Polaris 120 XC SP User Manual

Download

2003

120 XC SP

Owner's Manual

for Vehicle Maintenance

and Safety

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.

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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.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

Comments and suggestions regarding this manual may be forwarded in writing to: Polaris Industries Inc., Consumer Service, 2100 Highway 55, Medina, MN 55340.

TABLE OF CONTENTS

Table of Contents 3..........................

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 26................................

Operation Warnings 30............................

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

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

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

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

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

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

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

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

Service and Warranty 83......................

Warranty 85.................................

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

WELCOME

Dear Parents:

We believe your children should have the opportunity to enjoy The Way Out experience along with you. We’ve provided this owner’s manual to assist you and your children in learning about the safe operation and care of your new Polaris snowmobile. Please review the information in this manual with any child who may operate the snowmobile. Help your children learn to operate the snowmobile with safety as a top priority. Help them also learn to show respect for our environment and for the rights of others while operating the snowmobile. Since the operator will be a newcomer to the exciting winter sport of snowmobiling, please be sure he/she understands this information before riding the snowmobile. Never allow a child to operate the snowmobile without adult supervision.

The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child’s snowmobile are thoroughly inspected at various intervals. For safe and enjoyable operation of the vehicle, be sure to follow all of the instructions and recommendations in this manual. A table of Polaris-recommended products is provided on page 82. If you have any questions about the snowmobile, contact a Polaris dealer for assistance.

This Owner’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.

Dear Children:

Before you ride your new Polaris snowmobile, there are some important things that you need to know. Your parents and Polaris want you to enjoy riding your new snowmobile, and that’s why you need to read and understand the information in your owner’s m anual.

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 m ost 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. S o read your manual, and then enjoy riding your new Polaris snowmobile!

INTRODUCTION

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

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

We reserve the right to make product changes and improvements without notice.

n The illustrations and photos used in this manual are general

representations. Your model may differ.

n Follow the maintenance program outlined in this manual.

Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

n A t able 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.

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.

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 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 m ust 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 t o 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. Teach your child the following:

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

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 i dentification of your vehicle.

Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced. See your Polaris dealer.

Please record your snowmobile identification numbers below for future reference:

31XX

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

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

3. Key Number:

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.

SAFETY

Maintenance Program

As with all snowmobiles, caution must be observed to ensure operator safety. Particular caution must be taken to make sure that the snowmobile is in excellent operating condition at all times. We strongly recommend that the operator, as well as an adult, check major and vital safety components before each use of the vehicle.

We also recommend that you strictly follow the maintenance schedule outlined in this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at various mileage intervals.

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

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.

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.

NOTE:

A note will alert you to key information or instructions.

IMPORTANT

IMPORTANT will alert you to important information or instructions.

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 m achine.

1. Engine Stop Switch - When the engine is running, you can push this button down and the engine will stop. The stop switch must be in the UP position to start the engine again.

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

forward when you press it with your thumb. You must always make sure the throttle control does not stick before you operate your snowmobile. Read more about it on page 19.

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

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

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

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

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.

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

YOUTH SECTION

Know Your Snowmobile

6. 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.

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 t his key to turn off the engine.

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.

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.

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.

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

YOUTH SECTION

Know Your Snowmobile

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

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 s now, 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.

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.

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

YOUTH SECTION

Know Your Snowmobile

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

1. Push the stop switch down.

2. Pull off the tether strap.

3. Turn the key off.

YOUTH SECTION

Pre-Ride Check

You’re almost ready to have an adult start your snowmobile. Before the snowmobile is started for the first time, you must do a PRE-RIDE CHECK. In fact, every time you ride your snowmobile you must have an adult help you check these things before starting it. Let’s learn about these things now.

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

the handlebar and then let it go. The lever should come right back to where it was before you pushed it. If it comes back slowly or stays close to the handlebar, you have a sticky throttle. This means that something is wrong or broken. Don’t start the snowmobile until an adult fixes the sticky throttle.

Never start the engine if you have 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 brakes don’t stick. Squeeze the brake lever toward

the handlebar and then l et 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.

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 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.

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

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.

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.

YOUTH SECTION

Pre-Ride Check

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.

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

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.

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.

YOUTH SECTION

Riding Rules

Helmet

Face Shield

Jacket

Gloves

Pants

Boots

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

snowmobile. You’ll need a good helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your 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.

Riding Rules

YOUTH SECTION

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

To Machine

driving t hrough the flower garden or over the little trees you planted.)

" Always attach the tether strap to

To Wr i st

your wrist and machine before riding.

YOUTH SECTION

Riding Rules

Learn how to ride safely and correctly. Learn how to use your hands and arms as signals. Read and understand your Owner’s Manual.

Left Turn Right Turn

Stop

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.

ADULT SECTION

Pre-Ride Check

Before Starting The Engine

n Read and Understand Your Owner’s Manual

Read and make sure the operators understand the Owner’s Manual completely before allowing anyone to operate this snowmobile. It’s also a good idea to review it periodically to reinforce the information. It’s very important to familiarize the operator and guests with the cautions and warnings pertaining to the machine as well as safe operating procedures. We’ve attempted to provide you with as much information as possible to alert you to the safety requirements of snowmobiling.

WARNING

The throttle and brake are the primary controls of the snowmobile. If either should malfunction, the operator could lose control, which could lead to serious injury or death. Always check the throttle and brake levers for proper operation before operating the vehicle.

n Check throttle for proper operation

When checking the throttle, make sure the control l ever compresses evenly and smoothly. When the lever is released, it should immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, do not attempt to start the engine. Have the throttle serviced before starting the engine.

n Check brake for proper operation

The need for a properly functioning brake is critical. The brake must be checked for correct operation before starting the engine. See page 31 for brake lever travel specifications.

n Check for proper operation of steering system

Check for proper operation of the steering system by manually turning the skis completely to the right and to the left. If difficulty is encountered, check for ice and snow buildup which may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.

ADULT SECTION

Pre-Ride Check

n Check throttle safety switch

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

While seated in a normal riding position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration (A). Apply a slight amount of throttle opening. A properly functioning switch must shut down the engine.

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

If excessive play develops in the throttle cable, the safety switch may be activated and will prevent the engine from starting. If the engine doesn’t start and throttle safety switch malfunction is suspected, return the machine to an authorized Polaris dealer for service. If an adult must start the engine in an emergency situation, the throttle safety switch and engine stop switch may be disconnected from the wire harness. In this situation, the i gnition key switch must be used to shut off the engine. Be sure to reconnect the safety switches and have the snowmobile serviced before operating the vehicle again.

.03 in.

WARNING

Do not continue to operate the machine with the throttle safety switch disconnected as serious injury or death could result. Return the machine to an authorized Polaris dealer for service before operating.

ADULT SECTION

Pre-Ride Check

n Check engine stop switch

Test the engine stop switch before each use of the snowmobile. T o stop the engine in an emergency, push down on the stop switch (A). This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch mustbepulleduptotheON position.

n Inspect the track

Driving for extended periods of time with marginal lubrication could severely damage the track. Driving on icy trails or driving when there is little or no snow are two examples of situations that would provide marginal lubrication and are not recommended.

WARNING

Operating the snowmobile with a damaged track will increase the possibility of additional track damage and/or failure. This could cause loss of control, resulting in severe injury or death. Always inspect for damage before using the snowmobile.

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

ADULT SECTION

Operation Warnings

n Do not carry passengers

This snowmobile is designed for a single operator.

n Do not operate with intake silencer removed

CAUTION

If the engine is operated with the intake silencer removed, damage to the engine may occur. Do not operate the engine with the intake silencer removed.

n Stay clear of track

WARNING

During warm-up and operation, stand clear of the rotating track. Entanglement and serious injury or death may result. Use just enough throttle to rotate the track and warm up the engine.

n Do not operate with drive chain guard removed

WARNING

The drive chain guard is designed to protect the operator from metal parts in the event of a drive chain failure. Although the chance of failure is extremely remote, do not defeat the purpose of the guard by removing it. It is provided for the safety of the child.

ADULT SECTION

Operation Warnings

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

WARNING

Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running.

n Disabled operators

WARNING

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control, which could result in serious injury or death.

ADULT SECTION

Operation Warnings

n Check brake lever travel

Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance A should be no more than 3/4″ (1.9 cm).

Excessive travel indicates a need to adjust the brake cable. Refer to the mechanical brake adjustment information on page 59.

n Make sure the hood is securely latched

The hood of the snowmobile protects the operator from moving and hot parts as well as aiding in sound emission control and various other functions. Under no circumstances should your snowmobile be operated with the hood open or removed.

n Test stop switch operation

Start the engine and push the stop switch down to test for proper operation. The engine should immediately stop running.

n Test tether switch operation

Start the engine and disconnect the tether switch to test for proper operation. The engine should immediately stop running.

n Remove the ignition key

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

n Check lights

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

ADULT SECTION

Operation Warnings

n Check surroundings to verify clear operating area

It’s important to make sure there’s a clear area all around the snowmobile, including an area clear of bystanders. Some sideways movement is possible when starting out, and debris may be thrown by the track. Teach the operator to check the operating area before riding.

n Sit properly on the snowmobile

Improper operator position on the snowmobile can be the source of serious injury. Operating a snowmobile does require skill and balance for proper control, and an improper position can seriously reduce the child’s ability to control the snowmobile. The riding position may vary as the operator becomes more skilled, but under most conditions the proper position is to be seated with both feet on the running boards, in a comfortable position for proper throttle, brake and steering control.

WARNING

Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death.

This snowmobile is propelled by a revolving track, which must be partially exposed for proper operation. Serious injuries may be caused by operator carelessness, resulting in hands, feet, hair or clothing becoming entangled in the track. Teach your child to respect this machine and all the moving parts. Stress that being properly seated keeps the child clear of the track.

ADULT SECTION

Operation Warnings

n Stop engine before attempting adjustments

WARNING

The snowmobile engine compartment contains moving parts. Shields and guards have been provided for safety, but it is still possible to carelessly get your hands or fingers into a moving chain or a rotating shaft. For this reason never attempt adjustments with the engine running. Serious personal injuries can result. The proper method is to turn off the ignition, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then re-start the engine to check its operation. The same is true of track alignment. If the track must be re-aligned, it is recommended that this service be performed by your dealer.

n Always wear clothing designed for snowmobiling

Clothing designed for snowmobiling is warm, comfortable and safe.

WARNING

Always make sure the operator is wearing an approved helmet and eye protection. Do not allow the child to wear loose clothing or long scarves because they can easily become entangled in moving parts. If your child has long hair, be sure it is always tied up securely and tucked into the helmet or jacket.

Extremely cold weather can cause frostbite and/or hypothermia. Always be aware of weather conditions, especially the wind chill. See the table on page 36.

ADULT SECTION

Operation Warnings

n Know limitations of machine and skills of driver

The operator should be aware that there are state and local laws governing snowmobile operation and that these laws should be followed. They have been established for the protection of all snowmobile riders. Most states offer a snowmobile safety course for children. Check your state or county agencies for this service.

This vehicle is intended for daylight use only. Check both the headlight and taillight of the machine to ensure proper operation. IMPORTANT: The headlight and taillight are intended only to increase the visibility of the 120 XC SP during daylight operation. Do not operate the snowmobile in the dark.

ADULT SECTION

Operation Warnings

Wire fences are a serious hazard. Teach your child to always be on the alert for fences. Single strands are especially dangerous, since there can be a great distance between posts. Guy wires on utility poles are also difficult to distinguish. Teach your child to reduce speed when traveling near poles, posts, or other obstacles.

T each your child that the sound of the machine will make it difficult to hear the sound of approaching vehicles. Do not allow your child to operate the snowmobile on or near roads and railroad tracks.

T each your child what it means to drive defensively. Never tailgate and always allow ample stopping distances.

Your child must be taught to always be alert and pay attention to the driving area ahead.

When teaching inexperienced operators to ride, set up a nearby predetermined course. Establish boundaries and make sure the operator(s) know and understand them. Make sure they know how to drive and control the snowmobile before you allow them to make supervised longer distance runs. Teach them proper snowmobile courtesy.

It’s a good idea to predetermine some hand signals as a way to communicate with your child while giving instruction. It may be difficult for your child to hear your voice over t he sound of the snowmobile and through a helmet.

ADULT SECTION

40MPH

Operation Warnings

Windchill/Temperature Charts

The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile.

WIND CHILL CHART (°F)

Esti-

mate

Wind

Speed

in MPH

Calm 50 40 30 20 10 0 -10 -20 -30-40-50-6

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

15 36 22 9 -5 -18 -36 -45 -58 -72-85-99-1

20 32 18 4 -10 -25 -39 -53 -67 -82-96-110-1

25 30 16 0 -15 -29 -44 -59 -74 -88-104-118-1

30 28 13 -2 -18 -33 -48 -63 -79 -94-109-125-1

35 27 11 -4 -20 -35 -49 -67 -82 -98-113-129-1

40 26 10 -6 -21 -37 -53 -69 -85 -100-116-132-1

Wind Speeds Greater

Than

40 MPH

Have

Little

Added

Effect

50 40 30 20 10 0 -10 -20 -30-40-50-6

5 48 37 27 16 6 -5 -15 -26 -36-47-- 57-6

Little Danger

(For Properly

Clothed Person)

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

Operation Warnings

70KPH

WIND CHILL CHART (°C)

ADULT SECTION

Esti-

mate

Wind

pee

in KPH

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

Have

Little

Added

Effect

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

Little Danger

(For Properly

Clothed Person)

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

Increasing

Danger

Danger From Freezing of Exposed Flesh

Great

Danger

ADULT SECTION

Operation Warnings

Cold Weather Drive-Away

Whenever the machine has been parked for some l ength of time, especially overnight, always shake loose the skis and track for the operator before attempting to put the machine into motion. The throttle will require some pressure to move the machine. Teach the operator not to be afraid of applying pressure to the throttle but at the same time, teach them not to be too forceful with the throttle which could cause the machine to lurch forward.

Powder Snow Operation

This snowmobile is designed to operate best on snow. Maneuverability is attained by the steering, skis, and the shifting of the driver’s body weight. M aximum control will be attained by shifting body weight. Maneuverability will change for lighter operators.

If the machine becomes stuck in snow, free the running board area and step down the snow in front of the machine so that when the throttle is opened the machine will be able to climb out. The operator can then get back on the machine and continue. It is best to encourage the operator to stay on established riding areas to avoid the possibility of getting stuck.

Track Lubrication

Do not operate for prolonged periods in conditions of marginal lubrication.

CAUTION

It’s essential that this machine be operated under conditions with adequate snow cover, as snow provides the only lubrication for the track. Failure to do so will result in excessive wear and damage to the slide rail and track.

ADULT SECTION

Operation Warnings

Snow and Ice Build-Up

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

WARNING

Before allowing your child to drive the machine, be sure that ice and snow are not interfering with the steering. Manually turn the skis to the left and right. If difficulty is encountered, check for ice and snow buildup which may be obstructing the steering linkage.

Hard Packed Snow

T each your child to reduce speed as required to maintain control in all driving conditions. If necessary, maximum speed may be regulated by using the procedure outlined on page 47.

WARNING

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

ADULT SECTION

Operation Warnings

Driving on Ice

It is dangerous to operate on ice or under slippery conditions. If ice or slippery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction on a slippery surface. The chance of “spin-out” increases under these conditions. Being able to turn a snowmobile depends primarily on the skis being in snow. On hard surfaces, such as ice, the ability to turn is reduced and the machine will not turn very well. In this situation it may be best to dismount and move either the front or rear of the machine to point it in the proper direction.

T each your child to respect the unknown. Children must be taught that they are not to venture out on their own in unapproved territory. They must learn that they must never ride a snowmobile on a frozen body of water. You and the driver of the machine should know and understand that severe injury or death can result if the snowmobile and its occupant break through the ice.

Driving in Hilly Terrain

WARNING

Traveling on hilly terrain is not recommended. It takes some maneuvering of body weight that a child may not be capable of, which will leave the child at risk. If traveling on hilly terrain is unavoidable, teach your child to exercise extreme caution as well as the proper operating procedure as outlined below.

Driving Uphill

Riding uphill requires extreme caution and should be attempted only by experienced operators. The operator should assume a standing position with body weight kept low and forward, accelerating before the start of the climb and then releasing throttle pressure enough to prevent track slippage.

When reaching the crest of the hill, the operator must slow down and be prepared to react to obstacles, sharp drops, or other people or vehicles which may be on the other side of the hill.

ADULT SECTION

Operation Warnings

Driving Downhill

When riding downhill, the operator m ust keep the speed at a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow use of the engine’s compression to help slow the machine, and keep the snowmobile from rolling freely downhill.

WARNING

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

Driving Responsibly

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

ADULT SECTION

Component Identification

5,6

1. Hood 8. Rear Suspension

2. Headlight 9. Nosepan

3. Windshield 10. Trailing Arm

4. Handlebar 11. Skis

5. Seat 12. Front Bumper

6. Storage (under seat) 13. R ear Bumper

7. Taillight 14. Snow Flap

8. Track

Component Identification

ADULT SECTION

1. Stop Switch

2. Tether Strap

3. Throttle Control

4. Recoil Starter Handle

5. Hood Hold-Down

6. Choke Button

7. Gas Cap

8. Ignition Switch

9. Console

10. Brake Lever

11. Tether Switch

ADULT SECTION

Break-In Period

Engine Break-In

The break-in period for your new snowmobile is defined as the first ten hours of operation, or the time it takes t o use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

1. Drive slowly at first. Select an area that’ s open and will allow room to familiarize yourself with vehicle operation and handling.

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

3. Perform regularchecks on fluid levels, controls and all important areas on the vehicle, as outlined in the maintenance section.

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

CAUTION

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

oil passage blockage, resulting in severe engine damage and voiding of engine warranty. The only oil recommended for this system is Polaris Premium 4 All Season Synthetic oil. This oil has been specially formulated for all temperatures and has extreme cold flow characteristics.

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

of operation. Vary the throttle openings and machine speeds. This will reduce friction on all close fitting machined parts and allow them to break in slowly without damage.

S 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.

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

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

ADULT SECTION

Break-In Period

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season Synthetic oil. Never substitute or mix oil brands.

Checking Engine Oil

Before checking or refilling engine oil, be sure the engine is stopped and the vehicle is positioned on a stable, level surface. NOTE: Always change the oil if it’s become contaminated.

1. Remove the dipstick and wipe it dry with a clean shop towel.

2. Insert the dipstick (A) into the oil fill hole, then remove it and read the oil level. NOTE: Do not thread the dipstick into the hole to perform the oil check.

3. If the oil level is below the lower level mark (B) on the dipstick, add the recommended oil to the upper mark (C).

NOTE: Always use Polaris Premium 4 All Season Synthetic Oil or any class SE, SF (API classification) or higher grade oil. If multi-grade oil is used, oil consumption will increase when the ambient temperature is high.

ADULT SECTION

Operation

Fuel

When refueling, use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and 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 gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

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

your doctor immediately.

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

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

S Turn the fuel valve off whenever the vehicle is stored or

parked.

WARNING

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

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

ADULT SECTION

Operation

Speed/Performance Regulation

Adults have the responsibility for teaching children the proper and safe way to ride a snowmobile. Please set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow a child to operate this machine without adult supervision.

Under certain circumstances it may be necessary for an adult to regulate the speed and acceleration of the snowmobile by moving the governor lever spring. Use the following procedure to set the performance level.

CAUTION

Hot engine components can cause serious burns to skin. Always perform the following procedures when the engine is cool.

For maximum performance, move governor spring (A) to hole #3.

For minimum performance move governor spring to hole #1.

ADULT SECTION

Operation

Starting the Engine

Never start the snowmobile without checking all components to be sure of proper operation. Refer to the Pre-Ride Check beginning on page

25.

Starting a Cold Engine

1. Turn the key to ON.

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

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

NOTE: Do not depress the throttle while starting.

4. Grasp the starter handle and pull slowly until the recoil engages, then pull abruptly to start.

CAUTION

Extending the starter rope too far or allowing it to snap back into the housing will cause damage to the recoil assembly. Do not extend the starter rope to its maximum length, and do not drop the rope handle during starting.

5. If the engine slows or stops, position the choke knob half way in t o allow proper engine warm-up.

6. Apply the brakes and vary the engine RP M slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke all the way in. NOTE: To prevent excessive wear on the clutch components, don’t engage the clutch while performing the warm-up.

Starting a Warm Engine

1. Turn the key to ON.

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

3. Grasp the starter rope handle and pull slowly until the recoil engages, then pull abruptly to start.

ADULT SECTION

Operation

Emergency Stopping Procedures

The following chart lists methods for stopping the engine in the event of an emergency.

SYSTEM WHAT IT DOES THROTTLE

CONDITION

Engine Stop Switch Interrupts ignition circuit All

Ignition Switch Interrupts ignition circuit All

Tether Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Choke Floods engine 1/2 throttle or less

Brake Slows drive shaft All

Daily Storage

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

1. Park the snowmobile on a level surface and support it at the rear so the track is suspended approximately 4″ (20 cm) from the ground.

2. Remove the key and cover the machine using the Polaris cover available for your model. See your dealer for more information.

ADULT SECTION

Operation

Pre-Ride Warm-Up

Always warm up the engine, drive train and track before operating the snowmobile. With the snowmobile securely supported by the rear bumper with a minimum clearance of 4″ (10 cm) from the ground, use the following procedure to properly warm up the snowmobile.

WARNING

A loose track or flying debris could cause serious personal injury or death. Be sure the rear support is stable. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while performing this procedure. Do not use too much throttle during warm-up or when the track is free-hanging.

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

2. Engage the drive system abruptly and allow it to rotate the track several revolutions. NOTE: The outside temperature will determine the amount of track warm-up required.

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

4. Grasp the skis by their front loops and move from side to side. This will loosen frozen snow from the ski bottoms, allowing the machine to move forward more easily.

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

ADULT SECTION

Maintenance

Polaris Recommended Maintenance Program

Your Polaris snowmobile has been engineered and manufactured by skilled P olaris personnel to the highest degree of performance and reliability possible. In order t o m aintain this level of quality, your machine must have regular service and maintenance inspections.

The Polaris Recommended Maintenance Program is intended to assist you in performing routing maintenance that will ensure trouble-free enjoyment of your Polaris snowmobile. If the recommended regular maintenance and service checks are followed, you will be doing your part in keeping this snowmobile in excellent operating condition at all times.

The recommended maintenance schedule for your snowmobile calls for a service and maintenance inspection at 50 hours, at 100 hours and at 150 hours. These inspections should be performed by a qualified service technician. NOTE: Any replacement parts and labor incurred, with the exception of authorized warranty repairs, are the responsibility of the registered owner. If parts failures occur during the course of the warranty period as a result of owner neglect in performing the recommended periodic maintenance, the cost of repairs shall be the responsibility of the owner.

Please read and follow the recommended maintenance program illustrated on the following pages to maintain the performance and reliability of your Polaris snowmobile.

ADULT SECTION

Maintenance

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

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

NOTE: The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, we recommend the use of genuine Polaris parts, available from your Polaris dealer.

ITEM DAILY WEEKLY OR

Check brake operation and adjustment

Test engine stop switch (auxiliary shut-off switch)

Test throttle safety switch X 27

Test tether switch X 31

Test throttle lever operation X 26

Test brake lever operation X 26

Check steering system operation

Check operation of headlight and taillight

Clean dust and chaff from engine

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

Inspect fuel lines, replace if needed

Check engine oil level X 62

Oil the drive chain Every10Hrs

Check track tension, tighten if necessary

Grease the clutch Every15Hrs 61

Change oil At 20 Hrs X X X 62

X 58-59

X 28

X 26

X 31

X 76

X 56

BEFORE EXTENDED PERIOD OF

OPERATION

Every10Hrs 67

HRS

100

HRS

150

HRS

SEE

PAG E

ADULT SECTION

Maintenance

ITEM DAILY WEEKLY OR

Check track alignment X 69

Check drive chain tension X 60

Check and tighten any loose suspension mounting bolts

Tighten ski saddle and spindle bolts if loose

Check front and rear limiter strap condition, tighten loose bolts

Check hi-fax thickness, replace when worn (see dealer)

Tighten rear idler wheel bolts if loose

Check spark plug condition X 61

Check for brake cable wear and adjustment

Throttle cable pivot slug X X X 58

Lubricate steering post support bracket and pivot (aerosol)

Grease ski spindles X X X 63

Lubricate ski bushings to spindle area

Grease lower steering post pivot

Grease rear suspension pivot shafts

Lubricate throttle cable X X 58

Lubricate choke slide and cable X X 58

Inspect exhaust pipe for cracks or damage

BEFORE EXTENDED PERIOD OF

OPERATION

X 77

X 74

X 78

X 72

X 69

X 58

100

HRS

X X X 63

X X X 77

X X X 56

150

HRS

SEE

PAG E

ADULT SECTION Maintenance

Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile.

50 Hour Initial Maintenance Inspection