Polaris 120 Pro X Owner'S Manual Download

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ADULT SECTION

Maintenance

Oil Level

Maintain the oil level between the

safe marks (A) on the dipstick.

Oil Change

Change the oil after the initial 20

hours of operation and again after each 50 hours.

Washing 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.
The best and safest way to clean your sled is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots.

NOTE:

warning labels are damaged, contact your a Polaris dealer for free

replacement.
If a high pressure type car wash system is used, extreme care must be

taken to avoid water damage to the hood, console, nosepan, decals, and

warning labels. Many expensive repair bills can result from using high

pressure detergent systems.

NOTE:

If a high pressure car wash is used, grease all zerk fittings

immediately after washing. Also run the vehicle to evaporate any

water that might have entered the engine or exhaust system.

Waxing Your Snowmobile

Your snowmobile can be waxed with any high quality brand of

automotive paste wax. Avoid the use of harsh cleaners since they can

scratch the body finish.

Summary of Contents for 120 Pro X

Page 1: ......

Page 2: ...st from this product contains chemicals known to cause cancer birth defects or other reproductive harm 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 Keep this engine properly tuned and avoid unnecessary idling and spillage ...

Page 3: ...w A Polaris owner s Web site designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustries com owner ...

Page 4: ...duction components some minor discrepancies may result between 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 inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibite...

Page 5: ...Vehicle Identification Numbers 9 Safety 10 YOUTH SECTION 13 Know Your Snowmobile 14 Pre Ride Check 19 Riding Rules 21 ADULT SECTION 25 Pre Ride Check 26 Operation Warnings 30 Component Identification 42 Break In Period 44 Operation 46 Maintenance 51 Accessories 79 Troubleshooting 79 Specifications 80 Polaris Products 82 Warranty 83 Index 89 ...

Page 6: ...s intervals For safe and enjoyable operation of the vehicle be sure to follow all of the instructions and recommendations in this manual A table of Polaris recommended products is provided on page 82 If you have any questions about the snowmobile contact a Polaris dealer for assistance This Owner s Manual contains instructions for minor maintenance but major repairs are covered in the Polaris Serv...

Page 7: ...res that critical components of the snowmobile are inspected by your dealer at specific mileage intervals n A table of Polaris recommended products for your snowmobile is provided on page 82 n You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage n Protect and preserve your right to ri...

Page 8: ...adult use Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded The maximum rider weight capacity is 140 lbs 63 5 kg CHILDREN Before you ride your new Polaris snowmobile there are some important things that you need to know Your safety and the safety of others is the most important thing to think about at all times As the driver of the snowmobile you must learn h...

Page 9: ...with 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 we also ask your help in the effort to further reduce the impact of noise Air Pollution As a part of Polaris plan for the snowmobile s compatibility within the environment our engineers are inve...

Page 10: ...t 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 Teach your child the following Respect your snowmobile respect your environment and you will earn the respect ...

Page 11: ...t in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer Please record your snowmobile identification numbers below for future reference 1 Tunnel VIN lower right side of the tunnel ________________________________________________________________ 2 Engine Serial N...

Page 12: ...nts may result from operation with any modification especially those that increase speed or power There s a significant possibility of loss of control at higher speeds We are concerned for the safety of our customers and for the general public Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury Therefore we strongly r...

Page 13: ...s an adult check major and vital safety components before each use of the vehicle We also recommend that you strictly follow the maintenance schedule outlined in this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at various mileage intervals This snowmobile is not a toy It is a well engineered and well constructed recreational vehicle The i...

Page 14: ...ent will be provided by Polaris at no charge The part number is printed on the decal CAUTION Improper use of this snowmobile or failure to maintain it in good operating condition can result in injury To reduce this possibility read the important safety information on the following decal and make sure all operators and guests are familiar with all warnings cautions and safe operating procedures The...

Page 15: ...ou to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle IMPORTANT IMPORTANT will alert you to importan...

Page 16: ...r thumb You must always make sure the throttle control does not stick before you operate your snowmobile Read more about it on page 19 3 Recoil Starter Handle Pull the recoil starter handle to start your snowmobile An adult will help you start it the first time 4 Choke Knob You may need to use the choke to help start your snowmobile if the engine is cold Read more about it on page 48 Always have a...

Page 17: ...ut the tether strap attached to your right wrist and to your snowmobile Be careful not to let the cord get tangled around the handlebars or any part of your body 8 Tether Strap Switch The tether strap must always be attached snugly to your right wrist and to your snowmobile every time you drive If you fall off your snowmobile the tether strap will pull away from the switch and the engine will stop...

Page 18: ...16 YOUTH SECTION Know Your Snowmobile Let s learn more about the parts of your snowmobile before we talk about riding 1 2 3 4 5 6 9 8 10 7 ...

Page 19: ...r people see where you re riding Your snowmobile is smaller than an adult snowmobile so it s harder to see Never remove the flag from your snowmobile 6 Seat and Storage When the engine isn t running you can take the seat 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 re ridi...

Page 20: ...18 YOUTH SECTION Know Your Snowmobile Let s review the three ways to stop your snowmobile 1 Push the stop switch down 2 Pull off the tether strap 3 Turn the key off 1 2 3 ...

Page 21: ... sticky throttle Never start the engine if you have sticky brakes You could get hurt if you ride with sticky brakes Have an adult or your Polaris dealer fix the brakes before you ride n Make sure the brakes don t stick Squeeze the brake lever toward the handlebar and then let it go It should come right back to where it was before you squeezed it If it goes back slowly or stays close to the handleb...

Page 22: ...and warnings on page 46 in this Owner s Manual n Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running It could burn your skin Children should never check the oil Only an adult should be responsible for keeping the gas and oil levels to the full marks n The last check is done with the engine running Always check to make sure that ALL THRE...

Page 23: ... carry a passenger A passenger will make the snowmobile harder to drive You may lose control and hurt yourself and your passenger Never pull anything behind your snowmobile Make sure you know where you re going to drive when your snow mobile is started Make sure the area is safe all around your snow mobile Never ride alone An adult should always be watching you in case you need help Always drive w...

Page 24: ...ing part Never ever wear a long scarf Wear warm snowmobile boots and gloves and make sure your boot laces are tied If you have long hair be sure to tie it up Learn where there are lakes rivers ponds and ditches in your driv ing 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 re driv...

Page 25: ...me and space to stop your snowmobile Ride your snowmobile only where you know it s safe to drive and where you have per mission to drive Be careful of the things around you Always be a polite driver No driving through the flower gar den or over the little trees you planted Always attach the tether strap to your wrist and machine before riding Both Hands on Handlebars Sit Down Feet on Running Board...

Page 26: ...24 YOUTH SECTION 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 Left Turn Right Turn Stop ...

Page 27: ...eration n Check the brake for proper operation n Check for proper operation of steering system n Check the throttle safety switch for proper operation n Make sure all three ways to stop the engine are functioning n Inspect the track n Make sure the seat is locked into place n Make sure the track and skis are not frozen to the ground n An adult should check the gas and oil levels for the rider and ...

Page 28: ...ttle and brake levers for proper operation before operating the vehicle n Check throttle for proper operation When checking the throttle make sure the control lever compresses evenly and smoothly When the lever is released it should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly do not attempt to start the engine Have the throttle s...

Page 29: ... If excessive play develops in the throttle cable the safety switch may be activated and will prevent the engine from starting If the engine doesn t start and throttle safety switch malfunction is suspected return the machine to an authorized Polaris dealer for service If an adult must start the engine in an emergency situation the throttle safety switch and engine stop switch may be disconnected ...

Page 30: ...me with marginal lubrication could severely damage the track Driving on icy trails or driving when there is little or no snow are two examples of situations that would provide marginal lubrication and are not recommended WARNING Operating the snowmobile with a damaged track will increase the possibility of additional track damage and or failure This could cause loss of control resulting in severe ...

Page 31: ... 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 n Do not operate with drive chain guard removed WARNING The drive chain guard is designed to protect the operator from metal parts in the event of a drive chain failure Although the chance of f...

Page 32: ...ch engine and exhaust parts after the engine has been running 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 ...

Page 33: ...ding in sound emission control and various other func tions Under no circumstances should your snowmobile be operated with the hood open or removed n Test stop switch operation Start the engine and push the stop switch down to test for proper operation The engine should immediately stop running n Test tether switch operation Start the engine and disconnect the tether switch to test for proper oper...

Page 34: ... ability to control the snowmobile The riding position may vary as the operator becomes more 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 Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause s...

Page 35: ...rt the engine to check its operation The same is true of track alignment If the track must be re aligned it is recommended that this service be performed by your dealer 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 ...

Page 36: ...for the protection of all snowmobile riders Most states offer a snowmobile safety course for children Check your state or county agencies for this service This vehicle is intended for daylight use only Check both the headlight and taillight of the machine to ensure proper operation IMPORTANT The headlight and taillight are intended only to increase the visibility of the 120 PRO X during daylight o...

Page 37: ...ad tracks Teach your child what it means to drive defensively Never tailgate and always allow ample stopping distances Your child must be taught to always be alert and pay attention to the driving area ahead When teaching inexperienced operators to ride set up a nearby predetermined course Establish boundaries and make sure the operator s know and understand them Make sure they know how to drive a...

Page 38: ...0 20 10 0 10 20 3 0 4 0 5 0 6 0 5 48 37 27 16 6 5 15 26 3 6 4 7 5 7 6 8 10 40 28 16 4 9 21 33 46 5 8 7 0 8 3 9 5 15 36 22 9 5 18 36 45 58 7 2 8 5 9 9 1 12 20 32 18 4 10 25 39 53 67 8 2 9 6 1 10 1 24 25 30 16 0 15 29 44 59 74 8 8 1 04 1 18 1 33 30 28 13 2 18 33 48 63 79 9 4 1 09 1 25 1 40 35 27 11 4 20 35 49 67 82 9 8 1 13 1 29 1 45 40 26 10 6 21 37 53 69 85 1 00 1 16 1 32 1 48 Wind Speeds Greater ...

Page 39: ... 40 10 1 4 11 16 22 27 33 38 45 50 20 4 9 17 23 29 36 42 48 54 61 30 7 13 21 28 35 42 48 55 63 69 40 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 51 59 66 75 82 70 13 20 28 36 44 52 60 68 76 84 Wind Speeds Greater Than 70 KPH Little Danger For Properly Clothed Person Increasing Danger Great Danger 70 KPH Have Little Added Effect Danger From Freezing of Exposed Fl...

Page 40: ... shifting of the driver s body weight Maximum control will be attained by shifting body weight Maneuverability will change for lighter operators If the machine becomes stuck in snow free the running board area and step down the snow in front of the machine so that when the throttle is opened the machine will be able to climb out The operator can then get back on the machine and continue It is best...

Page 41: ...rn the skis to the left and right If difficulty is encountered check for ice and snow buildup which may be obstructing the steering linkage Hard Packed Snow Teach your child to reduce speed as required to maintain control in all driving conditions If necessary maximum speed may be regulated by using the procedure outlined on page 47 WARNING Steering and braking control are substantially reduced wh...

Page 42: ...e a snowmobile on a frozen body of water You and the driver of the machine should know and understand that severe injury or death can result if the snowmobile and its occupant break through the ice Driving in Hilly Terrain WARNING Traveling on hilly terrain is not recommended It takes some maneuvering of body weight that a child may not be capable of which will leave the child at risk If traveling...

Page 43: ...w 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 Driving Responsibly It is up to you the adult 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 you...

Page 44: ...tification 1 Hood 8 Rear Suspension 2 Headlight 9 Nosepan 3 Windshield 10 Trailing Arm 4 Handlebar 11 Skis 5 Seat 12 Front Bumper 6 Storage under seat 13 Rear Bumper 7 Taillight 14 Snow Flap 8 Track 2 1 3 4 5 6 7 8 9 10 11 12 14 13 8 ...

Page 45: ...ponent Identification 1 Stop Switch 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 Tether Switch 10 8 11 6 3 1 4 7 9 2 5 5 ...

Page 46: ...ver mix brands of oil Serious chemical reactions can cause oil passage blockage resulting in severe engine damage and voiding of engine warranty The only oil recommended for this system is Polaris Premium 4 All Season Synthetic oil This oil has been specially formulated for all temperatures and has extreme cold flow characteristics Do not operate at prolonged full throttle for the first three hour...

Page 47: ...ge the oil if it s become contaminated 1 Remove the dipstick and wipe it dry with a clean shop towel 2 Insert the dipstick A into the oil fill hole then remove it and read the oil level NOTE Do not thread the dipstick into the hole to perform the oil check 3 If the oil level is below the lower level mark B on the dipstick add the recommended oil to the upper mark C NOTE Always use Polaris Premium ...

Page 48: ...soline 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 in your eyes or if you swallow gasoline see your doctor immediately Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death...

Page 49: ...hine without adult supervision Under certain circumstances it may be necessary for an adult to regulate the speed and acceleration of the snowmobile by moving the governor lever spring Use the following procedure to set the performance level CAUTION Hot engine components can cause serious burns to skin Always perform the following procedures when the engine is cool For maximum performance move gov...

Page 50: ... far or allowing it to snap back into the housing will cause damage to the recoil assembly Do not extend the starter rope to its maximum length and do not drop the rope handle during starting 5 If the engine slows or stops position the choke knob half way in to allow proper engine warm up 6 Apply the brakes and vary the engine RPM slightly with the throttle to aid in warm up When the engine idles ...

Page 51: ...gnition circuit All Throttle Safety Switch Interrupts ignition circuit All Choke Floods engine 1 2 throttle or less Brake Slows drive shaft All Daily Storage Whenever the machine is placed in overnight or daily storage the following steps must be taken 1 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 2 Remove the ke...

Page 52: ...up or stand behind it while performing this procedure Do not use too much throttle during warm up or when the track is free hanging 1 Start the engine and allow it to warm up two to three minutes 2 Engage the drive system abruptly and allow it to rotate the track several revolutions NOTE The outside temperature will determine the amount of track warm up required 3 Shut off the engine and remove th...

Page 53: ...n keeping this snowmobile in excellent operating condition at all times The recommended maintenance schedule for your snowmobile calls for a service and maintenance inspection at 50 hours at 100 hours and at 150 hours These inspections should be performed by a qualified service technician NOTE Any replacement parts and labor incurred with the exception of authorized warranty repairs are the respon...

Page 54: ...arts we recommend the use of genuine Polaris parts available from your Polaris dealer ITEM DAILY WEEKLY OR BEFORE EXTENDED PERIOD OF OPERATION 50 HRS 100 HRS 150 HRS SEE PAGE Check brake operation and adjustment X 58 59 Test engine stop switch auxiliary shut off switch X 28 Test throttle safety switch X 27 Test tether switch X 31 Test throttle lever operation X 26 Test brake lever operation X 26 C...

Page 55: ... hi fax thickness replace when worn see dealer X 72 Tighten rear idler wheel bolts if loose X 69 Check spark plug condition X 61 Check for brake cable wear and adjustment X 58 Throttle cable pivot slug X X X 58 Lubricate steering post support bracket and pivot aerosol X X X 63 Grease ski spindles X X X 63 Lubricate ski bushings to spindle area X X X 63 Grease lower steering post pivot X X X 77 Gre...

Page 56: ...ris Servicing Dealer Servicing Technician Date Mileage 100 Hour Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 150 Hour Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Perfo...

Page 57: ...warmed up and the vehicle has been driven Immediately check the spark plug for correct color WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat...

Page 58: ...on after periods of storage Normal deterioration from weather and fuel compounds can occur 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 and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets CAUTION Serious bu...

Page 59: ...n 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 1 Engine 2 Carburetor Correct setup provides engine RPM within its given power band at full throttle settings and also provides maximum efficiency and operation at all other throttle openings See your dealer for carb...

Page 60: ...ttently before turning the machine off This draws moisture out of the choke plunger area and reduces the possibility of the choke becoming frozen Throttle Cable Pivot Slug Lubricate the throttle cable pivot slug A every 50 hours or twice a year using an aerosol lubricant Brake Lever Travel Measure the clearance between the lever and brake block Inspection should be made with the lever firmly depre...

Page 61: ...nch to hold the barrel nut B loosen the jam nut C with a 10mm 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 Check the actuator linkage to ensure there is adequate freedom of movement for positive brake operation and that all floating parts move freely and t...

Page 62: ...he chain tensioner A and raise until 1 B of deflection is attained Tighten nut to 15 18 ft lbs 20 24 Nm When the chain comes within 1 8 C of the muffler mount bracket D on the chassis the chain has stretched and must be replaced Inspect the sprockets as they also become worn and often need replacement when the chain is replaced A D C B ...

Page 63: ...life of the snowmobile s driveline lubricate as follows S Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease S 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 Carburetor 1 2 3 4 5 6 A B ...

Page 64: ... and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your a Polaris dealer for free replacement If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the hood console nosepan decals and warning labels Many expensive repair bills can result from using high pressure...

Page 65: ...ngs with a high quality bearing grease Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with Nyogelt grease and re connect Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust Front Suspension To m...

Page 66: ...ank Follow the instructions on the can Run the engine for five minutes to get additives through the entire fuel system Then top off the tank with fresh fuel NOTE This procedure is performed best when the front of the machine is elevated and the engine is tilted rearward Storage Off season or extended storage of your snowmobile requires you to take preventative measures to aid against deterioration...

Page 67: ...oth Remove the spark plug and pour approximately 5cc of engine oil into cylinder Slowly pull the recoil starter so the engine turns over two or three times Reinstall plug securely Position piston at bottom dead center BDC Observe all fire safety rules when draining carburetor See gasoline warnings on page 46 Slowly pull the recoil starter handle until resistance is felt Leave it in that position C...

Page 68: ... and use from your snowmobile we encourage you to arrange for a fall service tune up with your Polaris dealer He has an experienced and trained service technician who is interested in keeping your machine in peak operating condition Towing Do not use this snowmobile to tow If a situation arises requiring the snowmobile to be towed by another snowmobile attach the tow rope to the spindles not to th...

Page 69: ...anging of the track Track Tension Track adjustment is critical for proper handling Always maintain correct tension and alignment Tension adjustments should be made only after the track is warmed up and limber 1 Turn the machine off 2 Lift the rear of the machine and safely support it off the ground 3 Hang a 10 pound weight A 8 inches from the center of the rear idler wheel The deflection at this p...

Page 70: ...measurement on the other side of the track NOTE Check more frequently when the machine is new 4 Start machine and slowly rotate the track at least five revolutions let the track stop rotating by itself do not apply brakes 5 Check track alignment side to side by comparing the distance from the drive lug to the Hi fax on both sides Readjust until centered 6 Tighten idler shaft bolt 7 Readjust the to...

Page 71: ... to the machine while the track is rotating 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 by looking through the track windows to make sure the rails A are evenly spaced on each side If the track...

Page 72: ...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 WARNING Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious personal inju...

Page 73: ...track and inspecting for breakage The three most common places where breakage occurs are shown in the illustration Check the track clips and tighten if loose If any rod damage is found the track should be replaced WARNING Serious personal injury or death may occur if the snowmobile is operated with a damaged track Broken track rods are a serious hazard since they can cause a rotating track to come...

Page 74: ...laced 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 Take the machine to your dealer for Hi fax replacement 7 16 1 1 cm XTRA Lite ...

Page 75: ... wear indicates insufficient lubrication New hi fax can cause faster heat build up in limited lubrication than used hi fax resulting in excessive wear NOTE Track damage or failure caused by operation on ice or poor lubrication conditions may void the track warranty Steering System WARNING Improper alignment or adjustment may cause loss of steering control resulting in serious injury or death Do no...

Page 76: ... 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 If the skis are misaligned we recommend that your dealer make the necessary adjustments F E D C B A H...

Page 77: ...andlebar pad zippers and roll the pad to the side 7 To adjust remove the upper flange nut and carriage bolt 8 Loosen the lower flange nut only enough so the bracket can move freely 9 Position the handlebar to the desired height and re install the upper carriage bolt and flange nut 10 Torque the flange nuts to 15 17 ft lbs 20 23 Nm 11 Reinstall the handlebar pad ...

Page 78: ...ng and skag chart for recommended skags WARNING Worn skis and or skags will adversely affect handling and can cause loss of vehicle control which can lead to serious injury or death Replace worn skis and or skags when inspection reveals wear Skag Replacement 1 Raise and support the front of the machine so the skis are approximately 6 15 2 cm from the ground 2 Remove the attaching nuts and pry the ...

Page 79: ...mmer storage each year The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts NOTE A grease gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles See page 82 IMPORTANT Make it a weekly practice to check for loose bolts and nuts on the suspension system If any loose bolts are found on the rail be sure to...

Page 80: ...cation points are indicated by a L 1 Front Limiter Strap 8 Rail Bumper 2 Torsion Spring Sleeves 9 Torque Arm 3 Torsion Spring 10 Rail 4 Carrier Wheel 11 Hi fax 5 Rear Limiter Strap 12 Toe Guard 6 Spacer 13 Idler Wheel 7 Adjuster Bolts 4 6 2 1 5 12 11 8 10 9 L L 3 7 13 ...

Page 81: ...llowing chart Engine Turns Over Fails to Start Possible Cause Solution Tether switch not engaged Install tether switch strap Engine stop switch not on Pull stop switch up to RUN position Throttle safety 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 turne...

Page 82: ... 30_ to 50_ F 1_ to 10_C Above 50_F Above 10_C Altitude in Meters F t 0 600 0 2000 75 72 5 72 5 72 5 70 70 Meters Feet 600 1200 2000 4000 75 72 5 72 5 72 5 70 70 1200 1800 4000 6000 72 5 70 70 70 67 5 67 5 1800 2400 6000 8000 70 67 5 67 5 67 5 65 65 2400 3000 8000 10000 67 5 65 65 65 62 5 62 5 3000 3600 10000 12000 65 62 5 62 5 62 5 60 60 ...

Page 83: ...h 40 Suspension Front Type IFS IFS Shock Type Mini Rear Type Mini Indy Engine and Cooling Engine Model Number EH122PM013 Alternator Output 50 watt 3600 rpm Bore x Stroke 60 x 43 mm Displacement 121 cc Carburetor Model Mikuni BV18 Main Jet 72 5 Pilot Jet 50 Cutaway 170 Throttle Valve Fuel Screw 1 5 Turns Pilot Air Jet 1 3 Idle RPM 1600 200 Cooling Air Cylinders 1 Ignition Timing 23_ BTDC 3600 rpm I...

Page 84: ...ease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Additives Miscellaneous 2870791 Fogging Oil 12 oz Aerosol 2871326 Ca...

Page 85: ... 3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 763 417 8650 Canada 1 204 925 7100 Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles i...

Page 86: ... not 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 been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that oc cur during tra...

Page 87: ...st 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 however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polari...

Page 88: ...cuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark ...

Page 89: ...tomatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes S Damage due to accident fire explosion theft or other causes beyond Polaris control S Damage caused by the failure of other com...

Page 90: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 91: ...46 P Paint Codes 79 Pre Ride Warm Up 50 Pre Ride Check 19 20 Preservation of the Environment 7 8 R Riding Rules 21 24 S Safety 10 13 Safety Decals 12 Service and Warranty Information 83 84 Signal words 13 Skag Replacement 76 Ski Skags 76 Spark Plugs 55 56 Specifications 80 81 Speed Regulation 47 Starting a Cold Engine 48 Starting a Warm Engine 48 Starting the Engine 48 Steering Inspection and Adju...

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