2000 120 XCR RIDER’S SAFETY MANUAL AND OWNER’S OPERATION AND MAINTENANCE MANUAL
WARNING Parents and children need to understand how to operate the 120 XCR safely. Read, understand, and follow all of the safety information in this manual, in the safety video, and all product labels. Failure to follow these safety precautions could result in serious injury or death.
FOREWORD TO PARENTS Thank you for purchasing a Polaris snowmobile. We believe it is the standard of excellence for all snowmobiles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris snowmobile the finest machine we have ever produced. All machines, no matter how well engineered, require a certain amount of maintenance.
The Polaris Preferred Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two-year membership in the Polaris PRO Family----the Preferred Registered Owners Family. This is an owners’ program for Polaris consumers like you, people who have chosen the finest recreational vehicle available, and who share an interest in Polaris and its products. Once your new vehicle’s warranty is registered, you will receive a PRO Family membership packet.
TABLE OF CONTENTS RIDER’S SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1 - R-11 Understanding Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1 R-2 - R-7 Pre Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-8 Riding Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-9 - R-13 ADULT SECTION . . . . . . . . . . . . . . . . . . . . .
RIDER’S SECTION PARENTS: Review the information in this manual with any child who may be operating the snowmobile. It is up to you to teach your child the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision. CHILDREN: Before you ride your new Polaris snowmobile, there are some important things you should know.
KNOW YOUR MACHINE Before you have an 6 adult start the engine for you for the first time, let’s learn about the controls on your new 9 machine. 8 7 1 2 3 5 4 9 1. Engine Stop Switch - When the engine is running, you can push this button and the engine will stop. The stop switch must be in the “up” position to start the engine again. 2. Throttle Control - This makes your snowmobile go forward when you press it with your thumb.
KNOW YOUR MACHINE 6. Brake Lever - Squeeze this towards the handle to make your snowmobile slow down or stop. Always take your thumb off the throttle control when you pull the brake lever. 7. Ignition Switch - The 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. Tether Strap/Switch - This must always be attached snugly to your wrist and your machine when you are riding.
KNOW YOUR MACHINE Let’s learn more about your machine before we talk about riding. 1. Hood - The hood covers the moving and hot parts of the engine and must be securely latched before you ride the snowmobile. 2. Headlight - The headlight is always on when the engine is running. It helps others see you when you are riding. 3. Windshield - Always keep your windshield clean to help you see where you are driving. 4. Handlebar - The handlebar is connected to the skis.
KNOW YOUR MACHINE 6. Seat / Storage - You sit on the seat. When the engine isn’t running, you can take the cushion off and put things under the seat in the special compartment. 7. Taillight - The taillight is always on when the engine is running. It will help others see you when you are riding. 8. Snow Flap - The snow flap keeps snow, ice, or other things from flying out behind your snowmobile. 9. Track - The engine makes the track turn. The turning track makes your snowmobile go forward.
KNOW YOUR MACHINE Let’s review the three ways to stop your snowmobile. 1. Pushing down on the engine stop switch on the right handlebar control will shut off the engine. 2. Disconnecting the tether strap will shut off the engine. 3. Turning the key to off will shut off the engine.
PRE OPERATION CHECK You are almost ready to have an adult start your snowmobile. Before the snowmobile is started for the first time, you must do a PRE-OPERATION CHECK. In fact, every time you ride your snowmobile you must have an adult help you check these things before starting it. Let’s learn about these things now. Make sure the throttle doesn’t stick. Check this by pushing the lever toward the handlebar and then letting go. The lever should come right back to where it was before you pushed it.
PRE OPERATION CHECK Make sure your track and skis are not frozen to the snow. Stand behind the machine and lift up on the back of the sled. This will free the track if it is frozen to the ground. Turn the handlebars to move the skis back and forth to make sure they aren’t frozen. If any of this is hard too, have an adult help you. 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.
RIDING RULES Now you are ready to learn about riding a snowmobile. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won’t be safe when you ride. Remember that safety while you ride is the most important thing. Let’s learn how to ride! You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed. " Your snowmobile is made for one person.
RIDING RULES You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed. " Always wear the right kind of clothing when you are riding your snowmobile. You will need a good helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your clothing fits properly. If it is too small, it could keep you from moving easily. If it is too big, it could hang down and get caught in the track or another moving part.
RIDING RULES " Always drive your snowmobile while sitting down. Keep both hands on the handlebars and keep both feet on the running boards. Both Hands on Handlebars Sit Down Feet on Running Boards " When you are a beginner, always stay on level ground. " Don’t ride your snowmobile on roads or over railroad tracks. Your snowmobile makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. " Fences and snowmobiles don’t mix.
UNDERSTANDING WARNINGS RIDING RULES You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed. ADULT SECTION " Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away from them. Never ride on frozen water. You could get hurt or you could even die. All ice can be dangerous! " Always be alert and pay attention to where you are driving.
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.
UNDERSTANDING WARNINGS ADULT SECTION SAFETY ALERT The following precautionary signal words are used throughout this manual to convey the following messages: It is very important this owner’s manual is read and thoroughly explained to each operator(s) of this machine. The operator(s) should know and understand the risk if these important warnings and cautions are not heeded. This is the safety alert symbol.
SAFETY WARNING AND OPERATION DECALS 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. It is strongly recommended that the operator as well as an adult check major and vital safety components each time before riding. All Polaris snowmobiles have been designed and tested to provide safe operation when used as directed.
SAFETY WARNING AND OPERATION DECALS The information contained in this decal is printed below. WARNING D Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from not heeding the warnings. D This vehicle is intended for daylight use in restricted off-road areas clear of obstacles. primarily on snow and not on frozen bodies of water, by a child of not less than 6 years of age who is in the presence of, and in active supervision of an adult.
PRE OPERATION CHECK WARNING Teach the operators to perform the following Pre-Operation Check before starting the engine each time before they ride. If they do not check their machine properly before riding, they could be seriously injured or killed. Check the throttle for proper operation. Check the throttle safety switch for proper operation. Check the brake for proper operation. Make sure the seat is locked into place. Make sure the track and skis are not frozen to the ground.
OPERATION WARNINGS NOTE: It is up to you, the parent, to teach your child the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision. Before Starting The Engine Read and Understand Your Owner’s Manual Read and make sure the operators understand the Owner’s Manual completely before allowing anyone to operate this snowmobile.
OPERATION WARNINGS The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valve does not return to the normal closed position. Check for Proper Operation of Steering System Check for proper operation of the steering system by manually turning the skis completely to the right and to the left. If difficulty is encountered, check for ice and snow buildup which may be obstructing the steering linkage.
OPERATION WARNINGS Do Not Operate Engine With Intake Silencer or Filter Removed CAUTION When operating engine with intake silencer or filter removed, damage to the engine may occur. 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.
OPERATION WARNINGS 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. 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).
OPERATION WARNINGS Lighting Check Check headlight and taillight for normal operation. Check Surroundings to Verify Clear Operating Area It is important to make certain there is a clear area all around the snowmobile, including an area clear of bystanders. Remember that the possibility always exists of some sideways vehicle movement or of debris being thrown by the track. Teach the operator to check the operating area before riding.
OPERATION WARNINGS 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.
OPERATION WARNINGS Wire fences are a serious hazard. Teach your child to always be on the alert for fences. Single strands are especially dangerous, since there can be a great distance between posts. Guy wires on utility poles are also difficult to distinguish. Teach your child to reduce speed when traveling near poles, posts, or other obstacles. Teach your child that the sound of the machine will make it difficult to hear the sound of approaching vehicles.
OPERATION WARNINGS Windchill/Temperature Charts The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile.
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 Hard Packed Snow WARNING Steering and braking control are substantially reduced when operating on on hard surfaces, hard-packed snow, or icy surfaces. Teach 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 A--24. Ice It is dangerous to operate on ice or under slippery conditions.
OPERATION WARNINGS 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. Riding Uphill Riding uphill requires extreme caution and should be attempted only by experienced operators.
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.
IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature Refer to the illustrations on the following pages. 1. 2. 3. 4. 5. 6. 7. 8. 9. Hood Headlight Windshield Handlebar Seat Storage (under seat) Taillight Track Rear Suspension 10. 11. 12. 13. 14. 15. 16. Nosepan Trailing Arm Skis Front Bumper Vehicle I.D.
IDENTIFICATION AND SPECIFICATIONS Controls and Instruments 1. Stop Switch (Push/Pull). Operation found on page A--26. 2. Throttle Control 3. Recoil Starter Handle 4. Choke Button 5. Gas Cap 6. Ignition Switch 7. Brake Lever 8. Tether Switch 9. Hood Hold-Down 10. Console 11.
ENGINE BREAK-IN Engine Break-In The break-in period for your new snowmobile is defined as the first ten hours of operation, or the time 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. CAUTION Use only Polaris Premium 4 All Season synthetic oil.
ENGINE BREAK-IN CAUTION D 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. D Do not operate at prolonged full throttle for the first three hours of operation. Vary the throttle openings and machine speeds.
OPERATION Carburetion 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.
OPERATION Carburetion 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.
OPERATION WARNING Gasoline is extremely flammable and explosive under certain conditions. Improper handling can result in severe injury or death. S Always stop the engine and refuel outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck. S If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
OPERATION NOTE: It is up to you, the parent, to teach your child the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision. Speed/Performance Regulation Under certain circumstances it may be necessary for an adult to regulate the speed and acceleration potential of the snowmobile.
OPERATION Starting a Cold Engine 1. Turn key to “On”. 2. Pull engine stop switch (shut-off switch) up to “run” position. 3. Pull the choke lever outward to “Full On” position. 4. Grasp starter handle and pull slowly until recoil engages; then pull to start. CAUTION Do not pull the starter rope to its full extended position or allow it to snap back into the housing as damage can result. The recoil starter rope is full length. Be sure onlookers are standing clear while pulling the recoil starter.
OPERATION Engine Stop Switch To stop the engine in an emergency, push down on the stop switch (A). This will ground out the ignition and bring the engine to a quick stop. To re-start the engine, the switch must be pulled up to the “On” position. A Check Throttle Safety Switch Test the throttle safety switch system on a daily basis before the machine is used.
OPERATION The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position. WARNING If the throttle lever does not work properly, do not start the engine. 4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. 5. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service.
OPERATION Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emergency.
OPERATION Pre-ride Warm-Up The following steps must be taken to ensure proper warmup of the engine, drive train and track. With the snowmobile securely supported by the rear bumper, and with a minimum clearance of 4″ (10 cm) from the ground, use the following procedure. 1. Start the engine and allow it to warm up two to three minutes. WARNING Be sure the rear support is stable. Stand clear of the front of the machine and the moving track.
MAINTENANCE Polaris Recommended Owner Maintenance Program This Polaris snowmobile has been engineered and manufactured by skilled Polaris personnel to the highest degree of performance and reliability possible. In order to maintain this high degree of performance and reliability this machine must be given regular service and maintenance inspections. Uninterrupted snowmobiling will be important to the operator(s) in your family.
MAINTENANCE Weekly Maintenance Check For best machine performance and safe operation, check these points weekly and before any extended period of operation: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
MAINTENANCE Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained on the following chart and maintenance pages of this manual. For continued maximum machine performance and component life, it is recommended that maintenance checks be performed at indicated intervals. Service and adjustments are critical.
MAINTENANCE ITEM WEEKLY OR BEFORE EXTENDED PERIOD OF OPERATION 50 HOURS 100 HOURS 150 HOURS SEE PAGE Check front & rear limiter strap condition, tighten loose bolts X A--55 Check hi-fax thickness, replace when worn (Dealer) X A--51 Tighten rear idler wheel bolts, if loose X A--48 Check spark plug condition X A--35 Check for brake cable wear and adjustment X A--39 Throttle Cable Pivot Slug X X X A--38 Lubricate steering post support bracket and pivot (aerosol) X X X A--43 Greas
MAINTENANCE Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the unit.
MAINTENANCE Spark Plug Selection Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug with a heat range which is too low will cause excessive fouling and malfunction. In selecting a spark plug heat range for production, a manufacturer is forced to assume that the engine is going to operated under extreme heavy duty conditions.
MAINTENANCE Wet Fouled The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Causes could be excessive oil, use of non-recommended injection oil, excessive idling, idle too low or too rich, or weak ignition output. 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 General Carburetor Information The number size stamped in the end of the main jet indicates the jet size which was installed at the time of manufacture. The installed main jet is not necessarily correct for your elevation. It is the Polaris dealer’s responsibility to ensure that the correct main jets are installed in each machine for your area of operation.
MAINTENANCE Exhaust System At approximately 50 hours it is a good idea to check the exhaust system for wear or damage. To inspect, allow engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. CAUTION Exhaust system temperatures can exceed 900° F (500° C). Serious burns may occur if this inspection is performed without allowing adequate time for the exhaust system to cool.
MAINTENANCE Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable or caliper should be adjusted using the following methods. WARNING Improper brake adjustment could result in brake failure which could result in severe injury or death. Cable Adjustment 1. Make sure floating parts move freely and all parts are mounted securely. Tighten hardware as required. 2. Check actuator linkage to ensure there is adequate freedom of movement for positive brake operation.
MAINTENANCE Brake Adjustment 4. Install brake band. Route Insert cable through housing cable through cable housing. Install spring on cable and thread cable through set screw barrel. Hold opposite slotted side with flat tool Torque such as a feeler gauge. Insert 1/8″ allen wrench. Pull cable through barrel and tighten. The brake band is adjusted correctly when there is 1/8″-3/8″ (6-10mm) brake lever free play, and clearance between brake lever and block with lever fully depressed is no more than 3/4″ (1.
MAINTENANCE Mechanical Brakes Brake Lever Travel B Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance B should be no more than 3/4″ (1.9 cm) Excessive travel indicates a need to adjust the brake cable adjuster. Refer to the mechanical brake adjustment information on page A--39. Chain Tensioner Inspect the chain. The chain should have 1″ of deflection as shown.
MAINTENANCE Lubrication Points NOTE: To ensure longer life of the snowmobile’s driveline, lubricate as follows: NOTE: There is driveline noise that is normal and inherent of a chain drive system that this machine uses. S Lubricate Point A every 15 hours of operation with Polaris Premium All Season Grease. S Lubricate Point B every 10 hours of operation with aerosol chain lub or SAE 30 oil. 1. 2. 3. 4. 5. 6.
MAINTENANCE Oil Level Maintain the oil level between the safe marks on the dipstick. Safe Oil Level Between Marks Oil Change Change the oil after the initial 20 hours of operation and again after each 50 hours. Cleaning 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 Front Suspension To minimize fatigue on the front shocks and springs during extended storage, it is recommended that the front end of the machine be safely blocked off the ground to remove tension from the shocks and springs. 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.
MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken: 1. Turn the fuel valve to “Off”. 2. Be certain the fuel cap and oil cap are 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.
MAINTENANCE WARNING Your 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, or clothing becoming entangled in the track. Be alert. Remember, being properly seated keeps you clear of the track. Track and Suspension Under normal conditions moderate track tension should be maintained during summer storage.
MAINTENANCE Track Tension (Cont.) If the track needs adjustment: 5. Loosen rear idler shaft bolt (D). 6. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 7. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 8. Start machine and slowly rotate the track at least five revolutions, let the track stop rotating by itself (do not apply brakes). 9.
MAINTENANCE 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 certain the track contains no objects that could be thrown out while the track is rotating. Keep clear of track.
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 Track Inspection WARNING Never make this maintenance check with the engine running, as serious personal injury can result. Using a hoist or jackstand, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for any possible damage. 2 1 3 1 2 To inspect track rods, carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage.
MAINTENANCE Hi-Fax Replacement The 120 XCR uses XTRA Lite style HiFax. When any area of the Hi-Fax is worn to 7/16″ (1.1 cm), it should be replaced. This will save wear on other vital components. Hi Fax Wear Limit 7/16″ (1.1 cm) 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 Steering System The steering systems on Polaris snowmobiles can be adjusted with ski toe alignment. Improper toe alignment can cause erratic steering. Consult your dealer if a need for adjustment should become necessary. 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, and F in illustration at right.
MAINTENANCE Ski Skags The skag 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 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 NOTE: If rear idler wheel (1) assembly washers are removed, be sure they are reinstalled with the domed side of the washer facing out (2) as shown. 1 2 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, PN 2871066, several times during the season and again before summer storage each year.
MAINTENANCE Suspension Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Front Limiter Strap Torsion Spring Sleeves Torsion Spring Carrier Wheel Rear Limiter Strap Spacer Adjuster Bolts Idler Wheel Toe Guard Hi-fax Rail Torque Arm Rail Bumper Suspension Lubrication points are indicated by a L.
TROUBLESHOOTING Engine Troubleshooting The following information is provided to help you identify probable causes for questions you may have about the operation of your snowmobile. See your Polaris dealer with any additional questions you may have.
ACCESSORIES Accessories There are a wide range of accessories available for Polaris snowmobiles. Contact your dealer for a list of accessories available for your machine. Maintenance Items Gas Dock Recoil Starter Handle Tool Pouch Tool Kit Carbon Clean Grease, Premium All Season Anti-Corrosive Lubricant/Electrical Connector Lubricant Fuel Deicer, Isopropyl Fuel Stabilizer, 16 oz. Fogging Oil T-9 Metal Protectant Metal Polish Grease Gun Kit (All Season) 3 oz. Refill Grease Cartridge (All Season) 3 oz.
SPECIFICATIONS Specifications - 120 XCR Capacity 1 Dry Weight (lbs.)±4 lbs 140 Fuel Tank Capacity (Gal) .5 Height, in. 31 Length, in. 74 Ski Center Distance, in. 30 Width, in. 34 Engine Fuji 4 Stroke 4 hp Alternator Output 12V 50 W Bore x Stroke (mm) 60 x 43 Displacement (ccs) 121 Cylinders 1 Main Jet 72.5 Pilot Jet 50 Air Screw 1.5 Ignition Type Transistor Spark Plug Type BR6ES Brake Type Mechanical Band Clutch Center Distance 11.
WIRING DIAGRAM 2000 120 XCR A--59
SERVICE AND WARRANTY INFORMATION 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 #612-542-0500 Canada #204-925-7100 B.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, 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 ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
WARRANTY Polaris Extended Service Contract Polaris now is offering an extended engine service contract which provides the following benefits: D Additional engine protection beyond the original twelve month warranty. D Backed by the strength of Polaris - no third party involvement. D Repairs use only genuine top quality Polaris parts. D Peace of mind. The Polaris Extended Service Contract is honored by all authorized Polaris snowmobile dealers in North America.
INDEX Accessories . . . . . . . . . . . . . . . . . . . . A--57 Brake Adjustment . . . . . . . . . A--39 - A--40 Brake Lever Travel . . . . . . . . . A--8, A--41 Carburetor Adjustments . . . . . . . . . . A--37 Carburetor Protection . . . . . . . . . . . . A--44 Chain Tensioner . . . . . . . . . . . . . . . . A--41 Choke And Cable Lubrication . . . . . A--38 Cleaning Your Snowmobile . . . . . . . A--43 Controls And Instruments . . . . . . . . A--18 Daily Storage . . . . . . . . . . . . . . . . . . .
WARNING Parents and children need to understand how to operate the 120 XCR safely. Read, understand, and follow all of the safety information in this manual, in the safety video, and all product labels. Failure to follow these safety precautions could result in serious injury or death. Part No. 9915612 PRINTED IN THE U.S.A.
