Polaris 120 Dragon User Manual

Pantone 426C

Snowmobile Owner's Manual

for Maintenance and Safety

Pantone 426C

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922313 Rev 01 Printed in USA

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.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris enthusiasts. Visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more.

At Polaris we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

• Victory Motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

utility vehicles

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.

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 Master Service Dealer cian. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

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. If you have any questions about the snowmobile, contact a Polaris dealer for assistance. See page 82 for the part numbers of Polaris products.

(MSD) techni-

WELCOME

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!

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. 2010 120 Snowmobile Owner's Manual P/N 9922313

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

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

Youth Section . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

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

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

Adult Section . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

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

Component Identification. . . . . . . . . . . . . . . . . . . . . . . 40

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Emission Control Information . . . . . . . . . . . . . . . . . . . 48

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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

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

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

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

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 94

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold.

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.

NOTE: The illustrations and photos used in this manual are general represen-

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.

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. Never exceed the maximum rider weight capacity. See page 80.

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:

tations. Your model may differ.

IMPORTANT

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.

INTRODUCTION

Preservation of the Environment

Teach your child to drive their snowmobile with consideration for the protection and preservation of the environment.

Noise

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.

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. Protect and preserve your right to ride by joining your local trail riding clubs. Teach your child the following:

Respect your snowmobile; respect your environment; and you will earn the respect of everyone.

INTRODUCTION

Tunnel VIN

Vehicle Identification Numbers

Record your snowmobile's identification numbers in the spaces provided.

Vehicle Model Number:____________________________________________________

Tunnel VIN: _____________________________________________________________ (lower right side of the tunnel)

Engine Serial Number: ____________________________________________________ (right front side of engine crankcase)

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 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 injury or damage to the vehicle.

CAUTION

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

NOTE

A note will alert you to important information or instructions.

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 warning decals before operating a Polaris snowmobile. Adults must thoroughly explain this information, including all safe operating procedures, to all operators of the snowmobile. All operators must be at least six (6) years old and must understand the consequences and risks if they choose to ignore or neglect this information.

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 is 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.

SAFETY

Maintenance Program

This snowmobile is not a toy. The information in this manual is provided to aid you in its safe operation.

For the safety of the operator, always 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.

SAFETY

General

Warning

Decal

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. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

General Warning Decal

WARNING

• Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from

not heeding the warnings.

• This vehicle is intended for daylight use in restricted off-road areas clear of obstacles, primarily on snow and not on frozen bodies of water, by a child of not less than 6 years of age who is in the presence of, and in active supervision of an adult. Use of this vehicle on public trails, streets, roads, and highways can be hazardous and is prohibited by law in most cases.

• Do not start or operate this vehicle without guards and shields in position, or with hood not latched in place.

• This vehicle is intended for one operator only, no passenger. Passengers, cargo, or towed objects can cause loss of control.

• Verify proper operation of all controls before starting the engine.

• When operating this vehicle, the operator shall wear suitable protective clothing including an approved safety helmet and shield or goggles.

• Securely attach the safety lanyard to the child’s body before starting the engine.

• This vehicle can be operated between 0 and 8 mph (13 km/h). However, it is recommended that the adult supervising the child regulate the maximum speed to match the experience and ability of the child. Instructions for regulating maximum speed are provided in the Owner’s Manual.

• The Auxiliary Shut Off Switch is the primary means of stopping this vehicle in case of emergency and is located on the top of the throttle control assembly. Depress the switch to stop the engine. Routinely check this switch for proper function with the engine idling.

• If Owner’s Manual is missing, contact a Polaris Dealer for a replacement.

YOUTH SECTION

Gas Cap

Recoil Starter

Handle

Brake Lever

Throttle Lever

Engine Stop Switch

Choke

Knob

Hood

Hold-Down

Strap

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 snowmobile.

Engine Stop Switch

When the engine is running, push this button down to stop the engine. Pull the stop switch up before trying to start the engine again.

Throttle Lever

The throttle lever makes your snowmobile go forward when you press it with your thumb. Before you drive your snowmobile, always make sure the throttle lever does not stick. Read more about it on page 19.

Brake Lever

Squeeze the brake lever toward the handlebar to make your snowmobile slow down or stop.

Always take your thumb off the throttle lever when you squeeze the brake lever.

YOUTH SECTION

Attach to Switch

Attach to Loop or Wrist

Know Your Snowmobile

Gas Cap

An adult will take the gas cap off to put gas in your snowmobile. Never take the gas cap off. Always make sure it's tightly closed.

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

Recoil Starter Handle

Pull the recoil starter handle to start your snowmobile. An adult will help you start it the first time.

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 45.

Hood Hold-Down Strap

Two straps hold down the hood of your snowmobile. Always make sure both hood straps are securely latched before you start the engine.

Tether Strap/Switch

Always attach the tether strap to your body and to the switch on 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.

When you attach the strap to your body, you can clip it to a loop on your clothing, or you can wrap the strap around your right wrist and attach the clip to the strap.

Never ride without the tether strap attached to your body and to your snowmobile. Be careful not to let the cord get tangled around the handlebars or any part of your body.

YOUTH SECTION

Snow

Flap

Ski

Handlebar

Seat and

Storage

Hood

Headlight

Windshield

Tr ac k

Taillight

Know Your Snowmobile

Let's learn more about the parts of your snowmobile before we learn about riding.

YOUTH SECTION

Know Your Snowmobile

Hood

The hood covers the moving and hot parts of the engine. Always make sure both hood straps are securely latched before you start the engine.

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 meant to be strong enough to help you see in the dark. Drive your snowmobile only in the daylight.

Windshield

Always keep your windshield clean so you can see through it.

Handlebar

The handlebar is connected to the skis. When you turn the handlebar, the skis turn in the same direction.

Seat and Storage

When the engine is stopped, you can take the seat cushion off and put things under the seat in the special compartment.

Taillight

The taillight is always on when the engine is running. It will help others see you when you're riding.

Snow Flap

The snow flap keeps snow, ice or other things from flying out behind your snowmobile.

Track

When you squeeze the throttle lever, the track turns and makes the snowmobile move forward.

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.

Skis

The skis help you steer your snowmobile. When you turn the handlebar, the skis turn in the same direction.

YOUTH SECTION

STOP

Push the stop

switch down

Pull the strap off the tether switch

Know Your Snowmobile

Let's review the 2 ways to stop your snowmobile:

YOUTH SECTION

Pre-Ride Check

You're almost ready to have an adult start your snowmobile. But first you must do a PRE-RIDE CHECK to make sure the snowmobile is safe to ride. Every time you want to ride your snowmobile, always have an adult help you check these things before you start the engine.

n Throttle Lever

Squeeze the throttle lever toward the handlebar and then let it go. The lever should go right back to where it was before you squeezed it. If it goes 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 lever. You could get hurt if you ride with a sticky throttle.

n Brake Lever

Squeeze the brake lever toward the handlebar and then let it go. The lever should go right back to where it was before you squeezed it. If it goes back slowly or stays close to the handlebar, you have a sticky brake lever. This means that something is wrong or broken.

Don't start the snowmobile until an adult fixes the sticky lever. You could get hurt if you ride with sticky brakes.

n Seat Latches

Check the seat latches. Make sure they are latched tightly.

n Hood Hold-Down Straps

Check the hood hold-down straps. Always make sure both hood straps are securely latched before you start the engine.

n Track and Skis

Never check the track or skis when the engine is running. You could get hurt if the snowmobile moves unexpectedly. Never stand behind or in front of any snowmobile when the engine is running.

Make sure the engine is off, then stand behind the snowmobile and lift up the rear end. This will free the track if it is frozen to the ground.

Turn the handlebars all the way to the left and to the right. This will turn the skis to make sure they aren't frozen to the ground.

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

YOUTH SECTION

Pre-Ride Check

n Gas Level

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

Have an adult check the gas level to see if your snowmobile needs more gas. Children should never open the gas cap or add gas. Always have an adult do this. Before anyone adds gas to your snowmobile they must read the instructions and warnings on page 43 in this Owner's Manual.

n Oil Level

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. Always have an adult do this.

n 2 Ways to STOP

Always check to make sure that BOTH WAYS TO STOP are working the way they should. Do you remember what they are? Follow these steps:

1. Start the engine. Push the stop switch down. The engine should stop.

2. Start the engine. Pull the tether strap off the switch. The engine

should stop.

If the engine does not stop when you do these checks, do not ride the snowmobile until an adult fixes it.

YOUTH SECTION

Riding Rules

Now you're ready to learn about driving your Polaris snowmobile. This snowmobile is not a toy. 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 only one rider. 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 before you start the

engine. Make sure the area is safe all around your snowmobile.

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

you need help. Always drive where an adult can see you.

" 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 toward you.

" Stay away from fences. 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.

YOUTH SECTION

Goggles

Helmet

Jacket

Snowpants

Boots

Gloves

Riding Rules

" Always wear the right kind of clothing when you ride your snowmo-

bile. Always wear a helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your clothing fits properly. Tight clothing could keep you from moving easily. Baggy clothing could hang down and get caught in the track or another moving part. Never wear a long scarf. Wear warm snowmobile boots and gloves, and make sure your boot laces are tied. If you have long hair, tie it up or put it inside your helmet or jacket.

" Learn if there are lakes, rivers, ponds and ditches in your driving area.

Stay away from them. Never ride on frozen water. Your snowmobile could fall through the ice into the water and you could drown or freeze to death.

" Always be alert and pay attention to where you're driving. Always

watch out for objects or people in your driving area and stay a safe distance away from them.

YOUTH SECTION

Sit down

Keep both hands on

the handlebars

Keep both feet on

the running boards

Attach tether strap to the

switch on your snowmobile

Attach tether strap to loop or right wrist

Riding Rules

" Always sit down when you drive. Keep both hands on the handlebars.

Keep both feet on the running boards.

" Never follow another snowmobile too closely. Always allow lots of

space to stop your snowmobile.

" Ride your snowmobile only where you know it's safe to drive and

where you have permission to drive.

" Always be a polite driver. Don’t drive through the flower garden or

over small trees.

" Always attach the tether strap to your body and to the switch on your

snowmobile every time you drive.

YOUTH SECTION

Left Turn Right Turn Stop

Riding Rules

Learn how to use your hands and arms as signals. Use these signals to let others know when you are getting ready to turn or stop your snowmobile. Read and understand your Owner's Manual.

ADULT SECTION

Pre-Ride Check

As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehicle without adult supervision.

WARNING

Serious injury or death could result if the vehicle is not inspected properly before operation. Teach all operators to perform the following Pre-Ride Check before each use of the snowmobile.

n Check the throttle for proper operation. See page 26. n Check the brake for proper operation. See page 26. n Check the steering system for proper operation. See page 26. n Check the throttle safety switch for proper operation. See page 27. n Start the engine and push the stop switch down to test for proper

operation.The engine should stop immediately.

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

operation. The engine should stop immediately.

n Inspect the track. See page 28. n Make sure the seat is securely attached. n Always make sure both hood straps are securely latched before you

start the engine.

n Make sure the track and skis are not frozen to the ground. n Check the gas and oil levels for the rider. Add more if necessary. n Make sure the headlight and taillight are working properly.

These checks should become automatic for the child before each ride. As the adult teacher, you must instill in all riders the importance of performing this Pre-Ride Check before they operate the snowmobile.

ADULT SECTION

Pre-Ride Check

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 all operators 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 the throttle for proper operation

When checking the throttle, make sure the throttle 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 start the engine. Have the throttle serviced before operating the snowmobile.

n Check the brake for proper operation

Squeeze the brake lever toward the handlebar. When the lever is released, it should return to it’s original position smoothly. If the lever hesitates or seems sticky, do not start the engine. Have the brakes serviced before operating the snowmobile. See page 31 for brake lever travel specifications.

n Check for proper operation of the steering system

Check for proper operation of the steering system. Manually turn the skis completely to the right and to the left. If difficulty is encountered, check for ice and snow buildup that may be obstructing the steering linkage. Make sure all greaseable components are properly lubricated.

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