Polaris 120 XC SP User Manual

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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www.polarisindustries.com/owner

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.

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