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.
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FOREWORD TO PARENTS Thank you for purchasing a Polaris snowmobile and welcome to our world wide family of Polaris enthusiasts. Polaris takes great pride in engineering a product for the youngsters of the sport. Afterall, kids need a Way Out too. Following the instructions and recommendations in this manual will help assure safe and enjoyable operation of your vehicle. Your Owner’s Manual also contains instructions for minor maintenance.
TABLE OF CONTENTS RIDER’S SECTION R--1 - R--14 Understanding Warnings R--1 - R--2 Know Your Machine R--3 - R--7 Pre Operation Check R--8 - R--9 Riding Rules R--10 - R--14 ADULT SECTION Understanding Warnings A--1 - A--77 A--2 - A--3 Safety Decals Pre Operation Check A--7 - A--9 Operation Warnings A--10 - A--21 Preservation of the Environment A--22 - A--23 Identification and Specifications A--24 - A--25 Engine Break-in A--26 - A--27 Operation A--28 - A--36 Maintenance A--37 - A--67
IMPORTANT NOTES FOR OWNERS AND DRIVERS n After you read this manual store it in the vehicle for convenient reference. It should remain with the vehicle 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 further notice. n The drawings and photos used in this manual are general representations. Your model may differ. n Follow the maintenance program outlined in this manual.
IMPORTANT NOTES FOR OWNERS AND DRIVERS PARENTS: Do not allow anyone under the age of 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.
KNOW YOUR MACHINE Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine. 8 7 6 1 2 3 9 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. 3 2 4 5 1 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 7 10 8 9 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. n 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 n 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 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.
RIDING RULES Any operator of this machine must be at least 6 years old. 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.
RIDING RULES " Always wear the right kind of clothing when you are riding your snowmobile. You will need a good helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your clothing fits properly. If it is too small, it could keep you from moving easily. If it is too big, it could hang down and get caught in the track or another moving part. Never, ever wear a long scarf. Wear warm snowmobile boots and gloves. Make sure your boot laces are tied.
RIDING RULES " Always drive your snowmobile while sitting down. Keep both hands on the handlebars and keep both feet on the running boards. " When you are a beginner, always stay on level ground. " Don’t ride your snowmobile on roads or over railroad tracks. Your snowmobile makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. " Fences and snowmobiles don’t mix. Make sure you know where all the fences are before you ride.
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. " 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.
- NOTES - A--1
UNDERSTANDING WARNINGS 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 be at least 6 years old and be aware of the risk involved if these important warnings and cautions are not heeded.
UNDERSTANDING WARNINGS This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved! WARNING Indicates a potential hazard which could result in severe injury or death. CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the machine. CAUTION Indicates a situation that can result in damage to the machine.
UNDERSTANDING WARNINGS 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 DECALS NOTE: Warning decals have been placed on the vehicle for the operator’s protection. Make certain the operator understands the information on all the decals. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.
SAFETY DECALS The information contained in this decal is printed below. S S S S S S S S S A--6 Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from not heeding the warnings. 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. n Check the throttle for proper operation. n Check the throttle safety switch for proper operation. n Check the brake for proper operation. n Make sure the seat is locked into place. n Make sure the track and skis are not frozen to the ground.
PRE OPERATION CHECK Before Starting The Engine 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. 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.
PRE OPERATION CHECK n Check Throttle Safety Switch Test the throttle safety switch B system on a daily basis before the machine is used. While seated in a normal riding position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration (B). Apply a slight amount of throttle opening. A properly functioning switch must shut down the engine.
OPERATION WARNINGS n Single Rider Snowmobiles This snowmobile is designed for a single operator. n Do Not Operate Engine With Intake Silencer Removed CAUTION When operating engine with intake silencer removed, damage to the engine may occur. n Stay Clear of Track WARNING During warm-up and operation, stand clear of the rotating track. Entanglement and serious injury or death may result. Use just enough throttle to rotate the track and warm up the engine.
OPERATION WARNINGS n Do Not Touch the Engine After it Has Been Running WARNING The engine and exhaust become very hot when it is running. Touching the hot engine could cause a severe burn. 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 n Brake Lever Travel Measure the clearance between the lever and brake block. Inspection A 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 A--46.
OPERATION WARNINGS n Be Seated and in Position to Control the Vehicle Improper operator position on the snowmobile can be the source of serious injury. Operating a snowmobile does require skill and balance for proper control, and an improper position can seriously reduce the child’s ability to control the snowmobile.
OPERATION WARNINGS n Always Wear Clothing Designed for Snowmobiling Clothing designed for snowmobiling is warm, comfortable and safe. WARNING Always make sure the operator is wearing an approved helmet and eye protection. Do not allow the child to wear loose clothing or long scarves because they can easily become entangled in moving parts. If your child has long hair, be sure it is always tied up securely and tucked into the helmet or jacket. Be aware of the weather forecast and especially the wind chill.
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 WIND CHILL CHART (°C) Estimated Wind Speed in KPH 5 0 5 0 10 1 20 -4 30 40 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 -9 -16 -24 -32 -39 -47 -53 -61 -69 -76 50 -11 -18 -26 -34 -41 -49 -57 -64 -73 -80 60 -12 -19 -27 -35 -43
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 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.
OPERATION WARNINGS Ice It is dangerous to operate on ice or under slippery conditions. If ice or slippery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction on a slippery surface. The chance of “spin-out” increases under these conditions. Being able to turn a snowmobile depends primarily on the skis being in snow. On hard surfaces, such as ice, the ability to turn is reduced and the machine will not turn very well.
OPERATION WARNINGS Riding Downhill When riding downhill, the operator must keep the speed at a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow use of the engine’s compression to help slow the machine, and keep the snowmobile from rolling freely downhill. 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.
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.
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.
IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature Refer to the illustrations on the following pages. 4 3 5,6 2 7 1 15 17 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 12 Hood Headlight Windshield Handlebar Seat Storage (under seat) Taillight Track Rear Suspension A--24 8 13 12. 13. 14. 15. 16. 17. 18. 16 9 18 Nosepan Trailing Arm Skis Front Bumper Vehicle I.D.
IDENTIFICATION AND SPECIFICATIONS Controls and Instruments 11 1 10 2 3 9 4 7 8 5 6 5 1. Stop Switch (Push/Pull). Operation found on page A--33. 2. Tether Strap 3. Throttle Control 4. Recoil Starter Handle 5. Hood Hold-Down 6. Choke Button 7. Gas Cap 8. Ignition Switch 9. Console 10. Brake Lever 11.
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. 1. Drive slowly at first.
ENGINE BREAK-IN With a basic understanding of how the snowmobile works, and with close attention paid to maintenance tips, you will be ready to ride. Keep in mind these recommendations as well as those covered throughout this manual. CAUTION Use only Polaris Premium 4 All Season synthetic oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
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 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Fuel The fuel used in the Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There is a great deal of variability in the quality of the 87 octane gasoline available across the country.
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 Pre-Starting Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the snowmobile without checking all components to be sure of proper operation. See Operation Warnings beginning on page A--31. Important safety items include, but are not limited to: S Throttle system S Brake system S Steering system These systems must be checked each time before starting the engine.
OPERATION Starting a Warm Engine 1. Turn key to “On”. 2. Pull engine stop switch (shut-off switch) up to “run” position. 3. Grasp starter handle and pull slowly until recoil engages; then pull to start. 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.
OPERATION 4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. 5. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service. If excessive play develops in the throttle cable, the safety switch may be activated, preventing the engine from starting. Contact your dealer. If the engine does not start, and throttle safety switch malfunction is .03 in.
OPERATION Daily Storage Whenever the machine is placed in overnight or daily storage the following steps must be taken: S Park the snowmobile on a level surface and support it at the rear so the track is suspended approximately 4″ (20 cm) from the ground. S Remove the key and cover the machine using the Polaris cover available for your model. See your dealer for more information.
OPERATION Pre-ride Warm-Up The following steps must be taken to ensure proper warm-up 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. WARNING Be sure the rear support is stable. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while performing this procedure.
MAINTENANCE Polaris Recommended 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 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 Check ski skags, replace when worn to 1/2 original diameter Daily A-- 65 Inspect fuel lines, replace if bad Daily A-- 43 Check engine oil level Daily A-- 50 Check track alignment X A-- 57 Check drive chain tension X A-- 48 Check and tighten any loose suspension mounting bolts X A-- 66 Tighten ski saddle and spindle bolts, if loose X A-- 63 Check front & rear limiter strap condition, tighten
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 Spark Plug Selection 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. S Use recommended spark plugs S Proper electrode gap is .025,/0.635mm S Spark plug torque is 18 ft. lbs. (2.5 kg/m) for used plugs and 11 ft. lbs. (1.
MAINTENANCE Wet Fouled The insulator tip is black. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Causes could be 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. Normal deterioration from weather and fuel compounds can occur.
MAINTENANCE Carburetor Adjustments Proper carburetor adjustments include the following: S Carburetor component changes for specific altitude and ambient temperatures; S Choke adjustment; S Air screw settings, if applicable; S Idle RPM adjustments; S Throttle safety switch checks and servicing; S Throttle block to throttle flipper clearance adjustment CAUTION Using lower than the recommended octane fuels or operating with obstructed fuel systems will lead to costly engine damage, which is not covered under
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 Throttle Cable Pivot Slug Lubricate the throttle cable pivot slug (A) every 50 hours or twice a year using and aerosol lubricant. Brake Adjustment If excessive brake lever to brake block clearance is evident, the A 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.
MAINTENANCE Cable and Brake Adjustment 1. Slide the two rubber protector covers (A) back to expose the cable adjuster. 2. Using an 8mm wrench to hold the barrel nut (B), loosen the jam nut (C) with a 10mm Torque wrench. 3. With your left hand, grasp the cables (D) as close to the adjuster as possible. Use your right hand to rotate the barrel nut until you have reached the proper brake lever adjustment. 4.
MAINTENANCE 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--47. Chain Tensioner Inspect the chain. The chain should have 1″ of deflection as shown.
MAINTENANCE Lubrication Points 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: A Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease. B Lubricate Point B every 10 hours of operation with aerosol chain lube or SAE 30 oil. 1. Engine 2. Torque Converter (Centrifugal Clutch) 3. Chain 4. Drive Shaft 5. Track 6.
MAINTENANCE Oil Level Maintain the oil level between the safe marks (A) on the dipstick. A 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 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 LBS1, WD-40, etc. 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.
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 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.
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 NOTE: Measure at the point where the weight is hanging. 4. Check for specified slack between the wear surface of the track clip and the plastic hi-fax (C). 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.
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 1. Safely support the rear of the machine with the track off the ground using a jackstand. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine. 3. Inspect track alignment Rail by looking through the track windows to make sure the rails are evenly Looking through spaced on each side. If track window, make sure the rails the track runs to the left, are evenly spaced Hi-fax loosen left idler wheel on each side.
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. To inspect track rods, carefully examine the track along the entire length of each rod, bending the track and inspecting for breakage. The three most common places where breakage occurs are shown in the illustration.
MAINTENANCE Hi-Fax Replacement The 120 XC SP uses Hi Fax Wear Limit XTRA Lite style Hi-Fax. When any area of the Hi-Fax is 7/16″ (1.1 cm) worn to 7/16″ (1.1 cm), it should be XTRA Lite replaced. This will save wear on other vital components. 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 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.
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 Handlebar Adjustment S S S S S S 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. To adjust, remove the upper flange nut and carriage bolt. Loosen the lower flange nut only enough so the bracket can move freely. Position the handlebar to the desired height and re-install the upper carriage bolt and flange nut. Torque the flange nuts to 15-17 ft. lbs. Reinstall the handlebar pad.
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 Skag 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. Suspension Lubrication 1 2 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 Suspension Lubrication points are indicated by a L. 7 5 9 11 3 1 12 L 8 2 4 1. 3. 5. 7. 9. 11. 13. Front Limiter Strap Torsion Spring Sleeves Torsion Spring Carrier Wheel Rear Limiter Strap Spacer Adjuster Bolts 6 10 13 L 2. 4. 6. 8. 10. 12.
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 Maintenance Items and Accessories The tools and maintenance items mentioned in this book are available at your Polaris dealer as well as a long line of other Polaris accessories. 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 Specifications - 120 XC SP Rider Seating 1 Pilot Jet 50 Dry Weight (lbs.)±4 lbs 140 Air Screw 1.5 Fuel Tank Capacity (Gal) .5 Ignition Type Transistor Height, in. 31 Spark Plug Type BR6ES Length, in. 74 Brake Type Mechanical Band Ski Center Distance, in. 30 Clutch Center Distance 11.75 Width, in. 34 Clutch Type Centrifugal Engine Fuji 4 Stroke 4 hp Track Length, in. 68.04 Alternator Output 12V 50 W Track Width, in.
WIRING DIAGRAM 2001 120 XC SP A--71
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 55430, 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 Accessories . . . . . . . . . . . . . . . . . . . . . A-69 Auto Chain Tensioner . . . . . . . . . . . . . A-48 Brake Adjustment . . . . . . . . . . . . . . . . A-46 Brake Lever Travel . . . . . . . . . . . . . . . A-48 Carburetor Adjustments . . . . . . . . . . . A-44 Carburetor Protection . . . . . . . . . . . . . A-53 Choke and Cable Lubrication . . . . . . . A-45 CLEANING YOUR Snowmobile . . . . A-50 Controls and Instruments . . . . . . . . . . A-25 Daily Storage . . . . . . . . . . . . . . . . . .
