Polaris 120 XC SP Universal Owner'S Safety And Maintenance Manual Download

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A--63

MAINTENANCE

Steering Inspection and Adjustment

The steering assembly of the

machine should be checked

periodically for loose nuts and

bolts. See A,B,C,D,E, F, and

G in illustration at right.
With handlebars in straight

ahead position and measuring

from the straight edge of the

skis, the measurement

between the skis at point H

should be 1/8 inches greater

than point I, as shown on the

following page.

NOTE:

This

measurement should be taken

with the vehicle weight

compressing the suspension.

If the skis are misaligned, we

recommend that your dealer

make the necessary

adjustments.

D
C

Summary of Contents for 120 XC SP

Page 1: ......

Page 2: ...haust 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 k...

Page 3: ...now Our new web site It s 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...

Page 4: ...y Certified MSD Master Service Dealer Technician Before the snowmobile is used take a few minutes to read through this manual and familiarize yourself and your child with maintenance and operation pro...

Page 5: ...A 3 Safety Decals Pre Operation Check A 7 A 9 Operation Warnings A 10 A 21 Preservation of the Environment A 22 A 23 Identification and Specifications A 24 A 25 Engine Break in A 26 A 27 Operation A 2...

Page 6: ...cted by your dealer at various mileage intervals 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 insure...

Page 7: ...olaris snowmobile there are some important things you should know How to keep safe is the most important thing You must also learn some things that will keep you and those around you safe while you ar...

Page 8: ...hen you press it with your thumb You must always make sure the throttle control does not stick before you operate your snowmobile Read more about it on page R 11 3 Recoil Starter Handle Pull this to s...

Page 9: ...l pull off the switch and the engine will stop Put one end of the tether strap around your wrist The other end must be attached to the snowmobile Always attach the tether strap before you ride 9 Hood...

Page 10: ...eheadlight is always on when theengine is running It helps others see you when you are riding 3 Windshield Always keep your windshield clean to help you see where you are driving 4 Handlebar The handl...

Page 11: ...hen you are riding 8 Snow Flap The snow flap keeps snow ice or other things from flying out behind your snowmobile 9 Track The engine makes the track turn The turning track makes your snowmobile go fo...

Page 12: ...ee ways to stop your snowmobile 1 Pushing down on the engine stop switch on the right handlebar control will shut off the engine 2 Disconnecting the tether strap will shut off the engine 3 Turning the...

Page 13: ...a sticky throttle This means that something is wrong or broken n Make sure the brakes don t stick Check the brake lever by squeezing the lever toward the handlebar and then letting it go It should co...

Page 14: ...A 30 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 you Children should never check the oil o...

Page 15: ...is made for one person Never 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 snowmobil...

Page 16: ...eep you from moving easily If it is too big it could hang down and get caught in the track or another moving part Never ever wear a long scarf Wear warm snowmobile boots and gloves Make sure your boot...

Page 17: ...railroad tracks Your snowmobile makes noise that will keep you from hearing cars trucks or trains that may be coming towards you Fences and snowmobiles don t mix Make sure you know where all the fence...

Page 18: ...nd them because you don t know what they re going to do Never follow another snowmobile too closely Always allow lots of time and space to stop your snowmobile Only ride your snowmobile where you know...

Page 19: ...R 14 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 20: ...A 1 NOTES...

Page 21: ...his manual to convey the following messages It is very important this owner s manual is read and thoroughly explained to each operator s of this machine The operator s should be at least 6 years old a...

Page 22: ...rt you to important information or instructions CAUTION This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your sa...

Page 23: ...any equipment which is intended to increase the speed or power of the machine or make any other modifications to the machines for these purposes Any modifications to the original equipment or the snow...

Page 24: ...d on the decal CAUTION Although your Polaris has been designed to provide operators with a safe reliable snowmobile much of its safety depends on the operator and parents Improper use of this snowmobi...

Page 25: ...can cause loss of con trol S Verify proper operation of all controls before starting the en gine S When operating this vehicle the operator shall wear suitable protective clothing including an approve...

Page 26: ...r operation 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 add more if necessary...

Page 27: ...ing to your machine as well as safe operating procedures We have attempted to provide you with as much information as possible to alert you to the safety requirements of snowmobiling n Check Throttle...

Page 28: ...f the steering system by manually turning the skis completely to the right and to the left If difficulty is encountered check for ice and snow buildup which may be obstructing the steering linkage Mak...

Page 29: ...o the engine may occur CAUTION 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...

Page 30: ...t is running Touching the hot engine could cause a severe burn WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabi...

Page 31: ...be operated with the hood open or removed n Engine Stop Switch Check engine stop switch for proper operation Push down to stop engine Pull up to release and start engine n Tether Switch Check tether s...

Page 32: ...the track Teach your child to respect this machine and all the moving parts Stress that being properly seated keeps the child clear of the track n Stop Engine Before Attempting Adjustments Never hold...

Page 33: ...ice 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...

Page 34: ...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 W...

Page 35: ...0 40 30 20 10 0 10 20 30 40 50 60 5 48 37 27 16 6 5 15 26 36 47 57 68 10 40 28 16 4 9 21 33 46 58 70 83 95 15 36 22 9 5 18 36 45 58 72 85 99 112 20 32 18 4 10 25 39 53 67 82 96 110 124 25 30 16 0 15 2...

Page 36: ...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...

Page 37: ...ting 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...

Page 38: ...ed by using the procedure outlined on page A 31 Before allowing your child to drive the machine be sure that ice and snow are not interfering with the steering Manually turn the skis to the left and r...

Page 39: ...wmobile 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 Hilly Ter...

Page 40: ...chine and keep the snowmobile from rolling freely downhill Responsible Driving It is up to you the parent to teach your child the proper and safe way to ride a snowmobile You must set boundaries and a...

Page 41: ...oncern 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 42: ...rous 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...

Page 43: ...s on the following pages 1 Hood 12 Nosepan 2 Headlight 13 Trailing Arm 3 Windshield 14 Skis 4 Handlebar 15 Front Bumper 5 Seat 16 Vehicle I D Number Right Side 6 Storage under seat 17 Rear Bumper 7 Ta...

Page 44: ...Instruments 1 Stop Switch Push Pull Operation found on page A 33 2 Tether Strap 3 Throttle Control 4 Recoil Starter Handle 5 Hood Hold Down 6 Choke Button 7 Gas Cap 8 Ignition Switch 9 Console 10 Bra...

Page 45: ...f 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 Seaso...

Page 46: ...S If theoil level is belowthe lowerlev el line B on the dipstick you must add oil to the upper level C of the dipstick Use the table to determine the proper oil S Change the oil if it is contaminated...

Page 47: ...it can foul plugs and cause generally poor engine performance All carburetors have been pre set at the factory for adequate fuel supply Higher altitude operation may require different adjustment and...

Page 48: ...n your eyes or if you swallow gasoline see your doctor immediately S If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the en...

Page 49: ...to run on 87 octane non oxygenated or 89 octane oxygenated pump gasoline There is a great deal of variability in the quality of the 87 octane gasoline available across the country We encourage the us...

Page 50: ...n Under certain circumstances it may be necessary for an adult to regulate the speed and acceleration potential of the snowmobile Moving the governor lever spring is the adjustment used to control per...

Page 51: ...and or damage to the snowmobile Starting a Cold Engine 1 Turn key to On 2 Pull engine stop switch shut off switch up to run position 3 Pull the choke lever outward to Full On position 4 Grasp starter...

Page 52: ...tch Test the throttle safety switch system on a daily basis before the machine is used While seated in a normal riding position and with the engine idling hold the throttle lever pin stationary by exe...

Page 53: ...the wire harness Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emergency SYSTEM WHAT IT DOES THROTTLE CONDITION Engine Stop Switch Interrup...

Page 54: ...he following steps must be taken S Park the snowmobile on a level surface and support it at the rear so the track is suspended approximately 4 20 cm from the ground S Remove the key and cover the mach...

Page 55: ...This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily 5 The engine drive system and track are now properly warmed up and the machine can be driven followin...

Page 56: ...obile in excellent operating condition at all times The recommended maintenance schedule on this snowmobile calls for a service and maintenance inspection at 50 hours at 100 hours and at 150 hours The...

Page 57: ...conditions You may need to increase frequency based on riding conditions Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer ITEM W...

Page 58: ...limiter strap condition tighten loose bolts X A 67 Check hi fax thickness replace when worn Dealer X A 61 Tighten rear idler wheel bolts if loose X A 57 Check spark plug condition X A 42 Check for br...

Page 59: ...cing Dealer Servicing Technician Date Mileage 100 Hour Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 150 Hour Maintenance Inspection Authorized Polaris S...

Page 60: ...sume that the engine is going to operated under extreme heavy duty conditions This protects the engine from internal damage in the event that the purchaser actually does operate the engine in this man...

Page 61: ...ug to appear to be too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carburetor s The spark plug and its condition is indicative of...

Page 62: ...age Normal deterioration from weather and fuel compounds can occur General Carburetor Information The number size stamped in the end of the main jet indicates the jet size which was installed at the t...

Page 63: ...adjustment S Air screw settings if applicable S Idle RPM adjustments S Throttle safety switch checks and servicing S Throttle block to throttle flipper clearance adjustment Using lower than the recom...

Page 64: ...cable occasionally Turn the handlebars to the left and lubricate liberally as shown using LBS1 WD 40 etc Choke and Cable Lubrication Lubricate the choke slide and cables occasionally as shown Operate...

Page 65: ...brake lever to brake block clearance is evident the brake cable should be adjusted If proper adjustment cannot be achieved by using the following methods check the brake band for excessive wear Your...

Page 66: ...ment 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 that all parts are mounted securely Tighten h...

Page 67: ...cal brake adjustment information on page A 47 Chain Tensioner Inspect the chain The chain should have 1 of deflection as shown If not loosen the nut on the chain tensioner A and raise until 1 B of def...

Page 68: ...of the snowmobile s driveline lubricate as follows A Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease B Lubricate Point B every 10 hours of opera...

Page 69: ...sive 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 an...

Page 70: ...y bearing grease Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with Nyogelt grease PN 2871329 and re conne...

Page 71: ...low 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 fro...

Page 72: ...ve 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 de...

Page 73: ...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 mac...

Page 74: ...e machine off 2 Lift the rear of the machine and safely support it off the ground 3 Hang a 10 pound weight 8 inches from the center of the rear idler wheel The deflection at this point with this amoun...

Page 75: ...provide equal adjustment on both sides of the track 7 Repeat measurement on the other side of the track NOTE Check more frequently when machine is new 8 Start machine and slowly rotate the track at le...

Page 76: ...rforming the following checks and adjustments stay clear of all moving parts to avoid serious personal injury Before checking track tension make certain the track contains no objects that could be thr...

Page 77: ...the rails are evenly spaced on each side If the track runs to the left loosen left idler wheel mounting bolt and tighten the left track adjusting bolt If the track runs to the right loosen right idler...

Page 78: ...ck 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...

Page 79: ...ion Check the track clips and tighten if loose If any rod damage is found the track should be replaced NOTE The 120 XC SP track has molded in track clips It is common for a thin layer of rubber to det...

Page 80: ...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 impro...

Page 81: ...icates insufficient lubrication New hi fax can cause faster heat build up in limited lubrication than used hi fax resulting in excessive wear Steering System The steering systems on Polaris snowmobile...

Page 82: ...andlebars 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 pa...

Page 83: ...lebar pad zippers and roll the pad to the side S To adjust remove the up per flange nut and car riage bolt S Loosen the lower flange nut only enough so the bracket can move freely S Position the handl...

Page 84: ...racteristics Skags must be replaced when worn to half their original diameter NOTE See dealer track studding and skag chart for recommended skags Skag Replacement 1 Raise and support the front of the...

Page 85: ...PN 2871066 several times during the season and again before summer storage each year The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts NOTE A grease...

Page 86: ...points are indicated by a L 1 Front Limiter Strap 2 Rail Bumper 3 Torsion Spring Sleeves 4 Torque Arm 5 Torsion Spring 6 Rail 7 Carrier Wheel 8 Hi fax 9 Rear Limiter Strap 10 Toe Guard 11 Spacer 12 Id...

Page 87: ...FAILS TO START No Fuel Water in Fuel Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Contact Your Dealer Clogged Fuel Valve or filter ENGINE STOPS OR LOSES POWER No Fuel Contact Your De...

Page 88: ...this book are available at your Polaris dealer as well as a long line of other Polaris accessories Paint Codes Color Description Polaris P No Raw Material No Indy Red P293 8520297 Indy Black P067 852...

Page 89: ...4 Stroke 4 hp Track Length in 68 04 Alternator Output 12V 50 W Track Width in 10 Bore x Stroke mm 60 x 43 Drive Chain Length 74 Pitch Displacement ccs 121 Front Suspension 30 IFS Cylinders 1 Rear Sus...

Page 90: ...A 71 WIRING DIAGRAM 2001 120 XC SP...

Page 91: ...l and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifica...

Page 92: ...mber 5 Details of trouble experienced 2 Model number 6 Length of time and conditions of operation 3 Dealer name 7 Indicate previous correspondence 4 Date of purchase Use the following space to record...

Page 93: ...stomer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your snowmobile is ve...

Page 94: ...OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied w...

Page 95: ...wever you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will co...

Page 96: ...le value is increased S The Polaris Extended Service Contract is very affordable and can be fi nanced with the Polaris Star Card Conditions S The Polaris Extended Service Contract must be purchased wi...

Page 97: ...Codes A 69 Pre Operation Check R 8 A 7 Pre Ride Warm Up A 36 Pre Start Check A 32 Preservation of the Environment A 22 A 23 Safety Warning and Operation Decals A 4 A 6 Service and Warranty Information...

Page 98: ......

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