowmobile calls for

a service and maintenance inspection at 50 hours, at 100 hours and at

150 hours. These inspections should be performed by a qualified

service technician.

NOTE: Any replacement parts and labor incurred, with the exception

of authorized warranty repairs, are the responsibility of the

registered owner. If parts failures occur during the course of

the warranty period as a result of owner neglect in

performing the recommended periodic maintenance, the cost

of repairs shall be the responsibility of the owner.

Please read and follow the recommended maintenance program

illustrated on the following pages to maintain the performance and

reliability of your Polaris snowmobile.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the following chart and in the

maintenance section of this manual.

Service and adjustments are critical. If you’re not familiar with safe

service and adjustment procedures, have a qualified dealer perform

these operations.

NOTE: 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, we recommend the use of genuine

Polaris parts, available from your Polaris dealer.

ITEM

DAILY

WEEKLY OR

BEFORE

EXTENDED

PERIOD OF

OPERATION

HRS

100

HRS

150

HRS

SEE

PAGE

Check brake operation and

adjustment

58-59

Test engine stop switch

(auxiliary shut-off switch)

Test throttle safety switch

Test tether switch

Test throttle lever operation

Test brake lever operation

Check steering system

operation

Check operation of headlight

and taillight

Clean dust and chaff from

engine

Check ski skags, replace when

worn to 1/2 original diameter

Inspect fuel lines, replace if

needed

Check engine oil level

Oil the drive chain

Every 10 Hrs

Check track tension, tighten if

necessary

Grease the clutch

Change oil

Every 15 Hrs

At 20 Hrs

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

ITEM

DAILY

WEEKLY OR

BEFORE

EXTENDED

PERIOD OF

OPERATION

100

HRS

150

HRS

SEE

PAGE

HRS

Check track alignment

Check drive chain tension

Check and tighten any loose

suspension mounting bolts

Tighten ski saddle and spindle

bolts if loose

Check front and rear limiter

strap condition, tighten loose

bolts

Check hi-fax thickness, replace

when worn (see dealer)

Tighten rear idler wheel bolts if

loose

Check spark plug condition

Check for brake cable wear

and adjustment

Throttle cable pivot slug

Lubricate steering post support

bracket and pivot (aerosol)

Grease ski spindles

Lubricate ski bushings to

spindle area

Grease lower steering post

pivot

Grease rear suspension pivot

shafts

Lubricate throttle cable

Lubricate choke slide and cable

Inspect exhaust pipe for cracks

or damage

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

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.

50 Hour Initial Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

100 Hour Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

150 Hour Maintenance Inspection

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

Type of Service

Additional Services Performed

Authorized Polaris Servicing Dealer

Servicing Technician

Date

Mileage

Type of Service

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Spark Plugs

A new engine can cause temporary spark plug fouling even though the

heat range is proper, due to the preservative which has been added

during assembly of the engine to combat rust and corrosion. Avoid

prolonged idle speeds, as plug fouling and carbonization will result.

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

S Use BR6ES spark plugs.

S Proper electrode gap is .028″ (.70 mm).

S Spark plug torque is 12-14 ft. lbs. (16-19 Nm).

S Always carry spare spark plugs

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed

up and the vehicle has been driven. Immediately check the spark plug

for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear

protective gloves when removing a spark plug for inspection.

1. Normal

The normal insulator tip is gray, tan or light brown. There 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

incorrect carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended oil, improper use of the choke, or incorrect

carburetion adjustments.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Spark Plugs

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 12-14

ft. lbs. (16-19 Nm).

Fuel Valve/Fuel Lines

The fuel valve and the fuel lines should be

inspected regularly. Special attention

should be given to the system’s fuel line

condition after periods of storage. Normal

deterioration from weather and fuel

compounds can occur.

Exhaust System

At approximately 50 hours, check the

exhaust system for wear or damage. To

inspect, allow the engine and exhaust

system to 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.

CAUTION

Serious burns may occur if this inspection is performed without

allowing adequate time for the exhaust system to cool. Exhaust

system temperatures can exceed 900° F (500° C). Never

perform this procedure with the engine running or shortly after it’s

been running.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Carburetor

Proper carburetor adjustment is critical, since a mixture too lean (too

much air, too little fuel) will result in overheating of the combustion

chamber causing pre-ignition of the fuel. This results in piston

burning, bearing failure, or complete engine failure. A lean mixture

can be the result of fuel line restrictions, foreign matter in the

carburetor, etc. A mixture too rich (too much fuel, too little air) is also

unfavorable because it can foul plugs and cause generally poor engine

performance.

All carburetors have been pre-set at the factory for adequate fuel

supply. Higher altitude operation may require different adjustment and

settings. The number stamped in the end of the main jet indicates the

jet size that was installed at the time of manufacture. For questions

about optional jetting for conditions in your area, see your Polaris

dealer.

1. Engine

2. Carburetor

Correct setup provides engine RPM

within its given power band at full

throttle settings and also provides

maximum efficiency and operation

at all other throttle openings. See

your dealer for carburetor

adjustments, which may include the following:

S Carburetor component changes for specific altitude and ambient

temperatures;

S Choke adjustment;

S Air screw settings, if applicable;

S Idle RPM adjustments;

S Throttle safety switch checks and servicing;

S Throttle block to throttle flipper clearance adjustment

CAUTION

Improper carburetor adjustments can result in safety hazards as

well as serious engine damage. We recommend that all

carburetor adjustments be performed by your Polaris dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Throttle Cable Lubrication

With the engine off, lubricate the throttle

cable occasionally. Turn the handlebars

to the left and lubricate liberally with

Polaris All Season Grease.

Choke/Cable Lubrication

Lubricate the choke slide and cables

occasionally as shown. Operate the choke

intermittently before turning the machine

off. This draws moisture out of the choke

plunger area and reduces the possibility of

the choke becoming frozen.

Throttle Cable Pivot Slug

Lubricate the throttle cable pivot

slug (A) every 50 hours or twice

a year using an aerosol lubricant.

Brake Lever Travel

Measure the clearance between the lever

and brake block. Inspection should be

made with the lever firmly depressed.

Distance B should be no more than 3/4″

(1.9 cm)

Excessive travel indicates a need for brake

cable adjustment.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Brake Adjustment

If excessive brake lever to brake block clearance is evident, the brake

cable should be adjusted. If proper adjustment cannot be achieved by

using the following methods, check the brake band for excessive wear.

Your snowmobile dealer can install a new brake band when necessary.

WARNING

Improper brake adjustment can result in brake failure, which

could result in severe injury or death. Perform the adjustment

procedures exactly as outlined or see your Polaris dealer for

service.

1. Slide the two rubber protector covers (A) back to expose the cable

adjuster.

2. Using an 8mm wrench to hold the barrel nut (B), loosen the jam

nut (C) with a 10mm wrench.

3. With your left hand, grasp the cables (D) as close to the adjuster as

possible. Use your right hand to rotate the barrel nut until you have

reached the proper brake lever adjustment.

4. Check the actuator linkage to

ensure there is adequate freedom

of movement for positive brake

operation and that all floating parts

move freely and that all parts are

mounted securely. Tighten

hardware as required.

1/4-3/8″ (6-10 mm)

5. Tighten the adjuster jam nut and

slide the rubber protectors back

onto the adjuster.

6. The brake band is adjusted correctly when

there’s 1/4” - 3/8” (6-10mm) brake lever

freeplay and clearance between the brake

lever and block with the lever fully

depressed is no more than 3/4” (1.9cm).

Torque the band bolt nut (E) to 6 ft. lbs.

(8 Nm).

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Chain Tensioner

Inspect the chain. The chain should have 1″ of deflection as shown. If

not, loosen the nut on the chain tensioner (A) and raise until 1″ (B) of

deflection is attained. Tighten nut to 15-18 ft. lbs. (20-24 Nm).

When the chain comes within 1/8″ (C) of the muffler mount bracket

(D) on the chassis, the chain has stretched and must be replaced.

Inspect the sprockets as they also become worn and often need

replacement when the chain is replaced.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Lubrication

NOTE: Driveline noise is normal and inherent in a chain drive

system such as this machine uses.

To ensure long life of the snowmobile’s driveline, lubricate as follows:

S Lubricate Point A every 15 hours of operation with a small amount

of Polaris Premium All Season Grease.

S Lubricate Point B every 10 hours of operation with aerosol chain

lube or SAE 30 oil.

1. Engine

2. Torque Converter

(Centrifugal Clutch)

3. Chain

4. Drive Shaft

5. Track

6. Carburetor

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Oil Level

Maintain the oil level between the

safe marks (A) on the dipstick.

Oil Change

Change the oil after the initial 20

hours of operation and again after each 50 hours.

Washing Your Snowmobile

Keeping your snowmobile clean will not only improve its appearance

but it can also extend the life of various components. With a few

precautions, your sled can be cleaned much like an automobile.

The best and safest way to clean your sled is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots.

NOTE: If warning labels are damaged, contact your a Polaris dealer

for free replacement.

If a high pressure type car wash system is used, extreme care must be

taken to avoid water damage to the hood, console, nosepan, decals, and

warning labels. Many expensive repair bills can result from using high

pressure detergent systems.

NOTE: If a high pressure car wash is used, grease all zerk fittings

immediately after washing. Also run the vehicle to evaporate

any water that might have entered the engine or exhaust

system.

Waxing Your Snowmobile

Your snowmobile can be waxed with any high quality brand of

automotive paste wax. Avoid the use of harsh cleaners since they can

scratch the body finish.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Controls and Linkage

All bushings, spindle shafts, and tie rod ends should be coated with a

light coat of oil or grease. Throttle and brake controls and cables

should be lubricated with Polaris Premium All Season Grease. Force a

small amount of lubricant down the cable.

Bearings

To prevent corrosion which will destroy the bearings, always grease

drive shaft clutch side bearings with a high quality bearing grease.

Electrical Connections

Separate electrical connector blocks and clean corrosive build up from

connectors. Lubricate or pack connector blocks with Nyogelt grease

and re-connect. Replace worn or frayed electrical wire and connectors.

Be sure wiring harness is properly secured away from sharp edges,

steering linkage, moving parts, and hot exhaust.

Front Suspension

To minimize fatigue on the front shocks and springs during extended

storage, it is recommended that the front end of the machine be safely

blocked off the ground to remove tension from the shocks and springs.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Engine

Proper off-season preparation of the engine and fuel system is vital to

the prevention of rust and corrosion formation on precision engine

parts during storage.

Without proper storage, jet restriction can cause lean conditions and

very poor slow speed driving quality.

When preparing your snowmobile for off-season storage, we

recommend that you add fuel conditioner/stabilizer or Premium Carbon

Clean (PN2871326) to the fuel tank. Follow the instructions on the

can. Run the engine for five minutes to get additives through the entire

fuel system. Then top off the tank with fresh fuel.

NOTE: This procedure is performed best when the front of the

machine is elevated and the engine is tilted rearward.

Storage

Off season or extended storage of your snowmobile requires you to

take preventative measures to aid against deterioration and to prolong

the useful life of many components.

Your snowmobile should be stored in a dry garage or shed, out of

direct sunlight, and covered with a fabric snowmobile cover. Plastic

tarp can cause condensation to form and may damage some

snowmobile components.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Carburetor Protection During Off-Season Storage

When preparing your snowmobile for off-season storage we

recommend that you add a fuel conditioner/stabilizer or Premium

Carbon Clean (2871326) to the fuel tank. Follow the instructions on

the can. Run the engine for five minutes to get additives through the

entire fuel system. Then top off with fresh fuel and turn the fuel valve

to OFF.

If stabilizer is not used, make sure the fuel valve is OFF and drain the

carburetor. Catch fuel in a container or shop cloth.

Remove the spark plug and pour approximately 5cc of engine oil into

cylinder. Slowly pull the recoil starter so the engine turns over two or

three times. Reinstall plug securely. Position piston at bottom dead

center (BDC). Observe all fire safety rules when draining carburetor.

See gasoline warnings on page 46.

Slowly pull the recoil starter handle until resistance is felt. Leave it in

that position. Clean the engine thoroughly with an oiled cloth.

If stabilizer is not used, turn the fuel valve to OFF. Remove the

strainer cup, place the strainer over a container, and open the strainer

cock to discharge fuel from the fuel tank. Remove the carburetor float

chamber bolt from the bottom and discharge fuel from the carburetor.

Replace bolt.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Transporting the Snowmobile

Whenever the snowmobile is transported the following measures

should be taken:

1. Turn the fuel valve off.

2. Be sure the fuel cap is installed correctly.

3. Always tie the snowmobile to the transporting unit securely using

suitable straps.

NOTE: Transportation to and from a Polaris dealer is the

responsibility of the snowmobile owner. Any expenses

involved will not be reimbursed.

Fall Tune-Up

To obtain maximum performance and use from your snowmobile, we

encourage you to arrange for a fall service tune-up with your Polaris

dealer. He has an experienced and trained service technician who is

interested in keeping your machine in peak operating condition.

Towing

Do not use this snowmobile to tow.

If a situation arises requiring the snowmobile to be towed by another

snowmobile, attach the tow rope to the spindles, not to the ski toe

loops.

For Your Protection

For your added protection it is a good idea to carry the following items

in your snowmobile when traveling farther than a five-minute walk

from home.

S Extra Spark Plugs

S First Aid Kit

S Winter Survival Kit

S Extra Gloves

S Owner’s Manual

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

WARNING

Your snowmobile is propelled by a revolving track, which must be

partially exposed for proper operation. Serious injuries may be

caused by the operator’s hands, feet or clothing becoming

entangled in the track. Be alert. Always sit properly on the seat.

Track and Suspension

Under normal conditions

moderate track tension should

be maintained during summer

storage. The rear of the

machine should be supported

off the ground to allow free

hanging of the track.

Track Tension

Track adjustment is critical for

proper handling. Always

maintain correct tension and

alignment.

Tension adjustments should be

made only after the track is

warmed up and limber.

1. Turn the machine off.

2. Lift the rear of the machine

and safely support it off the

ground.

8″

3. Hang a 10 pound weight (A)

8 inches from the center of

the rear idler wheel. The deflection at this point with this amount of

weight should measure 3/4″ between the bottom of hi-fax (B) and

the inside of the track.

NOTE: Measure at the point where the weight is hanging.

4. Check for specified slack between the wear surface of the track clip

and the plastic hi-fax (C).

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Track Adjustment

If the track needs adjustment:

1. Loosen rear idler shaft bolt (D).

2. Tighten or loosen the track adjusting screws (E) as necessary to

provide equal adjustment on both sides of the track.

3. Repeat measurement on the other side of the track.

NOTE: Check more frequently when the machine is new.

4. Start machine and slowly rotate the track at least five revolutions,

let the track stop rotating by itself (do not apply brakes).

5. Check track alignment (side to side) by comparing the distance

from the drive lug to the Hi-fax on both sides. Readjust until

centered.

6. Tighten idler shaft bolt.

7. Readjust the toe block to proper spacing and tighten.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Track Alignment

A periodic check should be made to see that the track is centered and

running evenly on the slide rails. Misalignment will cause excessive

wear to the track and slide rail.

WARNING

When performing the following checks and adjustments, stay

clear of all moving parts to avoid serious personal injury.

Before checking track tension, make sure the track contains no

objects that could be thrown out while the track is rotating. Keep

clear of track. This includes but is not limited to hands, tools, feet

and clothing. Make sure no one is standing close to the machine

while the track is rotating.

1. Safely support the rear of the machine

with the track off the ground using a

jackstand.

2. Start the engine and apply a small

amount of throttle until the track

turns slowly at least five complete

revolutions. Stop the engine.

3. Inspect track alignment by looking

through the track windows to make

sure the rails (A) are evenly spaced

on each side. If the track runs to the

left, loosen the left idler wheel

mounting bolt and tighten the left

track adjusting bolt. If the track runs

to the right, loosen the right idler

wheel mounting bolt and tighten the

right track adjusting bolt.

4. After adjustments are complete, be

sure to tighten locknuts and idler

shaft bolts. Torque to 35-40 ft. lbs.

(47-54 Nm).

Hi-fax

5. Repeat step 2 to verify proper alignment.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Track Warm Up

When storing your snowmobile

outside overnight, it is

recommended that the track be

warmed up prior to driving the

snowmobile. This reduces drive

clutch wear. To warm up the track,

safely support the rear of the

snowmobile off the ground, start

the engine and abruptly engage the

clutch. Allow the track to turn for a

short time. Release the throttle,

apply the brakes and shut the

engine off prior to lowering it to the

ground.

WARNING

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Track Inspection

WARNING

Inspecting the track while the engine is running can result in

serious personal injury if the track should being to move. Never

inspect the track with the engine running

Using a hoist or jackstand,

safely lift and support the

rear of the snowmobile off

the ground. Rotate the track

by hand to check for any

possible damage.

To inspect track rods,

carefully examine the track

along the entire length of

each rod, bending the track

and inspecting for breakage.

The three most common

places where breakage

occurs are shown in the

illustration.

Lug

Track window

Check the track clips and tighten if loose. If any rod damage is found,

the track should be replaced.

WARNING

Serious personal injury or death may occur if the snowmobile is

operated with a damaged track. Broken track rods are a serious

hazard, since they can cause a rotating track to come off the

machine. Never operate the snowmobile or rotate under power a

track that’s torn or damaged.

NOTE: The 120 PRO X track has molded in track clips. It is

common for a thin layer of rubber to detach from clip area

and peel off during initial use.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Hi-Fax Replacement

The 120 PRO X uses XTRA

Lite style Hi-Fax. When any

area of the Hi-Fax is worn to

7/16″ (1.1 cm), it should be

replaced. This will save wear

on other vital components.

7/16″ (1.1 cm)

XTRA Lite

The slide rail is designed to

operate in conditions with

adequate snow cover to

provide sufficient lubrication. Excessive wear may be due to improper

alignment, improper track adjustment or machine operation on surfaces

without snow. Take the machine to your dealer for Hi-fax replacement.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Track Lubrication

Track failure, loss of vehicle control and braking ability can result from

extended use of this vehicle on surfaces providing marginal lubrication

between hi-fax and track guide clips. Examples of marginal lubrication

would include lakes without snow cover, icy trails and no-snow

conditions.

The slide rail is designed to operate in conditions with adequate snow

cover in order to provide sufficient lubrication. Excessive wear

indicates insufficient lubrication. New hi-fax can cause faster heat

build up in limited lubrication than used hi-fax, resulting in excessive

wear.

NOTE: Track damage or failure caused by operation on ice or poor

lubrication conditions may void the track warranty.

Steering System

WARNING

Improper alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Do not attempt to

change the ski alignment. Contact your Polaris dealer.

The steering systems on Polaris snowmobiles can be adjusted with ski

toe alignment. Improper toe alignment can cause erratic steering.

Consult your dealer if a need for adjustment should become necessary.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Steering Inspection and Adjustment

The steering assembly of the

machine should be checked

periodically for loose nuts and

bolts. See A,B,C,D,E, F, and

G in illustration at right.

With handlebars in straight

ahead position and measuring

from the straight edge of the

skis, the measurement

between the skis at point H

should be 1/8 inches greater

than point I, as shown on the

following page.

NOTE: This measurement

should be taken with

the vehicle weight

compressing the

suspension. If the

skis are misaligned,

we recommend that

your dealer make the

necessary

adjustments.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Handlebar Adjustment

6. Slide the handlebar pad

upward to access the adjuster

bolts. If additional room is

required, unzip one of the

handlebar pad zippers and roll

the pad to the side.

7. To adjust, remove the upper

flange nut and carriage bolt.

8. Loosen the lower flange nut

only enough so the bracket can

move freely.

9. Position the handlebar to the desired height and re-install the upper

carriage bolt and flange nut.

10. Torque the flange nuts to 15-17 ft. lbs. (20-23 Nm).

11. Reinstall the handlebar pad.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Ski Skags

The skag (A) is a replaceable bar

attached to the underside of

the ski. The purpose of the

skag is to assist in turning

the snowmobile and to

prevent the wearing away of the

ski caused by contact with roads

and other bare terrain. We

recommend that skags be checked

once a week to maintain positive

steering characteristics. Skags must be replaced when worn to half

their original diameter.

NOTE: See dealer track studding and skag chart for recommended

skags.

WARNING

Worn skis and/or skags will adversely affect handling and can

cause loss of vehicle control, which can lead to serious injury or

death. Replace worn skis and/or skags when inspection reveals

wear.

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 downward.

3. Remove the forward portion of the skag.

Reverse this procedure for new skag installation.

NOTE: If the rear idler wheel

assembly (1) washers

are removed, be sure

they are reinstalled with

the domed side of the

washer facing out (2) as

shown.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Suspension Lubrication

To maintain rider comfort and to retard wear of the pivot shafts, the

suspension pivot shafts should be lubricated with Polaris Premium All

Season Grease several times during the season and again before

summer storage each year. The riding characteristics of the

snowmobile will be affected by lack of lubrication of these shafts.

NOTE: A grease gun kit complete with grease and adaptors is

available to lubricate all fittings on Polaris snowmobiles. See

page 82.

IMPORTANT: Make it a weekly practice to check for loose bolts and

nuts on the suspension system. If any loose bolts are found on the rail

be sure to clean the threads and apply Loctite 262 before tightening.

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Maintenance

Suspension Components

Suspension Lubrication points are indicated by a L.

1. Front Limiter Strap

2. Torsion Spring Sleeves

3. Torsion Spring

4. Carrier Wheel

8. Rail Bumper

9. Torque Arm

10. Rail

11. Hi-fax

5. Rear Limiter Strap

6. Spacer

12. Toe Guard

13. Idler Wheel

7. Adjuster Bolts

Download from Www.Somanuals.com. All Manuals Search And Download.

ADULT SECTION

Accessories

Maintenance Items and Accessories

The tools and maintenance items mentioned in this book, as well as a

long line of other Polaris accessories, are available at your Polaris

dealer.

Paint Codes

Color Description

Indy Red

Polaris “P” No.

P293

Raw Material No.

8520297

Indy Black

P067

8520246

Paints can be ordered direct from Midwest Industrial Coatings (612)

942-1836. Mix as directed.

Troubleshooting

Contact your Polaris dealer for service if you’re unable to identify

solutions using the following chart.

Engine Turns Over, Fails to Start

Possible Cause

Solution

Tether switch not engaged

Engine stop switch not on

Throttle safety switch malfunction

Out of fuel

Install tether switch/strap

Pull stop switch up to RUN position

See your Polaris dealer

Refuel

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Overuse of choke

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Mechanical failure

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

Jetting Chart

Ambient

Temperature

Below

-30_F

(-34_C)

-30_ to

-10_F

(-34_ to

-23_C)

-10_ to

+10_F

-23_ to

-12_C

+10_ to

+30_F

-12_ to

-1_C

+30_ to

+50_ F

-1_ to

Above

+50_F

Above

+10_C

Altitude

Meters

(Feet)

0-600

72.5

(0-2000)

600-1200

(2000--4000)

1200--1800

(4000-6000)

72.5

67.5

1800-2400

(6000-8000)

67.5

2400-3000

(8000-10000)

67.5

62.5

3000-3600

(10000-12000)

62.5

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

Capacities and Dimensions

Body Style

Mini Indy

Riders/Weight

Engine Oil

1/150 lbs. (68 kg) maximum

.6 qts. (.57 l)

Dry Weight (est.)

Fuel Tank

147.5 lbs. (67 kg)

.5 gal. (1.9 l)

Height

Length

Ski Center Distance

Width

Brake Type

Clutch Type

Track Length

Track Width

Drive Chain Length

31 in. (78.7 cm)

75 in. (190.5 cm)

30 in. (76.2 cm)

34 in. (86.4 cm)

Mechanical

Centrifugal

69 in. (175.3 cm)

10 in. (25.4 cm)

#40

Suspension

Front Type

IFS

IFS Shock Type

Rear Type

Mini

Mini Indy

Engine and Cooling

Engine Model Number

Alternator Output

Bore x Stroke

Displacement

Carburetor Model

Main Jet

EH122PM013

50 watt @ 3600 rpm

60 x 43 mm

121 cc

Mikuni BV18

72.5

Pilot Jet

Cutaway

170 Throttle Valve

Fuel Screw

1.5 Turns

Pilot Air Jet

1.3

Idle RPM

1600 +/- 200

Cooling

Air

Cylinders

Ignition Timing

Ignition Type

Oil Injection

Spark Plug

23_ BTDC @ 3600 rpm

Flywheel Magneto (solid state)

0W-40 Synthetic

NGK BR6ES

Spark Plug Gap

Minimum Fuel Requirement

.028 in. (.70 mm)

87 Octane Non-Oxygenated or 89 Octane Oxygenated

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2871281

Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.)

Gearcase / Transmission Lubricants

Premium Synthetic Gearcase Lubricant (qt.)

Premium Front Gearcase Lube (8 oz.)

Premium Drive Hub Fluid (8 oz.)

2873602

2871653

2871654

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season (3 oz.)

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease (2 oz.)

2871312

2871322

2871423

2871460

2871515

2871551

2871329

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Dielectric Grease (Nyogelt)

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Fogging Oil (12 oz. Aerosol)

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

2870791

2871326

2870652

2870990

2872893

DOT3 Brake Fluid (12 oz.)

Engine Degreaser (12 oz.)

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Service And Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the Polaris warranty

information contained in this manual. Contact your Polaris dealer for

replacement parts, service or warranty. Your dealer receives frequent

updates on changes, modifications and tips on snowmobile

maintenance, which may supersede 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 6. Length of time and conditions of operation

3. Dealer name

7. Previous correspondence

4. Date of purchase

Use the page provided near the front of your Owner’s Manual to record

the identification numbers of your snowmobile and its engine.

Polaris Customer Service

United States: 1-763-417-8650

Canada: 1-204-925-7100

Polaris Anti-Theft System

The Polaris anti-theft system (PATS) monitoring program is designed

to aid owners of registered snowmobiles in recovery of stolen

machines.

Administration

1. Polaris snowmobile owner reports theft.

A. In addition to notifying the proper law enforcement offi-

cials, the owner must call Polaris Customer Service.

B. Owners must provide their name, address, telephone num-

ber and the model and serial number of stolen machines.

2. Polaris warranty will provide all dealerships with a monthly

updated list of all stolen units to further monitor thefts.

3. Polaris warranty will aid in notifying the proper owner when a unit

is recovered.

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Limited Warranty

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-

ITED WARRANTY on all components of the Polaris snowmobile against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts that are covered by this warranty. The warranty begins on

the date of purchase. This warranty is transferrable to another consumer, during the war-

ranty period, through a Polaris dealer.

Registration

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your snowmobile is very important in ensuring

trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer

set-up will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

This warranty excludes any failures not caused by a defect in material or workmanship.

The warranty does not cover accidental damage, normal wear and tear, abuse or improper

handling. The warranty also does not cover any snowmobile that has been structurally

altered, neglected, improperly maintained, used for racing or used for purposes other

than for which it was manufactured. The warranty does not cover any damages that oc-

cur during trailer transit or as a result of unauthorized service or parts. In addition, this

warranty does not cover physical damage to paint or finish, stress cracks, tearing or punc-

turing of upholstery material, corrosion or defects in parts, components or the snowmo-

bile due to fire, explosions or any other cause beyond Polaris’ control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the snowmobile.

The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,

repair or replacement of any defective materials, or components or products. THE REM-

EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-

ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL

OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF

EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEG-

LIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-

sion or limitation of incidental or consequential damages or implied warranties, so the

above limitations or exclusions may not apply to you if inconsistent with controlling

state law.

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you if

inconsistent with controlling state law.

How to Obtain Warranty Service

If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-

rized to repair Polaris snowmobiles. When requesting warranty service you must present

your copy of the Warranty Registration form to the dealer. (The cost of transportation to

and from the 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 additional assistance is needed.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms

will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We

recommend the use of Polaris engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Conditions and Exclusions

In order to qualify for warranty, the product must have been properly set up and tested by

a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre--

Delivery Inspection, perform all applicable service bulletins and have the consumer sign

the PDI form prior to delivery may void the warranty. Failure to provide proof of re-

quired periodic maintenance upon request may result in denial of warranty coverage. Use

of the recommended Polaris products for lubrication and maintenance as directed by the

Owner’s manual is highly recommended. Should a failure occur during the warranty

period resulting from the use of non-recommended products, warranty coverage may be

denied.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental

conditions and/or contamination. The following items are excluded from warranty con-

sideration if the failure was due to wear or not the direct result of a defect:

Skis

Tracks

Ski wear rods

Slide rails

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Light bulbs/Sealed beam lamps

Idler wheels

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered “consumable,” meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

Spark Plugs

Filters

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Fuel

Sealants

Hotel fees

Towing charges

Mileage

Meals

Shipping/ handling fees

Product pick-up/delivery

Rentals/Loss of product use Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper en-

gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or

contamination; operator error or abuse; improper component alignment, tension, adjust-

ment or altitude compensation; failure due to snow, water, dirt or other foreign substance

ingestion/contamination; improper maintenance; modified components; use of aftermar-

ket components resulting in failure; unauthorized repairs; repairs made after the warranty

period expires or by an unauthorized repair center; use of the product in competition or

for commercial purposes. Warranty will not apply to any product which has been dam-

aged by abuse, accident, fire or any other casualty not determined a defect of materials or

workmanship.

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Polaris Second Year Engine Service Contract

Second Year Engine Service Contract is standard on all eligible new and unused

snowmobiles that were Snow Checked through an authorized Polaris dealer during the

March/April Snow Check promotion. The free Second Year Engine Service Contract is

honored by all authorized Polaris snowmobile dealers in North America and is

transferable 120 days after the original purchase date, free of charge, through any Polaris

snowmobile dealer. Coverage on Snow Check units is automatic. Although you do not

receive a warranty card, your dealership should have printed a copy of the warranty

registration form. This form is your proof of warranty.

Consumer Exclusions

Each repair visit after the first twelve months of standard warranty coverage is subject

to a $50 deductible.

The free Second Year Engine Service Contract applies to the first 5,000 miles or two

(2) calendar years from date of purchase, whichever comes first. Tampering with the

odometer shall void all warranties/service contracts. No extensions to coverage under

this engine service contract can be given. Used snowmobiles are not eligible under

this program.

Snowmobiles used for commercial purposes or for racing are excluded from cover-

age.

Coverage

Coverage for second year engine failures due to defects in materials and workmanship

will be determined by Polaris in its sole discretion. Coverage is automatic with no

additional paperwork required. The free Second Year Engine Service Contract is subject

to a $50 deductible per visit. Regular, documented service maintenance visits are

required to validate this warranty.

A partial list of items excluded from coverage includes:

Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.

Damage caused by the failure of other components of the snowmobile.

Failures caused by improper fuel or oil.

Piston seizures, unless caused by a defective engine component.

Failures caused due to improper adjustments.

S Failure due to unauthorized service.

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’s manual.

Failure due to use of unauthorized parts or modifications.

Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,

and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and

exhaust manifolds excluding paint coverage.

Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring

and other electrical components are excluded from coverage.

Cooling system coverage is limited to the water pump assembly and components, fan,

fan bearings, temperature sensor, gasket and seals.

Non wear related throttle body parts are covered. The fuel pump is covered.

Clutches and related clutch parts, including but not limited to, the drive belt, are ex-

cluded from coverage.

Electrical components are excluded from coverage.

Gearcases and transmissions are excluded from coverage.

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs 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 was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer’s authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance (see page 83).

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

A-B

Accessories . . . . . . . . . . . . . . . . . . . . . 79

Auto Chain Tensioner . . . . . . . . . . . . . 60

Brake Adjustment . . . . . . . . . . . . . . . . 59

Brake Lever Travel . . . . . . . . . . . . . . . 58

Break-In Period . . . . . . . . . . . . . . 44-45

Riding Rules . . . . . . . . . . . . . . . . . 21-24

Safety . . . . . . . . . . . . . . . . . . . . . . 10-13

Safety Decals . . . . . . . . . . . . . . . . . . . 12

Second Year Engine Service Contract 87

Service And Warranty Information . . 83

Signal words . . . . . . . . . . . . . . . . . . . . 13

Skag Replacement . . . . . . . . . . . . . . . 76

Ski Skags . . . . . . . . . . . . . . . . . . . . . . 76

Spark Plug Removal and Replacement 56

Spark Plugs . . . . . . . . . . . . . . . . . . 55-56

Specifications . . . . . . . . . . . . . . . . 80-81

Speed Regulation . . . . . . . . . . . . . . . . 47

Starting a Cold Engine . . . . . . . . . . . . 48

Starting a Warm Engine . . . . . . . . . . . 48

Starting the Engine . . . . . . . . . . . . . . . 48

Steering Inspection and Adjustment . 74

Steering System . . . . . . . . . . . . . . . . . 73

Storage . . . . . . . . . . . . . . . . . . . . . 63-64

Storage, Daily . . . . . . . . . . . . . . . . . . . 49

Maintenance . . . . . . . . . . . . . . . . . 51-78

Suspension Components . . . . . . . . . . 78

Suspension Lubrication . . . . . . . . . . . 77

Symbols . . . . . . . . . . . . . . . . . . . . . . . 13

Carburetor . . . . . . . . . . . . . . . . . . . . . 57

Carburetor Protection . . . . . . . . . . . . . 65

Checking Engine Oil . . . . . . . . . . . . . 45

Choke and Cable Lubrication . . . . . . . 58

Component Identification . . . . . . . 42-43

Electrical Connections . . . . . . . . . . . . 63

Emergency Stopping Procedure . . . . . 49

Engine Break-In . . . . . . . . . . . . . . . . . 44

Engine Stop Switch . . . . . . . . . . . . . . 28

Equipment Modifications . . . . . . . . . . 10

Exhaust System . . . . . . . . . . . . . . . . . 56

Fall Tune-Up . . . . . . . . . . . . . . . . . . . 66

Front Suspension . . . . . . . . . . . . . . . . 63

Fuel Safety . . . . . . . . . . . . . . . . . . . . . 46

H-M

Hi-Fax Inspection/Replacement . . . . . 72

Jetting Chart . . . . . . . . . . . . . . . . . . . . 80

Know Your Snowmobile . . . . . . . 14-18

Lubrication . . . . . . . . . . . . . . . . . . . . . 61

Maintenance Inspection . . . . . . . . . . . 54

Maintenance Program . . . . . . . . . 11, 51

Throttle Cable Lubrication . . . . . . . . . 58

Throttle Cable Pivot Slug . . . . . . . . . . 58

Throttle Safety Switch . . . . . . . . . . . . 27

Towing . . . . . . . . . . . . . . . . . . . . . . . . 66

Track Adjustment . . . . . . . . . . . . . . . . 68

Track Alignment . . . . . . . . . . . . . . . . . 69

Track and Suspension . . . . . . . . . . . . . 67

Track Inspection . . . . . . . . . . . . . . . . . 71

Track Lubrication . . . . . . . . . . . . . . . . 73

Track Tension . . . . . . . . . . . . . . . . . . . 67

Track Warm Up . . . . . . . . . . . . . . . . . 70

Transporting . . . . . . . . . . . . . . . . . . . . 66

Troubleshooting . . . . . . . . . . . . . . . . . 79

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Oil Change . . . . . . . . . . . . . . . . . . . . . 62

Oil Level . . . . . . . . . . . . . . . . . . . . . . . 62

Operation . . . . . . . . . . . . . . . . . . . 46-50

Operation Warnings . . . . . . . . . . . 29-41

Oxygenated Fuels . . . . . . . . . . . . . . . . 46

V-W

Vehicle Identification Numbers . . . . . . 9

WARRANTY . . . . . . . . . . . . . . . . 83-88

Washing . . . . . . . . . . . . . . . . . . . . . . . 62

Waxing . . . . . . . . . . . . . . . . . . . . . . . . 62

Welcome . . . . . . . . . . . . . . . . . . . . . . . . 4

Windchill/Temperature Charts . . . . . . 36

Paint Codes . . . . . . . . . . . . . . . . . . . . . 79

Polaris Products . . . . . . . . . . . . . . . . . 82

Pre-Ride Warm Up . . . . . . . . . . . . . . . 50

Pre-Ride Check . . . . . . . . . . . . . . 19-20

Preservation of the Environment . . . 7-8

Download from Www.Somanuals.com. All Manuals Search And Download.

Philips Air Cleaner AC4053 User Manual
Philips CD Player AZ8051 User Manual
Philips Home Theater System TSU3517 User Manual
Philips Light Therapy Device HB 576 77 User Manual
Philips Radio PET730 User Manual
Philips TV VCR Combo 36PT71B1 User Manual
Pico Communications Power Supply PICOPSU 90 User Manual
Planet Technology Digital Camera ICA 110 User Manual
Polaris Offroad Vehicle RZR 170 User Manual
Princeton Digital USA Music Pedal G92tt2q User Manual