Polaris 120 Pro X User Manual
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.
Copyright 2004 Polaris Sales Inc. All information contained within this publication is
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
2
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.....................................
3
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 P olaris 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!
4
INTRODUCTION
After reading this manual, store it in t he snowmobile for convenient
reference. It should remain with the snowmobile when sold.
n This manual contains the latest i nformation at the time of printing.
We reserve t he right to make product changes and improvements
without notice.
n The illustrations and photos used in this manual are general
representations. Your model m ay 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.
5
INTRODUCTION
Important Notes for Owners and Drivers
P ARENTS: 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.
6
INTRODUCTION
Preservation of the Environment
T each your child to drive their snowmobile with consideration for the
protection and preservation of the environment.
Noise Level
One of t he 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 m anufacture 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 t o 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.
7
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.
8
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
3
1
1. Tunnel VIN (lower right side of the tunnel)
________________________________________________________________
2. Engine Serial Number (right front side of engine crankcase)
________________________________________________________________
3. Key Number:
________________________________________________________________
9
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.
10
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 t o aid you in its safe operation.
11
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.
12
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.
13
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.
7
6
99
5
4
8
1
2
3
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 m ust 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.
14
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.
15
YOUTH SECTION
Know Your Snowmobile
Let’s learn more about the parts of your snowmobile before we talk
about riding.
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6
7
8
9
4
3
2
1
10
16
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.
17
YOUTH SECTION
Know Your Snowmobile
Let’s review the three ways to stop your snowmobile:
1. Push the stop switch down.
2. Pull off t he tether strap.
3. Turn the key off.
3
2
1
18
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 t hings 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 l ever 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. Y ou
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.
19
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.
20
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 snowmobile.
" 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.
21
YOUTH SECTION
Riding Rules
Helmet
Boots
" Always wear the right kind of clothing when you’re riding your
Face
Shield
Jacket
Gloves
Pants
snowmobile. You’ll need a good helmet with a face shield or
goggles. Wear a warm jacket and snowpants. Make sure your clothing 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 because you don’t know what they’re going to do.
22
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 permission to drive. Be careful of
the things around you.
" Always be a polite driver. (No
driving through the flower garden or over the little trees you
planted.)
" Always attach the tether strap to
your wrist and machine before
riding.
To Machine
To Wr i st
23
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
24
Stop
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.
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