Polaris 120 PRO R 2013 Owner'S Manual Download Page 4

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For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone 1-888-704-5290
Part No. 9923917 Rev 01
Printed in USA

*9923917 *

Summary of Contents for 120 PRO R 2013

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

Page 2: ...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 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923917 Rev 01 Printed in USA 9923917...

Page 5: ...t POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory Motorcycles Low emission vehicles LEVs We belie...

Page 6: ...etween the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omiss...

Page 7: ...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 8: ...er 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 co...

Page 9: ...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 10: ...hild 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 11: ...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 and...

Page 12: ...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 13: ...ro vided Vehicle Model Number ____________________________________________________ Tunnel VIN _____________________________________________________________ lower right side of the tunnel Engine Serial...

Page 14: ...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 15: ...l 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 is...

Page 16: ...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 17: ...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 18: ...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 abou...

Page 19: ...atched and both screws are tightly installed 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 y...

Page 20: ...H 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 Seat...

Page 21: ...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 22: ...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 23: ...g 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 and screws Always make sure both hood straps are latch...

Page 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...erate 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...

Page 30: ...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 shou...

Page 31: ...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 32: ...mar ginal lubrication and are not recommended Do not operate the snowmo bile with a damaged track TIP Track damage or failure caused by operation under poor lubrication condi tions will void the track...

Page 33: ...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 34: ...o 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 o...

Page 35: ...icates 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 we...

Page 36: ...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 37: ...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 38: ...PORTANT 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 c...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ...41 ADULT SECTION Component Identification Brake Lever Throttle Lever Engine Stop Switch Gas Cap Recoil Starter Handle Choke Knob Hood Hold Down Strap and Screw...

Page 46: ...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 47: ...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 48: ...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 49: ...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 50: ...ide park the snow mobile on a level surface Support the rear with an appropriate track stand The track should be suspended approxi mately 4 10 cm off the ground Cover the snowmobile with an appro pria...

Page 51: ...eral 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 si...

Page 52: ...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 53: ...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 54: ...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 55: ...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 56: ...your snowmo bile 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 Immediate...

Page 57: ...The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjust ments Wet Fouled Plug The wet fouled insulator tip is b...

Page 58: ...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 59: ...ells of the jetting chart on page 81 Higher altitude oper ation may require different adjustment and settings TIP The number stamped in the end of the main jet indicates the jet size that was installe...

Page 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...ter 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 66: ...t 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 Us...

Page 67: ...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 p...

Page 68: ...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 69: ...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 70: ...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 71: ...reakage occurs are shown in the illus tration 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...

Page 72: ...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 73: ...g Adjustment With the handlebars in a straight ahead position and with vehicle weight compressing the suspen sion measure from the straight edge of the skis at the center of the ski mounting bolt The...

Page 74: ...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 75: ...lf 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 approxi mately 6 15 cm o...

Page 76: ...ing illustration indicate lubrication points A grease gun kit complete with grease and adaptors is available to lubricate all fit tings on POLARIS snowmobiles See page 82 for the part numbers of POLAR...

Page 77: ...ols and cables with POLARIS Pre mium 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 78: ...not use a power washer to clean the vehicle TIP If a high pressure car wash is used not recommended grease all zerk fit tings immediately after washing Remove the spindle shafts and lubricate the bus...

Page 79: ...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 80: ...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 recom mended amount TIP Carbon Cle...

Page 81: ...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 82: ...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 83: ...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 84: ...g Engine Model Number EH122PM01D 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 be used in conjuncti...

Page 85: ...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 62 5 60 Pilot Jet 50 50 50 50 45 45 45 45 Clip Pos...

Page 86: ...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 87: ...ontained in 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 fol lowi...

Page 88: ...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 89: ...stration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registrat...

Page 90: ...IS control 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 P...

Page 91: ...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 yo...

Page 92: ...r s manual is highly recommended Should a failure occur dur ing the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts...

Page 93: ...ent or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failu...

Page 94: ...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 95: ...S Customer Assistance and the customs department of the destination country before you move Vehicles importa tion rules vary considerably from country to country You may be required to present documen...

Page 96: ...omponents of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 97: ...by a defect in material or workman ship 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...

Page 98: ...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 99: ...95 MAINTENANCE LOG DATE HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 100: ...rt 50 51 Maintenance Log 94 95 Maintenance Program 12 49 Modifications 11 O Oil Engine 61 62 Operation 43 47 Operation Warnings 29 39 P POLARIS Products 82 Pre Ride Check 19 28 Pre Ride Warm Up 47 R R...

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