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.
What’s the hottest thing on snow? Our new web site. It’s designed just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
INTRODUCTION Important Notes for Owners and Drivers PARENTS: Do not allow anyone under the age of six (6) to operate this machine. Review the information in this manual with any child who may be operating the snowmobile. It is up to you to teach any operator the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping the operator’s safety foremost in your mind. Never allow a child to operate this machine without adult supervision.
INTRODUCTION Preservation of the Environment Teach 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.
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.
INTRODUCTION Vehicle Identification Numbers The frame vehicle identification number (VIN) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys.
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.
Maintenance Program SAFETY 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.
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.
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.
YOUTH SECTION Know Your Snowmobile Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine. 8 7 6 1 2 3 9 5 4 9 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.
Know Your Snowmobile YOUTH SECTION 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 this key to turn off the engine. 8.
YOUTH SECTION Know Your Snowmobile Let’s learn more about the parts of your snowmobile before we talk about riding.
Know Your Snowmobile YOUTH SECTION 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.
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.
Pre-Ride Check YOUTH SECTION 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.
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.
Riding Rules YOUTH SECTION 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.
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.
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 To Machine the things around you. " Always be a polite driver.
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.
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.
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.
ADULT SECTION Pre-Ride Check n Check throttle safety switch A 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.
ADULT SECTION Pre-Ride Check n Check engine stop switch Test the engine stop switch before each use of the snowmobile. 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 restart the engine, the switch must be pulled up to the ON position. A n Inspect the track Driving for extended periods of time with marginal lubrication could severely damage the track.
Operation Warnings ADULT SECTION 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.
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.
Operation Warnings ADULT SECTION n Check brake lever travel Measure the clearance A 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.
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.
Operation Warnings ADULT SECTION 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.
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.
Operation Warnings ADULT SECTION 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.
ADULT SECTION Operation Warnings Windchill/Temperature Charts The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile.
ADULT SECTION Operation Warnings WIND CHILL CHART (°C) Estimated Wind Speed in KPH 5 0 5 0 10 1 20 -4 30 Actual Thermometer Reading (°C) 0 -5 -10 -15 -20 -25 -30 -35 -40 Equivalent Temperature (°C) -5 -10 -15 -20 -25 -30 -35 -40 -4 -11 -16 -22 -27 -33 -38 -45 -50 -9 -17 -23 -29 -36 -42 -48 -54 -61 -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 -1
ADULT SECTION 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 throttle but at the same time, teach them not to be too forceful with the throttle which could cause the machine to lurch forward.
Operation Warnings ADULT SECTION 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.
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.
Operation Warnings ADULT SECTION Driving 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. 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.
ADULT SECTION Component Identification 4 5,6 3 7 2 1 14 12 13 8 1. 2. 3. 4. 5. 6. 7. 8. 42 8 9 Hood Headlight Windshield Handlebar Seat Storage (under seat) Taillight Track 10 11 8. 9. 10. 11. 12. 13. 14.
Component Identification ADULT SECTION 11 1 10 2 3 9 4 7 5 8 6 5 1. Stop Switch 2. Tether Strap 3. Throttle Control 4. 5. 6. 7. 8. 9. 10. 11.
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 to 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.
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. A 1. Remove the dipstick and wipe it dry with a clean shop towel. 2.
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.
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.
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.
ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emergency.
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.
Maintenance ADULT SECTION Polaris Recommended Maintenance Program Your 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 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.
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.
ADULT SECTION Maintenance ITEM DAILY WEEKLY OR BEFORE EXTENDED PERIOD OF OPERATION 50 HRS 100 HRS 150 HRS SEE PAGE Check track alignment X 69 Check drive chain tension X 60 Check and tighten any loose suspension mounting bolts X 77 Tighten ski saddle and spindle bolts if loose X 74 Check front and rear limiter strap condition, tighten loose bolts X 78 Check hi-fax thickness, replace when worn (see dealer) X 72 Tighten rear idler wheel bolts if loose X 69 Check spark plug conditi
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.
Maintenance ADULT SECTION Spark Plugs A new engine can cause temporary spark plug fouling even though the heat range is proper, due to the preservative which has been added during assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization will result. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. S S S S Use BR6ES spark plugs. Proper electrode gap is .028″ (.70 mm).
ADULT SECTION Maintenance Spark Plugs Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. Torque to 12-14 ft. lbs. (16.6-19.3 Nm). Fuel Valve/Fuel Lines The fuel valve and the fuel lines should be inspected regularly. Special attention should be given to the system’s fuel line condition after periods of storage.
Maintenance ADULT SECTION Carburetor Proper carburetor adjustment is critical, since a mixture too lean (too much air, too little fuel) 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.
ADULT SECTION Maintenance Throttle Cable Lubrication With the engine off, lubricate the throttle cable occasionally. Turn the handlebars to the left and lubricate liberally with Polaris All Season Grease. Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown. Operate the choke intermittently before turning the machine off. This draws moisture out of the choke plunger area and reduces the possibility of the choke becoming frozen.
ADULT SECTION Maintenance Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable should be adjusted. If proper adjustment cannot be achieved by using the following methods, check the brake band for excessive wear. Your snowmobile dealer can install a new brake band when necessary. WARNING Improper brake adjustment can result in brake failure, which could result in severe injury or death.
ADULT SECTION Maintenance Chain Tensioner Inspect the chain. The chain should have 1″ of deflection as shown. If not, loosen the nut on the chain tensioner (A) and raise until 1″ (B) of deflection is attained. Tighten nut to 15-18 ft. lbs. When the chain comes within 1/8″ (C) of the muffler mount bracket (D) on the chassis, the chain has stretched and must be replaced. Inspect the sprockets as they also become worn and often need replacement when the chain is replaced.
ADULT SECTION Maintenance Lubrication NOTE: Driveline noise is normal and inherent in a chain drive system such as this machine uses. To ensure long life of the snowmobile’s driveline, lubricate as follows: S Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease. S Lubricate Point B every 10 hours of operation with aerosol chain lube or SAE 30 oil. 1 1. Engine 2. Torque Converter (Centrifugal Clutch) 3. Chain 4. Drive Shaft 5. Track 6.
ADULT SECTION Maintenance Oil Level A Maintain the oil level between the safe marks (A) on the dipstick. Oil Change Change the oil after the initial 20 hours of operation and again after each 50 hours. Washing Your Snowmobile Keeping your snowmobile clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your sled can be cleaned much like an automobile.
Maintenance ADULT SECTION Controls and Linkage All bushings, spindle shafts, and tie rod ends should be coated with a light coat of oil or grease. Throttle and brake controls and cables should be lubricated with Polaris Premium All Season Grease. Force a small amount of lubricant down the cable. Bearings To prevent corrosion which will destroy the bearings, always grease drive shaft clutch side bearings with a high quality bearing grease.
ADULT SECTION Maintenance Engine Proper off-season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage. Without proper storage, jet restriction can cause lean conditions and very poor slow speed driving quality. When preparing your snowmobile for off-season storage, we recommend that you add fuel conditioner/stabilizer or Premium Carbon Clean (PN2871326) to the fuel tank. Follow the instructions on the can.
Maintenance ADULT SECTION Carburetor Protection During Off-Season Storage When preparing your snowmobile for off-season storage we recommend that you add a fuel conditioner/stabilizer or Premium Carbon Clean (2871326) to the fuel tank. Follow the instructions on the can. Run the engine for five minutes to get additives through the entire fuel system. Then top off with fresh fuel and turn the fuel valve to OFF. If stabilizer is not used, make sure the fuel valve is OFF and drain the carburetor.
ADULT SECTION Maintenance Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken: 1. Turn the fuel valve off. 2. Be sure the fuel cap is installed correctly. 3. Always tie the snowmobile to the transporting unit securely using suitable straps. NOTE: Transportation to and from a Polaris dealer is the responsibility of the snowmobile owner. Any expenses involved will not be reimbursed.
ADULT SECTION Maintenance WARNING Your snowmobile is propelled by a revolving track, which must be partially exposed for proper operation. Serious injuries may be caused by the operator’s hands, feet or clothing becoming entangled in the track. Be alert. Always sit properly on the seat. Track and Suspension Under normal conditions moderate track tension should be maintained during summer storage. The rear of the machine should be supported off the ground to allow free hanging of the track.
ADULT SECTION Maintenance Track Adjustment If the track needs adjustment: 1. Loosen rear idler shaft bolt (D). 2. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 3. Repeat measurement on the other side of the track. NOTE: Check more frequently when the machine is new. 4. Start machine and slowly rotate the track at least five revolutions, let the track stop rotating by itself (do not apply brakes). 5.
Maintenance ADULT SECTION Track Alignment A periodic check should be made to see that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury. Before checking track tension, make sure the track contains no objects that could be thrown out while the track is rotating. Keep clear of track.
ADULT SECTION Maintenance Track Warm Up When storing your snowmobile outside overnight, it is recommended that the track be warmed up prior to driving the snowmobile. This reduces drive clutch wear. To warm up the track, safely support the rear of the snowmobile off the ground, start the engine and abruptly engage the clutch. Allow the track to turn for a short time. Release the throttle, apply the brakes and shut the engine off prior to lowering it to the ground.
Maintenance ADULT SECTION Track Inspection WARNING Inspecting the track while the engine is running can result in serious personal injury if the track should being to move. Never inspect the track with the engine running Using a hoist or jackstand, 2 1 3 1 2 safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for any possible damage.
ADULT SECTION Maintenance Hi-Fax Replacement The 120 XC SP uses XTRA Hi Fax Wear Limit Lite style Hi-Fax. When any area of the Hi-Fax is worn to 7/16″ (1.1 cm), it should be 7/16″ (1.1 cm) replaced. This will save wear on other vital components. XTRA Lite The slide rail is designed to operate in conditions with adequate snow cover to provide sufficient lubrication. Excessive wear may be due to improper alignment, improper track adjustment or machine operation on surfaces without snow.
Maintenance ADULT SECTION Track Lubrication Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between hi-fax and track guide clips. Examples of marginal lubrication would include lakes without snow cover, icy trails and no-snow conditions. The slide rail is designed to operate in conditions with adequate snow cover in order to provide sufficient lubrication. Excessive wear indicates insufficient lubrication.
ADULT SECTION Maintenance Steering Inspection and Adjustment The steering assembly of the machine should be checked periodically for loose nuts and bolts. See A,B,C,D,E, F, and G in illustration at right. With handlebars in straight ahead position and measuring from the straight edge of the skis, the measurement between the skis at point H should be 1/8 inches greater than point I, as shown on the following page. NOTE: This measurement should be taken with the vehicle weight compressing the suspension.
Maintenance ADULT SECTION Handlebar Adjustment 6. Slide the handlebar pad upward to access the adjuster bolts. If additional room is required, unzip one of the handlebar pad zippers and roll the pad to the side. 7. To adjust, remove the upper flange nut and carriage bolt. 8. Loosen the lower flange nut only enough so the bracket can move freely. 9. Position the handlebar to the desired height and re-install the upper carriage bolt and flange nut. 10. Torque the flange nuts to 15-17 ft. lbs. 11.
ADULT SECTION Maintenance Ski Skags The skag (A) is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads and other bare terrain. We A recommend that skags be checked once a week to maintain positive steering characteristics. Skags must be replaced when worn to half their original diameter. NOTE: See dealer track studding and skag chart for recommended skags.
Maintenance ADULT SECTION Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease several times during the season and again before summer storage each year. The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts. NOTE: A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles.
ADULT SECTION Maintenance Suspension Components Suspension Lubrication points are indicated by a L. 1. Front Limiter Strap 8. Rail Bumper 2. Torsion Spring Sleeves 9. Torque Arm 3. Torsion Spring 10. Rail 4. Carrier Wheel 11. Hi-fax 5. Rear Limiter Strap 12. Toe Guard 6. Spacer 13. Idler Wheel 7.
ADULT SECTION Accessories Maintenance Items and Accessories The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer. Paint Codes Color Description Polaris “P” No. Raw Material No. Indy Red P293 8520297 Indy Black P067 8520246 Paints can be ordered direct from Midwest Industrial Coatings (612) 942-1836. Mix as directed.
SPECIFICATIONS Jetting Chart Altitude Meters (Feet) Ambient Temperature Below -30_F Below -34_C -30_ to -10_F -34_ to -23_C -10_ to +10_F -23_ to -12_C +10_ to +30_F -12_ to -1_C +30_ to +50_ F -1_ to +10_C Above +50_F Above +10_C 0-600 (0-2000) 75 72.5 72.5 72.5 70 70 600-1200 (2000--4000) 75 72.5 72.5 72.5 70 70 1200--1800 (4000-6000) 72.5 70 70 70 67.5 67.5 1800-2400 (6000-8000) 70 67.5 67.5 67.5 65 65 2400-3000 (8000-10000) 67.5 65 65 65 62.5 62.
SPECIFICATIONS Capacities and Dimensions Body Style Riders/Weight Engine Oil Dry Weight (est.) Fuel Tank Height Length Ski Center Distance Width Brake Type Clutch Type Track Length Track Width Drive Chain Length Mini Indy 1/150 lbs./68 kg maximum .6 qts./.57 l 147.5 lbs./67 kg .5 gal./1.9 l 31 in./78.7 cm 75 in./190.5 cm 30 in./76.2 cm 34 in./86.4 cm Mechanical Centrifugal 69 in./175.3 cm 10 in./25.
POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.) 2871653 Premium Front Gearcase Lube (8 oz.) 2871654 Premium Drive Hub Fluid (8 oz.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz.
SERVICE AND WARRANTY Polaris Anti-Theft System The Polaris anti-theft system monitoring program (PATS) is designed to aid owners of registered snowmobiles in recovery of their machines, if stolen. Administration 1 Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call the Polaris warranty department in the United States and Canada. US #763-542-0500 Canada #204-925-7100 B.
SERVICE AND WARRANTY When writing about parts, service or warranty, always include the following information: 1. Serial number 5. Details of trouble experienced 2. Model number 6. Length of time and conditions of operation 3. Dealer name 7. Indicate previous correspondence 4. Date of purchase Use the following space to record the model and serial numbers of your machine and engine. Machine Model No. Machine Serial No. Engine Model No. Engine Serial No.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340, gives a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer.
WARRANTY This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your snowmobile requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.
WARRANTY Polaris Extended Service Contract Polaris now is offering an extended engine service contract which provides the following benefits: S Additional engine protection beyond the original twelve month warranty. S Backed by the strength of Polaris - no third party involvement. S Repairs use only genuine top quality Polaris parts. S Peace of mind. The Polaris Extended Service Contract is honored by all authorized Polaris snowmobile dealers in North America.
INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . 79 Auto Chain Tensioner . . . . . . . . . . . . . 60 B Brake Adjustment . . . . . . . . . . . . . . . . 59 Brake Lever Travel . . . . . . . . . . . . . . . 58 Break-In Period . . . . . . . . . . . . . . 44-45 C Carburetor . . . . . . . . . . . . . . . . . . . . . 57 Carburetor Protection . . . . . . . . . . . . . 65 Checking Engine Oil . . . . . . . . . . . . . 45 Choke and Cable Lubrication . . . . . . . 58 Clutching Chart . . . . . . . . .
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