Polaris 120 2008 Owner'S Manual Download

Page: 63 / 100

ADULT SECTION

Maintenance

Driveline Lubrication

NOTE:

Driveline noise is normal for this vehicle.

To ensure long life of the snowmobile's driveline, lubricate as follows:
• Lubricate Point A every 15 hours of operation with a small amount of

Polaris Premium All Season Grease.

• Lubricate Point B every 10 hours of operation with aerosol chain lube

or SAE 30 oil.

Carburetor

Track

Drive Shaft

Chain

Point B

Point A

Torque Converter

(Centrifugal Clutch)

Engine

Summary of Contents for 120 2008

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Page 3: ...ns in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to th...

Page 4: ...ll terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many ye...

Page 5: ...r sport of snowmobiling please be sure he she understands this information before riding the snowmobile Never allow a child to operate the snowmobile without adult supervi sion This Owner s Manual con...

Page 6: ...the information in your owner s manual Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others...

Page 7: ...nd quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication...

Page 8: ...afety 10 Youth Section 14 Know Your Snowmobile 14 Pre Ride Check 19 Riding Rules 21 Adult Section 25 Pre Ride Check 25 Operation Warnings 29 Component Identification 40 Break In Period 42 Operation 43...

Page 9: ...child to operate this machine without adult supervision These units are not designed for adult use Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded Never exceed...

Page 10: ...concern for others As a snowmobile operator you may not realize the sound of your snowmobile may annoy non snowmobilers We are attempting to do our part through the manufacture of quieter machines an...

Page 11: ...also encourage protec tion 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 th...

Page 12: ...ro vided Vehicle Model Number ____________________________________________________ Tunnel VIN _____________________________________________________________ lower right side of the tunnel Engine Serial...

Page 13: ...on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety al...

Page 14: ...ll on a Polaris snowmobile any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your Polaris snowmobile i...

Page 15: ...le is in excellent operating condition at all times We strongly recommend that the operator as well as an adult check major and vital safety com ponents before each use of the vehicle We also recommen...

Page 16: ...this vehicle without guards and shields in position or with hood not latched in place This vehicle is intended for one operator only no passenger Passengers cargo or towed objects can cause loss of c...

Page 17: ...again Throttle Lever The throttle lever makes your snowmobile go forward when you press it with your thumb Before you drive your snowmobile always make sure the throttle lever does not stick Read more...

Page 18: ...are latched before you start the engine Tether Strap Switch Always attach the tether strap to your body and to the switch on your snow mobile every time you drive If you fall off your snowmobile the t...

Page 19: ...6 YOUTH SECTION Know Your Snowmobile Let s learn more about the parts of your snowmobile before we learn about riding Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Track Taillight...

Page 20: ...dlebar the skis turn in the same direction Seat and Storage When the engine is stopped you can take the seat cushion off and put things under the seat in the special compartment Taillight The tailligh...

Page 21: ...18 YOUTH SECTION Know Your Snowmobile Let s review the 2 ways to stop your snowmobile STOP Push the stop switch down Pull the strap off the tether switch...

Page 22: ...sticky brake lever This means that something is wrong or broken n Seat Latches Check the seat latches Make sure they are latched tightly n Hood Hold Down Straps Check the hood hold down straps Make su...

Page 23: ...ne is very hot after it has been running It could burn your skin Children should never check the oil Always have an adult do this n 2 Ways to STOP Always check to make sure that BOTH WAYS TO STOP are...

Page 24: ...pull anything behind your snowmobile Make sure you know where you re going to drive before you start the engine Make sure the area is safe all around your snowmobile Never ride alone An adult should...

Page 25: ...scarf Wear warm snowmobile boots and gloves and make sure your boot laces are tied If you have long hair tie it up or put it inside your helmet or jacket Learn if there are lakes rivers ponds and ditc...

Page 26: ...ile only where you know it s safe to drive and where you have permission to drive Always be a polite driver Don t drive through the flower garden or over small trees Always attach the tether strap to...

Page 27: ...ing Rules Learn how to use your hands and arms as signals Use these signals to let others know when you are getting ready to turn or stop your snow mobile Read and understand your Owner s Manual Left...

Page 28: ...ly n Start the engine and disconnect the tether switch to test for proper operation The engine should stop immediately n Inspect the track See page 28 n Make sure the seat is securely attached n Make...

Page 29: ...do not start the engine Have the throttle serviced before operating the snowmobile n Check the brake for proper operation Squeeze the brake lever toward the handlebar When the lever is released it sh...

Page 30: ...ng A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or...

Page 31: ...mar ginal lubrication and are not recommended Do not operate the snowmo bile with a damaged track NOTE Track damage or failure caused by operation under poor lubrication conditions will void the trac...

Page 32: ...cur Do not operate the engine with the intake silencer removed WARNING During warm up and operation stand clear of the rotating track Entanglement and serious injury or death may result Use just enoug...

Page 33: ...to skin Do not touch engine and exhaust parts after the engine has been running WARNING Safe operation of this rider active vehicle requires good judgement and physi cal skills Persons with cognitive...

Page 34: ...cates a need to adjust the brake cable Refer to the mechanical brake adjustment information on page 56 n Secure the hood The hood of the snowmobile protects the operator from moving and hot parts as w...

Page 35: ...ore skilled but under most conditions the proper position is to be seated with both feet on the running boards in a comfortable position for proper throttle brake and steering control WARNING This sno...

Page 36: ...ndards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle s...

Page 37: ...IMPORTANT The headlight and taillight are intended only to increase the visibility of the snowmobile during daylight operation Do not oper ate this snowmobile in the dark WARNING The snowmobile engine...

Page 38: ...wmobile and through a helmet Teach the operator that the sound of the engine will make it difficult to hear the sound of approaching vehicles Do not allow a child to operate the snowmobile on or near...

Page 39: ...lly to move the snowmobile Teach operators not to be afraid of applying extra throttle in this situation but make sure they understand that too much throttle could cause the snowmobile to lurch forwar...

Page 40: ...ard surfaces hard packed snow or icy surfaces Teach your child to reduce speed to maintain control in all driving conditions If necessary limit the maximum speed of the snowmobile as outlined on page...

Page 41: ...the throttle as needed to prevent the track from slipping on the snow 3 Slow down at the crest of the hill Be prepared to avoid obstacles sharp drops or other people or vehicles that may be on the ot...

Page 42: ...79 86 93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min...

Page 43: ...40 ADULT SECTION Component Identification Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Track Taillight Rear Suspension Nosepan Trailing Arm Front Bumper Rear Bumper...

Page 44: ...41 ADULT SECTION Component Identification Gas Cap Recoil Starter Handle Brake Lever Throttle Lever Engine Stop Switch Choke Knob Hood Hold Down Strap...

Page 45: ...oline 2 Check the oil level See page 61 3 Drive slowly at first Select an area that s open and will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions...

Page 46: ...gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing If you get gasoline i...

Page 47: ...r allow the child to operate this vehi cle without adult supervision You can regulate the speed and acceleration of the snowmobile Move the governor spring to hole 3 for maximum performance highest av...

Page 48: ...oil engages then pull abruptly to start the engine 4 If the engine slows or stops position the choke knob half way in 5 Apply the brakes and vary the engine RPM slightly with the throttle to aid in wa...

Page 49: ...ide park the snow mobile on a level surface Support the rear with an appropriate track stand The track should be suspended approxi mately 4I 10 cm off the ground Cover the snowmobile with an appro pri...

Page 50: ...eral revolutions NOTE In colder weather the track will need a few more revolutions to fully warm it 3 Stop the engine Remove the rear support 4 Grasp the skis by their front loops and move them from s...

Page 51: ...sion control system designation per SAE J1930 is EM If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a quali fied dealer for diagnostic service...

Page 52: ...ith the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in perf...

Page 53: ...e stop switch 20 25 X Test throttle safety switch 27 X Test tether switch 20 X Test throttle lever operation 19 26 X Test brake lever operation 19 X Check brake operation and adjustment 56 X Check ste...

Page 54: ...tighten loose bolts X Check slider thickness replace when worn see dealer 68 X Tighten rear idler wheel bolts if loose X Check spark plug condition 52 X Check for brake cable wear and adjustment 56 X...

Page 55: ...ne has been warmed up and the vehicle has been driven Immediately check the spark plug for correct color Spark Plug Removal and Replacement 1 Stop the engine 2 Remove the spark plug cap 3 Using the sp...

Page 56: ...E The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Plug The wet fouled insulator tip is b...

Page 57: ...d components Exhaust System At approximately 50 hours check the exhaust system for wear or dam age To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffl...

Page 58: ...umber stamped in the end of the main jet indicates the jet size that was installed at the time of manufacture For questions about optional jetting for conditions in your area see your Polaris dealer C...

Page 59: ...of a new band 1 Slide the two rubber protector covers back to expose the cable adjuster 2 Using an 8mm wrench to hold the barrel nut loosen the jam nut with a 10mm wrench 3 With your left hand grasp...

Page 60: ...at all parts are mounted securely Tighten hardware as required 5 Tighten the adjuster jam nut and slide the rubber protectors onto the adjuster 6 The brake band is adjusted correctly when brake lever...

Page 61: ...Grease Choke Cable Lubrication Lubricate the choke slide and cables occasionally as shown Operate the choke intermittently before turning the engine off This draws moisture out of the choke plunger a...

Page 62: ...sioner 2 Raise the tensioner until the correct deflection is attained 3 Tighten the nut to 15 18 ft lbs 20 24 Nm NOTE When the chain has stretched to within 1 8 3 mm of the muffler mount bracket on th...

Page 63: ...snowmobile s driveline lubricate as follows Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease Lubricate Point B every 10 hours of operation with a...

Page 64: ...ter 20 hours of operation Always change the oil any time it s contaminated with water fuel or debris Oil Level Maintain the oil level between the upper and lower marks on the dip stick 1 Position the...

Page 65: ...ick and wipe it dry with a clean shop towel NOTE The oil will drain faster with the dipstick removed 5 Allow the oil to drain completely 6 Reinstall the drain plug and sealing washer 7 Using a long fu...

Page 66: ...htly off the ground with an appropriate snow mobile support 4 Hang a 10 pound 4 5 kg weight 8 inches 20 cm from the center of the rear idler wheel 5 Measure the distance between wear surface of the tr...

Page 67: ...to stop rotating by itself do not apply brakes 5 Check and adjust track alignment See page 65 6 Tighten the idler shaft bolt Torque to 35 40 ft lbs 47 54 Nm 7 Readjust the toe block to proper spacing...

Page 68: ...are evenly spaced on each side If the track runs to the left loosen the left idler wheel mounting bolt and tighten the left track adjusting bolt If the track runs to the right loosen the right idler...

Page 69: ...with an appropriate snowmobile support 2 Start the engine 3 Abruptly engage the clutch allowing the track to turn for several revolutions 4 Release the throttle and apply the brakes 5 Stop the engine...

Page 70: ...reakage occurs are shown in the illustration 4 Check the track clips and tighten any loose clips If any rod damage is found install a new track NOTE This snowmobile track has molded in track clips It...

Page 71: ...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 A new slider can c...

Page 72: ...ns Steering Adjustment With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting...

Page 73: ...bar pad zippers and roll the pad to the side 2 Remove the upper flange nut and carriage bolt 3 Loosen the lower flange nut only enough so the bracket can move freely 4 Position the handlebar to the de...

Page 74: ...kags Skag Replacement 1 Raise and support the front of the machine so the skis are approxi mately 6 15 cm off the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the forward port...

Page 75: ...ing illustration indicate lubrication points A grease gun kit complete with grease and adaptors is available to lubri cate all fittings on Polaris snowmobiles See page 82 for the part num bers of Pola...

Page 76: ...rols and cables with Polaris Premium All Season Grease Force a small amount of lubricant down the cable See page 58 Bearings Always grease drive shaft clutch side bearings with a high quality bear ing...

Page 77: ...ely after washing Remove the spindle shafts and lubricate the bushings on the top and bottom of the trailing arm Also run the vehicle to evaporate any water that might have entered the engine or exhau...

Page 78: ...c 0W40 engine oil into the cylinder 6 Slowly pull the recoil starter to turn the engine over two or three times 7 Reinstall the spark plug 8 Rotate the piston to bottom dead center BDC and 9 Slowly pu...

Page 79: ...s products 1 Fill the fuel tank with fresh fuel 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Cle...

Page 80: ...the front end of the machine and place blocks securely under it to remove tension from the shocks and springs This will minimize fatigue on the front shocks and springs Storage Area Your snowmobile s...

Page 81: ...r snowmobile we encourage you to arrange for a fall service tune up with your Polaris dealer Towing Do not pull or tow any person or object behind this snowmobile If a disabled snowmobile must be towe...

Page 82: ...afety switch malfunction See your Polaris dealer Out of fuel Refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is of...

Page 83: ...dy Engine and Cooling Engine Model Number EH122PM018 Alternator Output 50 watt 3600 rpm Bore x Stroke 60 x 43 mm Displacement 121 cc Carburetor Model Mikuni BV18 NOTE These carburetor settings are to...

Page 84: ...lot jet is the second number in italics 0 600 0 2000 72 5 55 72 5 55 70 50 70 50 70 50 67 5 50 67 5 45 67 5 45 600 1200 2000 4000 70 50 70 50 70 50 67 5 50 67 5 50 67 5 50 65 45 65 45 1200 1800 4000 6...

Page 85: ...ium Front Gearcase Fluid 8 oz 2871654 Premium Demand 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...

Page 86: ...tained in this manual Your dealer is also familiar with Polaris policies and pro cedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowi...

Page 87: ...owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the mode...

Page 88: ...ot caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has...

Page 89: ...present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer...

Page 90: ...verage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress he...

Page 91: ...omatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions Each repair vis...

Page 92: ...to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of una...

Page 93: ...have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bu...

Page 94: ...Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu ment...

Page 95: ...des compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection components exhaust g...

Page 96: ...s beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical...

Page 97: ...your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE HOURS TECHNI...

Page 98: ...95 MAINTENANCE LOG DATE HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 99: ...2 93 Engine Oil 61 62 Engine Starting 45 Engine Stop Switch 14 Environment 7 8 Exhaust System 54 F Fall Tune Up 78 Fuel 43 Fuel Lines 54 Fuel Valve 54 G Gas Cap 15 H Handlebar Adjustment 70 Hood Hold...

Page 100: ...ing 18 Stopping Procedures 46 Storage 46 75 77 Engine Fogging 75 Stabilize the Fuel 76 Storage Area 77 Track and Suspension 77 Suspension Components 72 Suspension Lubrication 72 T Tether Strap Switch...

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Polaris 120 2008, Owner'S Manual

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Summary of Contents for 120 2008

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