Polaris 120 Indy Owner'S Manual Download Page 84

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

2870791

Fogging Oil (Aerosol)

2874865

Performance Synthetic 4-Stroke (PS-4) Oil (qt./.95 l)

2874866

Performance Synthetic 4-Stroke (PS-4) Oil (gal./3.8 l)

2876244

Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt./.95 l)

2876245

Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal./3.8 l)

Gearcase/Transmission Lubricants

2873602

Premium Synthetic Gearcase Lubricant (qt./.95 l)

2871653

Premium Front Gearcase Fluid (8 oz./.24 l)

2871654

Premium Demand Drive Hub Fluid (8 oz./.24 l)

Grease/Specialized Lubricants

2871312

Grease Gun Kit, Premium All Season (3 oz./89 ml)

2871322

Premium All Season Grease (3 oz./89 ml cartridge)

2871423

Premium All Season Grease (14 oz./414 ml cartridge)

2871329

Dielectric Grease (Nyogel™)

Additives/Miscellaneous

2871326

Carbon Clean Plus

2870652

Fuel Stabilizer

2872893

Engine Degreaser

2870505

Isopropyl

Summary of Contents for 120 Indy

Page 1: ...Snowmobile Owner s Manual for Maintenance and Safety 120 INDY...

Page 2: ...e safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other rep...

Page 3: ...recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pr...

Page 4: ...the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or...

Page 5: ...s 9 Safety 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 Operati...

Page 6: ...g winter sport of snowmobiling please be sure he she understands this information before riding the snowmobile Never allow a child to operate the snowmobile without adult supervision This owner s manu...

Page 7: ...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 8: ...ild 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 t...

Page 9: ...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 10: ...ms 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 enco...

Page 11: ...the tunnel wrap doesn t provide an opening for these labels remove the section of wrap where the labels are located Vehicle Model Number ____________________________________________________ Tunnel VIN...

Page 12: ...ation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicat...

Page 13: ...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 14: ...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 components before each use of the vehicle We also recommend...

Page 15: ...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 co...

Page 16: ...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 17: ...are latched properly before you start the engine Tether Strap Switch Always attach the tether strap to your body and to the switch on your snowmobile every time you drive If you fall off your snowmobi...

Page 18: ...w 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 Front Bumper Seat...

Page 19: ...can take the seat cushion off and put things under the seat Push the two seat latches in and pull the seat up to remove it Always put the seat back on and make sure the latches are locked in place be...

Page 20: ...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 21: ...means that something is wrong or broken Seat Latches Check the seat latches Make sure they are latched tightly Hood Hold Down Straps Check the hood hold down straps Always make sure both hood straps a...

Page 22: ...e 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 2 Ways to STOP Always check to make sure that BOTH WAYS TO STOP are wor...

Page 23: ...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 a...

Page 24: ...carf 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 ditch...

Page 25: ...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 26: ...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 snowmobile Read and understand your Owner s Manual Left T...

Page 27: ...rate the snowmobile WARNING Serious injury or death could result if the vehicle is not inspected properly before operation Teach all operators to perform the following Pre Ride Check before each use o...

Page 28: ...y do not start the engine Have the throttle serviced before operating the snowmobile Check the brake for proper operation Squeeze the brake lever toward the handlebar When the lever is released it sho...

Page 29: ...g 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 v...

Page 30: ...e marginal lubrication and are not recommended Do not operate the snowmobile with a damaged track TIP Track damage or failure caused by operation under poor lubrication conditions will void the track...

Page 31: ...ar of track Do not operate with drive chain guard removed WARNING During warm up and operation stand clear of the rotating track Entanglement and serious injury or death may result Use just enough thr...

Page 32: ...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 physical skills Persons with cognitive o...

Page 33: ...cates a need to adjust the brake cable Refer to the mechanical brake adjustment information on page 56 Secure the hood The hood of the snowmobile protects the operator from moving and hot parts as wel...

Page 34: ...e 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 snowm...

Page 35: ...dards 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 su...

Page 36: ...PORTANT The headlight and taillight are intended only to increase the visibility of the snowmobile during daylight operation Do not operate this snowmobile in the dark WARNING The snowmobile engine co...

Page 37: ...owmobile 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 38: ...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 39: ...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 40: ...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 41: ...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 5...

Page 42: ...40 ADULT SECTION Component Identification Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Track Taillight Nosepan Front Bumper Rear Suspension Trailing Arm Rear Bumper...

Page 43: ...41 ADULT SECTION Component Identification Brake Lever Throttle Lever Engine Stop Switch Hood Hold Down Strap Gas Cap Recoil Starter Handle Choke Knob...

Page 44: ...p during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds during the first three hours of use 1 Fill the fuel tank with gasoline...

Page 45: ...e 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...

Page 46: ...er allow the child to operate this vehicle 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 47: ...coil engages then pull abruptly to start the engine NOTICE Extending the starter rope too far or allowing it to snap back into the housing will cause damage to the recoil assembly Do not extend the st...

Page 48: ...ride park the snowmobile on a level surface Support the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Cover the snowmobile with an appropriate...

Page 49: ...veral revolutions TIP 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 50: ...h a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications...

Page 51: ...with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in perf...

Page 52: ...e stop switch 14 20 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 53: ...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 Throttl...

Page 54: ...our snowmobile Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven Immediately...

Page 55: ...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 bl...

Page 56: ...ce any worn or damaged components Exhaust System At approximately 50 hours check the exhaust system for wear or damage To inspect allow the engine and exhaust system to cool completely Open the hood a...

Page 57: ...d by the shaded cells of the jetting chart on page 81 Higher altitude operation may require different adjustment and settings TIP The number stamped in the end of the main jet indicates the jet size t...

Page 58: ...n 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 59: ...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 60: ...n 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...

Page 61: ...sioner 2 Raise the tensioner until the correct deflection is attained 3 Tighten the nut to 15 18 ft lbs 20 24 Nm TIP When the chain has stretched to within 1 8 3 mm of the muffler mount bracket on the...

Page 62: ...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 ae...

Page 63: ...fter 20 hours of operation Always change the oil any time it s contaminated with water fuel or debris NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the...

Page 64: ...it dry with a clean shop towel TIP The oil will drain faster with the dipstick removed 5 Allow the oil to drain completely 6 Reinstall the drain plug and sealing washer Torque to 10 ft lbs 13 5 Nm 7 U...

Page 65: ...inches 20 cm from the center of the rear idler wheel 5 Measure the distance between wear surface of the track clip and the plastic slider at the point where the weight is hanging Deflection at this po...

Page 66: ...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 67: ...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 68: ...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 69: ...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 TIP This snowmobile track has molded in track clips It i...

Page 70: ...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 ca...

Page 71: ...ustment 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 bolt The measur...

Page 72: ...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 73: ...alf their original diameter TIP See the dealer track studding and skag chart for recommended skags Skag Replacement 1 Raise and support the front of the machine so the skis are approximately 6 15 cm o...

Page 74: ...g illustration indicate lubrication points A grease gun kit complete with grease and adaptors is available to lubricate all fittings on POLARIS snowmobiles See page 82 for the part numbers of POLARIS...

Page 75: ...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 bearing...

Page 76: ...o not use a power washer to clean the vehicle TIP If a high pressure car wash is used not recommended grease all zerk fittings immediately after washing Remove the spindle shafts and lubricate the bus...

Page 77: ...e 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 pull the recoi...

Page 78: ...IS 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 TIP Carbon Cle...

Page 79: ...e 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...

Page 80: ...rmance from your 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 snowmobi...

Page 81: ...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 82: ...1G Alternator Output 50 watt 3600 RPM Bore x Stroke 60 x 43 mm Displacement 121 cc Carburetor Throttle Body 1 Mikuni Tamperproofed NOTE These carburetor settings are to be used in conjunction with the...

Page 83: ...A N A 1200 1800 4000 6000 Main Jet 67 5 67 5 67 5 65 65 65 62 5 62 5 Pilot Jet 50 50 50 50 50 45 45 45 Clip Position N A N A N A N A N A N A N A N A 1800 2400 6000 8000 Main Jet 65 65 65 65 65 62 5 6...

Page 84: ...earcase Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant qt 95 l 2871653 Premium Front Gearcase Fluid 8 oz 24 l 2871654 Premium Demand Drive Hub Fluid 8 oz 24 l Grease Specialized...

Page 85: ...this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following informati...

Page 86: ...by POLARIS including but not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract See your dealer for details and separate terms and conditions for any...

Page 87: ...components use of aftermarket components unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial pur...

Page 88: ...VAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IM...

Page 89: ...e selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another count...

Page 90: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Page 91: ...mponents of systems if their only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This Emissions Limited...

Page 92: ...or workmanship This Limited Warranty does not cover damage due to accidents abuse or improper handling maintenance or use This Limited Warranty also does not cover any engine that has been structurall...

Page 93: ...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 94: ...92 MAINTENANCE LOG DATE HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 95: ...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 Down Straps...

Page 96: ...pension 77 Suspension Components 72 Suspension Lubrication 72 Switches Engine Stop Switch 14 Tether Strap Switch 15 Throttle Safety Switch 27 T Tether Strap Switch 15 Throttle Cable Lubrication 58 Thr...

Page 97: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9926031 Rev 01 Printed in USA...

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