Polaris 120 XC Rider's Safety Manual And Owner's Operation And Maintenance Manual

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Page 1

Rider’s Safety Manual

and Owner’s Operation

and Maintenance Manual

2001

120 XC

Snowmobile

Part No. 9916124

PRINTED IN THE U.S.A.

Page 2

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 cause cancer, birth defects or other reproductive harm.

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.

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FOREWORD TO PARENTS

Thank you for purchasing a Polaris snowmobile. We believe it is the standard of excellence for all snowmobiles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris snowmobile the finest machine we have ever produced.

All machines, no matter how well engineered, require a certain amount of maintenance. Before the snowmobile is used, take a few minutes to read through this manual and familiarize yourself and your child with maintenance and operation procedures. It may be the most important time spent in knowing how to keep your machine running perfectly every day.

YourPolarisdealer will register your new snowmobile with Polaris Industries Inc. electronically. No confirmations or validations of warranties will be issued by Polaris.

This manual also contains important pages devoted to safety and environment. Since the operator will be a newcomer to this exciting winter sport, make certain he understands his information.

Operators must be aware of risks involved when traveling on icy or hard packed surfaces, at night or in unfamiliar terrain. Young novice riders who do not have the ability or experience to physically control the machine in difficult situations should be instructed to reduce their speed until they become skilled riders.

Keep the running boards free of ice and snow and in good condition. The safe and courteous operation of the snowmobile - with respect for the environment and private property - will ensure the the continued enjoyment of the sport of s nowmobiling.

If you should experience any problems with your snowmobile, please return it to your dealer. Dealers have received training which will enable them to perform any required repairs. Should any additional assistance be required, your dealer will work with our technical services department to resolve any problems.

All of us at Polaris would like to extend our best wishes for plenty of fun-filled,safe snowmobiling pleasure with this new Polaris.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

Comments and suggestions regarding this manual may be forwarded in writing to:

Polaris Industries Inc.

Consumer Service

2100 Highway 55

Medina, MN 55340

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The Polaris Preferred

Registered Owners

(PRO) Family

Your Owners Program

As the owner of a new Polaris vehicle, you are entitled to a FREE two-year membership in the PolarisPRO Family----the Preferred RegisteredOwnersFamily. This is an owners’ program for Polaris consumers like you, people who have chosen the finest recreational vehicle available, and who share an interest in Polaris and its products.

Once your new vehicle’s warranty is registered, you will receive a PRO Family membership packet. Your packet will be mailed to the address on your warranty registration. Membership packets are mailed quarterly.

Your packet will include:

A letter of welcome to the PRO Family.

A PRO Family card with your name and membership number.

A colorful sticker of the PRO logo.

A PRO merchandise brochure and order form.

As a PRO Family member, you’re entitled to opportunities such as:

A free subscription to PRO Spirit, the official magazine of the PRO Family.

The chance to buy insurance for your Polaris vehicle. The toll-free insurance

telephone number is: 1-800-473-0111

The chance to arrange travel through the Polaris Travel Center. The toll-free

travel telephone number is: 1-800-267-1915

The chance to apply to serve on PRO Consumer Councils that provide input

into the Polaris vehicles of the future.

The chance to serve as a PRO Field Evaluator and provide feedback on your

new vehicle.

The chance to take part in national PRO snowmobile, ATV or personal water-

craft rides.

The chance to purchase exclusive PRO Family merchandise.

And more!

To order PRO merchandise, complete the order form you receive with your membership packet. Take the form to your Polaris dealer and pay for the merchandise. The merchandise will be shipped directly to your home from the PRO merchandise fulfillment center.

Watch for your PRO membership packet and the next issue of PRO Spirit magazine. This quarterly magazine will keep you informed about Polaris news and events, and special PRO merchandise, travel, and ride opportunities.

Enjoy your new Polaris vehicle and welcome to the family----The Polaris PRO Family.

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TABLE OF CONTENTS

RIDER’S SECTION R-1 - R-11................................

Understanding Warnings R-1............................

Know Your Machine R-2 - R-6...........................

Pre Operation Check R-7 - R-8...........................

Riding Rules R-9 - R-13.................................

ADULT SECTION A-1 - A-63................................

Understanding Warnings A-1.............................

Safety Warning and Operation Decals A-2 - A-3.............

Pre Operation Check A-4................................

Operation Warnings A-5 - A-15..........................

Preservation of the Environment A-16.....................

Identification and Specifications A-17 - A-18...............

Engine Break-in A-19 - A-20..............................

Operation A-21 - A-29..................................

Maintenance A-30 - A-55................................

Troubleshooting A-56...................................

Clutching Chart A-57....................................

Specifications A-58......................................

Wiring Diagram A-59....................................

Service and Warranty A-60..............................

Warranty A-61 - A-63...................................

Parents should sit down with their child and read the Rider’s Section with them before letting them use this snowmobile. Parents should also read the Adult Section before allowing their child to ride this snowmobile.

IMPORTANT

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R--1

PARENTS: Review the information in this manual with any child who may be operating the snowmobile. It is up to you 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.

CHILDREN: Before you ride your new Polaris snowmobile, there are some important things you should know. How to keep safe is the most important thing. You must also learn some things that will keep you and those around you safe while you are riding.

Pay attention when you see these symbols and these words:

RIDER’S

SECTION

This is the safety alert symbol. When you see this symbol on your machine or in this manual it means PAY ATTENTION. If you don’t, you could get hurt very badly or even killed. Your safety is involved!

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R--2

KNOW YOUR MACHINE

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 r unning, you can push this button and the engine will stop. The stop switch must be in the “up” position to start the engine again.

2. Throttle Control - This 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 R--7.

3. Recoil Starter Handle - Pull this to start your snowmobile.

An adult will help you start it the first time.

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

snowmobile if the engine is cold.

5. Gas Cap - This is where the gas goes that will run your

snowmobile. Your snowmobile will not r u n without gas. Only adults should fill the gas tank.

Always have an adult put gas in your machine.

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R--3

KNOW YOUR MACHINE

6. Brake Lever - Squeeze this towards the handle to make your snowmobile slow down or stop.

7. Ignition Switch - The key must be turned “on” before

pulling on the recoil starter handle to star t your snowmobile. You can also use this key to turn off the engine.

8. Tether Strap/Switch - This must always be attached

snugly to your wrist and your machine when you are riding. If you fall off your snowmobile, the tethe r will pull off the switch and the engine will stop. Put one end of the tether strap around your wrist. The other end must be attached to the snowmobile. Always attach the tether strap before you ride.

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

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

Always take your thumb off the throttle control when you

pull the brake lever.

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

Always make sure that these straps are latched before you ride.

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R--4

KNOW YOUR MACHINE

Let’s learn more about your machine before we talk about riding.

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 are riding.

3. Windshield - Always keep your windshield clean to help you see where you are 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 are riding your snowmobile. Never remove the flag from your snowmobile.

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R--5

KNOW YOUR MACHINE

6. Seat / Storage - Yousit on the seat. When the engine isn’t running, you can take the 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 are riding.

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

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.

Never get close to a moving track.

Never wear clothing that could get caught in a moving track, like a long scarf or clothing that is too big.

Tie up long hair.

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R--6

KNOW YOUR MACHINE

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

1. Pushing down on the engine stop switch on the right handlebar control will shut off the engine.

2. Disconnecting the tether strap will shut off the engine.

3. Turning the key to off will shut off the engine.

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R--7

PRE OPERATION CHECK

You are almost ready to have an adult start your snowmobile. Before the snowmobile is started for the first time, you must do a PRE-OPERATION 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.

Make sure the throttle doesn’t stick. Check this by pushing the lever toward the handlebar and then letting go. The lever should come right back to where it was before you pushed it. If it comes back slowly or stays open, you have a sticky throttle. This means that something is wrong or broken.

Make sure the brakes don’t stick. Check the brake lever by squeezing the lever toward the handlebar and then letting it go. It should come right back to where it was before you squeezed it. If it goes back slowly or stays on, your brakes are sticking.

If you have used the storage area under the seat, make

sure the seat locking tabs are in place.



If you have a sticky throttle, do not start the engine. You could get hurt if you ride when you have a sticky throttle. Have an adult or your Polaris Dealer fix the throttle.



If you have sticky brakes, do not start the engine. You could get hurt if you ride when you have sticky brakes. Have an adult or your Polaris Dealer fix the sticky brakes.



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R--8

PRE OPERATION CHECK

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 too, have an adult help you.

Have an adult check the gas level to see if your snowmobile needs more. Children should never add their own gasoline. This should always be done by an adult. Before anyone adds gasoline to your snowmobile they must read the instructions and warnings on page A--23 in this Owner’s Manual.

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 you. Children should never check the oil on their own. An adult should be in charge of keeping the gas and oil levels to the full marks.

Make sure your hood is latched tight before starting your

machine.

This last check is done with the engine running. You must

check to make certain that ALL THREE WAYS TO STOP your snowmobile are working the way they should. Do you remember what they are? If you cannot list them, go back to page R--6 and review.



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.



Always have an adult put gas in your machine.



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R--9

RIDING RULES

Now you are ready to learn about riding a snowmobile. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won’t be safe when you ride. Remember that safety while you ride is the most important thing. Let’s learn how to ride!

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

passenger. A passenger will ma ke the snowm obile 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 are going to drive when

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

You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.

Helmet

Face Shield

Gloves

Boots

Jacket

Pants

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R--10

RIDING RULES

" Always wear the right kind of clothing when you are riding

your snowmobile. You will need a good helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your clothing fits properly. If it is too small, it could keep you from moving easily. If it is 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. Make sure your boot laces are tied. If you have long hair, be sure to tie it up.

" 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.

You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.

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R--11

RIDING RULES

" Always drive your snowmobile while sitting down. Keep

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

" When you are 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. M ake sure you know

where all the fences are before you ride. If you drive into one, you could get hurt.

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

there only so that others can see you driving during the day.

Both Hands on

Handlebars

Sit Down

Feet on Running Boards

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R--12

RIDING RULES

" Learn where there are lakes, rivers, ponds and ditches in

your driving 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 are driving.

Pay attention to other drivers and be even more careful around them because you don’t know what they’re going to do.

" Never follow another snowmobile too closely. Always allow

lots of time and space to stop your snowmobile.

" Only ride your snowmobile where you know it is safe to

drive. No driving over the flower garden or on the little trees you planted. Be careful of the things around you.

" Always attach the tether strap to your wrist and machine

before riding.

You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.

Respect your snowmobile; respect your environment;

and you will earn

the respect of everyone.

To Wrist

To Machine

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R--13

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

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A--1

UNDERSTANDING WARNINGS

SAFETY ALERT

The following precautionary signal words are used throughout this manual to con vey the following messages: It is very important this owner’s manual is read and thoroughly explained to each operator(s) of this machine.

The operator(s) should know and understand the risk if these important warnings and cautions are not heeded.

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved!

WARNING

Indicates a potential hazard which could result in serious injury or death.

CAUTION

Indicates a potential hazard which may result in personal injury or damage to the snowmobile.

NOTE

The word “NOTE:” in this manual will alert you to key information or instructions.

ADULT SECTION

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A--2

SAFETY WARNING AND OPERATION DECALS

As with all snowmobiles, caution must be observed to ensure operator safety. Particularcaution must be taken to make sure that the snowmobile is in excellentoperating condition at all times. It is strongly recommended that the operator as well as an adult check major and vital safety components each time before riding.

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 which increase speed or power. There is a significant possibility of loss of control at higher speeds.

Due to our concern for the safety of our customers and the general public, Polaris hereby requests that consumers do not install on a Polaris snowmobile any equipment which is intended to increase the speed or power of the machine, or make any other modifications to the machines for these purposes. Any modifications to the original equipment or the snowmobiles substantially increase the risk of bodily injury. Be aware that these modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on a snowmobile is terminated on the entire machine if any such equipment has been added to the machine or any modifications have been made to the machine which increase its speed or power.

We also advise you to strictly follow the recommended maintenance program outlined on pages A--30-A--55. This preventive maintenance program is designed to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at various mileage intervals.

Your snowmobile is not a toy. It is a well-engineered and well-constructed recreational vehicle. The following information is provided to aid you in its safe operation.

NOTE: Warningdecals have been placed on the vehicle for the operator’s protection. Make certain the operator understands the information on all the decals. In the event 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: Although your Polaris has been designed to provide operators with a safe, reliablesnowmobile, much of its safety depends on the operator and parents. Improperuse of this snowmobile or failuretomaintainit in good operating condition can result in injury. To reduce this possibility, read the following important safety information and make certain the operators and guests are familiar with all the warnings, cautions and safe operating procedures. They must also understand the consequences and risks if they choose to ignore or neglect this information.

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A--3

SAFETY WARNING AND OPERATION DECALS

D Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from not heeding the warnings.

D This vehicle is intended for daylight use in restrictedoff-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.

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

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

D Verify proper operation of all controls before starting the engine. D When operating this vehicle, the operator shall wear suitable protective

clothing including an approved safety helmet and visor or goggles. D Securely attach the safety lanyard to the child’s body before starting the

engine. D 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.

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

WARNING

The information contained in this decal is printed below.

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A--4

PRE OPERATION CHECK

WARNING

Teach the operators to perform the following Pre-Operation Check before starting the engine each time before they ride. If they do not check their machine properly before riding, they could be seriously injured or killed.

 Check the throttle for proper operation.

 Check the brake for proper operation.

 Make sure the seat is locked into place.

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

 An adult should check the gas and oil levels for the rider and

add more, if necessary.

 Make sure the hood is latched.

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

 Check the throttle safety switch for proper operation.

These checks should become automatic for your child before each ride. It is up to you, the adult, to instill in your child the importance of performing this Pre-Operation Check before they operate the snowmobile.

A more detailed description of these checks is found in the following “Operation Warnings” section and also in the Rider’s Section on pages R--7 and R--8.

 Make sure headlight and taillight are working properly.

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A--5

OPERATION WARNINGS

NOTE: It is up to you, the parent, to teach your child the proper and safe way to

ride a snowmobile. You must set boundaries and adhere to them, keeping your child’ssafety foremost in your mind. Never allow your child to operate this machine without adult supervision.

Before Starting The Engine

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 is also a good idea to read it periodically to reinforce the information. It is very important for to familiarize the operator and guests with the cautions and warnings pertaining to your machine as well as safe operating procedures. We have attempted to provide you with as much information as possible to alert you to the safety requirementsof snowmobiling.

Check Throttle and Brake for Proper Operation

When checking the throttle, make sure the control lever will compress 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.

The need for a properly functioning brake is vital. The brake must be checked for correct operation before starting the engine. See page A--8 for details.

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 (B). Apply a slight amount of throttle opening. A properly functioning switch must shut down the engine.



WARNING

The throttleand brake are the primary controlsof the snowmobile. If either should malfunction, a serious loss of control could result.



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A--6

OPERATION WARNINGS

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.

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 certain all greasable components are properly lubricated.

Track Inspection

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.

NOTE: Track damage or failure caused by operation under poor lubrication conditions will void the track warranty.

Single Rider Snowmobiles

This snowmobile is designed for a single operator.



WARNING

Always inspect for damage before using the snowmobile. 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.

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A--7

OPERATION WARNINGS

Do Not Operate Engine With Intake Silencer or Filter Removed

Stay Clear of Track

Do Not Operate Engine With Drive Chain Guard Removed

Do Not Touch the Engine After it Has Been Running



CAUTION

When operating engine with intake silencer or filter removed, damage to the engine may occur.



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.



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.



WARNING

The engine and exhaust become v ery hot when it is running. Touching the hot engine could cause a severe burn.

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A--8

OPERATION WARNINGS

Disabled Operators

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 pin only. Refer to the mechanical brake adjustment information on page A--39.

Check to See That 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 functions. Under no cir- cumstances should your snowmobile be operated with the hood open or removed.

Engine Stop Switch

Check engine stop switch for proper operation. Push down to stop engine. Pull up to release and start engine.

Tether Switch

Check tether switch for proper operation.

Remove Ignition Key

Don’t tempt someone to steal or ride your snowmobile without permission by leaving the key in the ignition.



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.



Lever Travel

Distance A not to exceed 3/4″ (1.9 cm)



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A--9

OPERATION WARNINGS

Lighting Check

Check headlight and taillight for normal operation.

Check Surroundings to Verify Clear Operating Area

It is important to make certain there is a clear area all around the snowmobile, including an area clear of bystanders. Remember that the possibility always exists of some sideways vehicle movement or of debris being thrown by the track. Teach the operator to check the operating area before riding.

Be Seated and in Position to Control the Vehicle

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 improperposition 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, feet on the running boards, and in a comfortable position for proper throttle, brake, and steering control.

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 clothingbecoming 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.



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.

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A--10

OPERATION WARNINGS

Stop Engine Before Attempting Adjustments

Always Wear Clothing Designed for Snowmobiling

Clothing designed for snowmobiling is warm, comfortable and safe.

Know the Limitations of the Machine and the Skills of the 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 tail- light are intended only to increase the visibility of the 120 XC SP during daylight operation.



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. Seriouspersonalinjuries can result. The proper method is to turn off the ignition, raise the hood, make the adjustment,secure s hields 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.



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.

Be aware of the weather forecast and especially the wind chill. A table is provided on page A--12 for your reference. Be prepared. Be warm and comfortable.



Page 29

A--11

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 y our 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 certain 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 is a good idea to predetermine some hand signals as a way to communicate with your child whilegivinginstruction. Itmay be difficultfor your child to hear your voice over the sound of the snowmobile and through a helmet.

Page 30

A--12

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)

Estimated

Actual Ther mometer Reading (°F)

ind

pee

MPH

50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

Equivalent Temperature (°F)

Calm 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60

5 48 37 27 16 6 -5 -15 -26 -36 -47 -- 5 7 -68

10 40 28 16 4 -9 -21 -33 -46 -58 -70 -83 -95

15 36 22 9 -5 -18 -36 -45 -58 -72 -85 -99 -112

20 32 18 4 -10 -25 -39 -53 -67 -82 -96 -110 -124

25 30 16 0 -15 -29 -44 -59 -74 -88 -104 -118 - 133

30 28 13 -2 -18 -33 -48 -63 -79 -94 -109 -125 -140

35 27 11 -4 -20 -35 -49 -67 -82 -98 -113 - 129 -145

40 26 10 -6 -21 -37 -53 -69 -85 -100 -116 -132 -148

Wind Speeds Greater Than

40 MPH Have

Little Danger

(For Properly

Clothed Pers on)

Increasing

Danger

Great

Danger

40MPHHave

Little Added

Effect

ClothedPerson

)

Danger From Freezing of Exposed Flesh

WIND CHILL CHART (°C)

Estimated

Actual Ther mometer Reading (°C)

ind

pee

KPH

5 0 -5 -10 -15 -20 -25 -30 -35 -40

Equivalent Temperature (°C)

0 5 0 -5 -10 -15 -20 -25 -30 -35 -40

10 1 -4 -11 -16 -22 -27 -33 -38 -45 -50

20 -4 -9 -17 -23 -29 -36 -42 -48 -54 -61

30 -7 -13 -21 -28 -35 -42 -48 -55 -63 -69

40 -9 -16 -24 -32 -39 -47 -53 -61 -69 -76

50 -11 -18 -26 -34 -41 -49 -57 -64 -73 -80

60 -12 -19 -27 -35 -43 -51 -59 -66 -75 -82

70 -13 -20 -28 -36 -44 -52 -60 -68 -76 -84

Wind Speeds Greater Than

70 KPH H ave

Little Danger

(For Properly

Clothed Pers on)

Increasing

Danger

Great

Danger

70KPHHave

Little Added

Effect

ClothedPerson

)

Danger From Freezing of Exposed Flesh

Page 31

A--13

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 throttlebut 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.

Do not operate for prolonged periods with marginal lubrication.

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

CAUTION

It is 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.

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.

Page 32

A--14

OPERATION WARNINGS

Hard Packed Snow

Teach your child to reduce speed as required to maintaincontrolin all driving conditions. If necessary,maximum speed may be regulatedby using the procedure outlined on page A --24.

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 snowmobiledepends primarilyon 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.

WARNING

Steering and braking control are substantially reduced when operating on on hard surfaces, hard-packed snow, or icy surfaces.

Page 33

A--15

OPERATION WARNINGS

Hilly Terrain

Riding 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.

Riding 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.

Responsible Driving

It is up to you, the parent, 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 foremostin your mind. Never allow your child to operate this machine without adult supervision.

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 travelingon hilly terrain is unavoidable, teach your child to exercise extreme caution as well as the proper operating procedure as outlined below.

WARNING

Teach y our child to never stand or get off the machine on the downhill side of the machine. Serious injury or death could result.

Page 34

A--16

PRESERVATION OF THE ENVIRONMENT

Teach your child to drive theirsnowmobile withconsideration for the protection and preservation of the environment.

Noise Level

One of the most publicized subjects with regard to snowmobilesis noise. The Society of Automotive Engineers (SAE), which is the standard-setting body for snowmobiles, has recommended that snowmobilesconform to prescribed sound levels. This Polarissnowmobilehas 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 investigatingways 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.

Environmental Protection

As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety trainingprograms which also encourage protection of our environment, wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. It is v ery 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.

Page 35

A--17

IDENTIFICATION AND SPECIFICATIONS

Vehicle Nomenclature

Refer to the illustrations on the following pages.

1. Hood 10. Nosepan

2. Headlight 11. Trailing Arm

3. Windshield 12. Skis

4. Handlebar 13. Front Bumper

5. Seat 14. Vehicle I.D. Number (Right Side)

6. Storage (under seat) 15. Rear Bumper

7. Taillight 16. Snow Flap

8. Track

9. Rear Suspension

5,6

Page 36

A--18

IDENTIFICATION AND SPECIFICATIONS

Controls and Instruments

1. Stop Switch (Push/Pull). Operation found on page A--26.

2. Throttle Control

3. Recoil Starter Handle

4. Choke Button

5. Gas Cap

6. Ignition Switch

7. Brake Lever

8. Tether Switch

9. Hood Hold-Down

10. Console

11. Tether Strap

Page 37

A--19

ENGINE BREAK-IN

Engine Break-In

The break-in period for your new snowmobile is defined as the first ten hours of operation,or the time ittakes to use the firsttwo tanks fullofgasoline. No single action on your part is as important as a proper break-in period. Careful treatmentof a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

1. Fill the fuel tank with either unleaded or leaded fuel that has a minimum pump octane number of 87.

2. To check the oil reservoir level, remove the dipstick and wipe off with a clean shop towel. Replace the dipstick, making sure to screw it completely in. Remove the dipstick and check the oil level. If the oil level is anywhere between the two marks on the dipstick, there is adequate oil to operate the machine. Add oil if necessary.

3. Drive slowly at first. Select an area which is open and will allow room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle. CAUTION: Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close-fitted engine parts.

5. Perform regular checks on fluid levels, controls and all important areas on the vehicle, as outlined in the maintenance section.

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

CAUTION

Use only Polaris Premium 4 All Season syntheticoil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty c an result.

Dipstick

Safe Oil Level Between Marks

Page 38

A--20

ENGINE BREAK-IN

With a basic understanding of how the snowmobile works, and with close attention paid to maintenance tips, you will be ready to ride. Keep in mind these recommendations as well as those covered throughout this manual.

CAUTION

D Never mix brands of oil. Seriouschemical reactions can cause oilpassage

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.

D Do not operate at prolonged full throttlefor the firstthree 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.

D 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.

D Drive with extra caution during the break-inperiod. Perform regular checks

on fluid levels, lines, and all important areas of the machine.

Page 39

A--21

OPERATION

Carburetion

Proper carburetor adjustment is critical, since a mixture too lean (too much air, too littlefuel) 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.

Remember,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. Your dealer has the training and tools required to perform any adjustments for you.

1. Engine

2. Carburetor

CAUTION

Carburetoradjustments must be performed by your dealer,since mistakes can result in possible operator safety hazards as well as serious engine damage.

Page 40

A--22

OPERATION

Carburetion

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.

WARNING

Carburetoradjustments must be performed by your dealer,since mistakes can result in possible operator safety hazards as well as serious engine damage.

Page 41

A--23

OPERATION

S Always stop the engine and refuel outdoors or in a well ventilated area.

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

is performed or where gasoline is stored.

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

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

immediately.

S If you spill gasoline on your skin or clothing, immediatelywash it offwith soap and

water and change clothing.

S Never start the engine or let it run in an enclosed area. Gasoline powered engine

exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

Fuel

The fuel used in the Polaris engine is as important to engine life and performance as the lubricant used.

Most Polaris engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There is a great deal of variability in the quality of the 87 octane gasoline available across the country. We encourage the use of premium fuel when possible.

WARNING

Gasoline is extremely flammable and explosive under certain conditions. Improper handling can result in severe injury or death.

WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Page 42

A--24

OPERATION

NOTE: It is up to you, the parent, to teach your child the proper and safe way to

ride a snowmobile. You must set boundaries and adhere to them, keeping your child’ssafety foremost in your mind. Neverallow your child to operate this machine without adult supervision.

Speed/Performance Regulation

Under certaincircumstancesit may be necessary for an adult to regulatethe speed and acceleration potential of the snowmobile. Moving the governor lever spring is the adjustment used to control performance. Use the following procedure to set the performance level.

1. For maximum performance, move governor spring to hole #3.

2. For minimum performance move governor spring to hole #1.

Pre-Starting

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the snowmobile without checking all components to be sure of proper operation. See Operation Warnings beginning on page A--24.

Important safety items include, but are not limited to:

D Throttle system D Brake system D Steering system

These systems must be checked each time before starting the engine. Incorrect adjustments, damage, or excessive wear due to neglect could result in personal injury and/or damage to the snowmobile.

CAUTION

Always wait for the engine to cool down if it has been running. Touching a hot engine can cause serious burns.

Governor Spring

Page 43

A--25

OPERATION

Starting a Cold Engine

1. Turn key to “On”.

2. Pull engine stop switch (shut-off switch) up to “run” position.

3. Pull the choke lever outward to “Full On” position.

4. Grasp starter handle and pull slowly until recoil engages; then pull to start.

NOTE: Do not depress throttle until engine starts.

5. After engine starts, the choke lever should be pushed in to the “Off” position. If the engine slows or wants to stop, intermittentchoking to the “Half On” position may be helpful.

Starting a Warm Engine

1. Turn key to “On”.

2. Pull engine stop switch (shut-off switch) up to “run” position.

3. Grasp starter handle and pull slowly until recoil engages; then pull to start.

CAUTION

Do not pull the starter rope to its full extended position or allow it to snap back into the housing as damage can result. The recoil starter rope is full length. Be sure onlookers are standing clear while pulling the recoil starter.

Page 44

A--26

OPERATION

Engine Stop Switch

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 re-start the engine, the switch must be pulled up to the “On” position.

Check Throttle Safety Switch

Test the throttle safety switch system on a daily basis before the machine is used.

Page 45

A--27

OPERATION

The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

4. If the throttle lever operates properly,turn the ignition switch on and go through normal starting procedures.

5. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service.

If excessive play develops in the throttle cable, the safety switch may be activated, preventing the engine from starting. Contact your dealer.

If the engine does not start, and throttle safety switch malfunction is suspected, return the machine to an authorized Polaris dealer for service. If an emergency exists and it is necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness.

WARNING

If the throttle lever does not work properly, do not start the engine.

.03 in.

WARNING

With the throttle safety switch and engine stop switch disconnected, the ignition key switch must be used to shut off the engine. Do not continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealerfor service as soon as possible.

Page 46

A--28

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 Interrupts ignition circuit All

Ignition Switch Interrupts ignition circuit All

Tether Switch Interrupts ignition circuit All

Choke Floods engine 1/2 throttle or less

Brake Slows drive shaft All

Throttle Safety Switch Interrupts ignition circuit All

Referto page A--26 for more information on the engine kill switch and throttlesafety switches.

Daily Storage

Whenever the machine is placed in overnight or daily storage the following steps must be taken:

D 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.

D Remove the key and cover

the machine using the Polaris cover available for your model. See your dealer for more information.

Page 47

A--29

OPERATION

Pre-ride Warm-Up

The following steps must be taken to ensure proper warmup of the engine, drive train and track.

With the snowmobile securely supported by the rear bumper, and with a minimum clearance of 4″ (10 cm) from the ground, use the following procedure.

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 frozensnow from the ski bottoms, allowing the machine to move forwardmore easily.

5. The engine, drive system and track are now properly warmed up and the machine can be driven following normal safety practices.

NOTE: It is up to you, the parent, to teach your child the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping your child’ssafety foremost in your mind. Never allow your child to operate this machine without adult supervision.

WARNING

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 track is free-hanging. A loose track or flying debris could cause serious personal injury or death.

Page 48

A--30

MAINTENANCE

Polaris Recommended Owner Maintenance Program

This 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 high degree of performance and reliability this machine must be given regular service and maintenance inspections.

Uninterrupted snowmobiling will be important to the operator(s) in your family. To assure trouble-free enjoyment, the Polaris Owner Maintenance Program has been developed. 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 on this 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. All necessary

replacement parts and labor incurred,with the exception of authorized warranty repairs, become the responsibility of the registered owner.

If during the course of the warranty period parts failures occur as a result of owner neglect in performingthe recommended periodic maintenance, the cost of such repairs shall be borne by the owner. Please consider the recommended maintenance program illustrated on the following pages as a preventative maintenance program designed to maintain the performance and reliability of your snowmobile in the years to follow.

Page 49

A--31

MAINTENANCE

Weekly Maintenance Check

For best machine performance and safe operation, check these points weekly and before any extended period of operation:

1. Track alignment and adjustments

2. Drive chain tension

3. Brake operation, adjustment

4. Headlight and taillight

5. Emergency shut off switch operation and throttle safety switch function

6. Suspension mounting bolts (tightness)

7. Steering arm and tie rod ends (check for play or looseness)

8. Ski saddle and spindle bolts (tighten)

9. Suspension rear limiter strap bolt (tighten)

10. Condition of front and rear limiter straps

11. Throttle cable condition

12. Engine oil level (between crosshatches)

13. Clutch (grease)

14. Chain (oil)

Page 50

A--32

MAINTENANCE

Careful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and lubrication of importantcomponents are explained on the following chart and maintenance pages of this manual.

For continued maximum machine performance and component life, it is recommended that maintenance checks be performed at indicated intervals.

Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

NOTE: The followingchart is a guide based on average ridingconditions. You may need to increase frequency based on riding conditions. Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.

ITEM WEEKLY OR

BEFORE EXTENDED PERIOD OF

OPERATION

HOURS

100

HOURS

150

HOURS

SEE

PAG E

Oil the drive c hain Every 10

Hours

A--42

Check track tension, tight en if necessary

Every 10

Hours

A--46

Grease the clut ch Every 15

Hours

A--42

Change Oil At 20 Hours X X X A--43

Check brake operation and adjustment

Daily A--39

Test engine s top switch (auxiliary shut-off switch)

Daily A--26

Test throttle safety switch Daily A--26

Test tether switch Daily R--8

Test throt tle lever operation Daily A--5

Test speed limiter Daily A--24

Check operation of headlight and taillight

Daily A--9

Clean dust & c haff from engine Daily

Check ski skags, replace when worn to 1/2 original diameter

Daily A--53

Inspect fuel li nes, replace if bad Daily A--36

Check engine oil level Daily A--43

Check track alignment X A--48

Check drive c hain tension X A--41

Check and tight en any loose suspension mount ing bolts

X A--54

Tighten ski saddle and s pindle bolts, if loose

X A--52

Page 51

A--33

MAINTENANCE

ITEM WEEKLY OR

BEFORE EXTENDED PERIOD OF

OPERATION

HOURS

100

HOURS

150

HOURS

SEE

PAG E

Check front & rear limiter strap condition, tighten loose bolts

X A--55

Check hi-fax thickness, replace when worn (Dealer)

X A--51

Tighten rear idler wheel bolts, if loose

X A--48

Check spark plug c ondition X A--35

Check for brake cable wear and adjustment

X A--39

Throttle Cable Pi vot Slug X X X A--38

Lubricate steeri ng post s upport bracket and piv ot (aerosol)

X X X A--43

Grease ski s pindles X X X A--43

Lubricate ski bushings to spindle area

X X X A--43

Grease lower steering post pivot X X X A--54

Grease rear suspensi on piv ot shafts

X X X A--54,

A--55 Lubricate thrott le c able X X A--38

Lubricate choke slide and c able X X A--38

Inspect ex haust pipe for cracks or damage

X X X A--38

Page 52

A--34

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 unit.

50 Hour Initial Maintenance Inspection