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UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

Throughout this manual, important information is brought to your attention by the following symbols:

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or

person(s) inspecting or servicing the vehicle.

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

MEASUREMENT provides a key for a determined measurement specification.

TORQUE provides a key for a required torque value.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
M-10, Registerd Trademark of FAST, Inc

Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or

by contacting the nearest Polaris dealer.

WARNING

CAUTION

CAUTION

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In. / mm.

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Summary of Contents for 2000 120 XCR

Page 1: ...BAR CODE 9920517 Cover_9920517 5 11 06 12 32 PM Page 1 ...

Page 2: ...ools Use only the proper tools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2000 2007 120 Youth Snomobile Service Manual PN 9920517 Copyright 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to ...

Page 3: ...ying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components MEASUREMENT provides a key for a determined measurement specification TORQUE provides a key for a required torque value TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm F N...

Page 4: ...ECIFICATIONS 1 1 CHAPTER 1 MODEL SPECIFICATIONS 1 SPECIFICATIONS 1 2 2007 DRAGON 120 1 2 2006 120 PRO X 1 4 2005 PRO X 120 1 6 2004 120 PRO X 2003 120XC SP 1 8 2002 120 XC SP 2001 120 XCR 1 10 2000 120 XCR 1 12 ...

Page 5: ...o 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 72 5 55 72 5 55 70 50 70 50 70 50 67 5 50 67 5 45 67 5 45 600 1200 2000 4000 70 50 70 50 70 50 67 5 50 67 5 50 67 5 50 65 45 65 45 1200 1800 4000 6000 67 5 50 67 5 50 67 5 50 65 50 65 50 65 45 62 5 45 62 5 45 1800 2400 6000 8000 65 50 65 50 65 50 65 50 65 45 62 5 45 62 5 45 60 45 2400 3000 8000 10000 65 50 65 50 62 5 50 62 5 45 60 45 60 45 60 45 60 45 3000...

Page 6: ...nsion type Mini Indy Front track shock FTS N A FTS Spring Rate lbs in kg mm N A FTS pre load N A Rear track shock N A Rear travel in cm 4 5 11 4 notes that shock is rebuildable Torsion spring PNs LH RH 7041844 067 LH 7041845 067 RH Torsion spring diameter in mm 406 SLED DIMENSIONS Width in cm 34 86 Length in cm 75 191 Height in cm 31 79 Est dry weight lb kg 145 65 8 ELECTRICAL Ignition timing 23 3...

Page 7: ...F to 65 F 7 C to 18 C 60 F 16 C 0 600 0 2000 72 5 55 72 5 55 70 50 70 50 70 50 67 5 50 67 5 45 67 5 45 600 1200 2000 4000 70 50 70 50 70 50 67 5 50 67 5 50 67 5 50 65 45 65 45 1200 1800 4000 6000 67 5 50 67 5 50 67 5 50 65 50 65 50 65 45 62 5 45 62 5 45 1800 2400 6000 8000 65 50 65 50 65 50 65 50 65 45 62 5 45 62 5 45 60 45 2400 3000 8000 10000 65 50 65 50 62 5 50 62 5 45 60 45 60 45 60 45 60 45 3...

Page 8: ... 43 IFS Spring installed length in mm 6 75 17 1 Front vertical travel in cm 3 0 7 62 Ski Center Distance 30 76 2 Camber in mm N A Toe in mm 125 3175 REAR SUSPENSION Suspension type Mini Indy Rear travel in cm 4 5 11 4 notes that shock is rebuildable Torsion spring PNs LH RH 7041844 067 LH 7041845 067 RH Torsion spring diameter in mm 406 SLED DIMENSIONS Width in cm 34 86 Length in cm 75 191 Height ...

Page 9: ...ude meters feet Ambient Temperature 30 F 34 C 30 F to 10 F 34 C to 23 C 10 F to 10 F 23 C to 12 C 10 F to 30 F 12 C to 1 C 30 F to 50 F 1 C to 10 C 50 F 10 C 0 600 0 2000 75 72 5 72 5 72 5 70 70 600 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 65 65 3000 3700 10000 12000 65 65 65 65...

Page 10: ... 17 5 notes that shock is rebuildable Torsion spring PNs LH RH 7041844 067 LH 7041845 067 RH Torsion spring diameter in mm 406 SLED DIMENSIONS Width in cm 34 86 Length in cm 75 191 Height in cm 31 79 Est dry weight lb kg 147 67 ELECTRICAL Ignition timing 26 3600 Spark plug gap in mm 028 70 Spark plug NGK BR6ES Voltage regulator output 50w 3600 ...

Page 11: ...ct Oxy JETTING Altitude meters feet Ambient Temperature 30 F 34 C 30 F to 10 F 34 C to 23 C 10 F to 10 F 23 C to 12 C 10 F to 30 F 12 C to 1 C 30 F to 50 F 1 C to 10 C 50 F 10 C 0 600 0 2000 75 72 5 72 5 72 5 70 70 600 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 65 65 3000 3700 100...

Page 12: ... 17 5 notes that shock is rebuildable Torsion spring PNs LH RH 7041844 067 LH 7041845 067 RH Torsion spring diameter in mm 406 SLED DIMENSIONS Width in cm 34 86 Length in cm 75 191 Height in cm 31 79 Est dry weight lb kg 147 67 ELECTRICAL Ignition timing 23 3600 Spark plug gap in mm 028 70 Spark plug NGK BR6ES Voltage regulator output 50w 3600 ...

Page 13: ...y JETTING Altitude meters feet Ambient Temperature 30 F 34 C 30 F to 10 F 34 C to 23 C 10 F to 10 F 23 C to 12 C 10 F to 30 F 12 C to 1 C 30 F to 50 F 1 C to 10 C 50 F 10 C 0 600 0 2000 75 72 5 72 5 72 5 70 70 600 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 3700 1000...

Page 14: ...9 17 5 notes that shock is rebuildable Torsion spring PNs LH RH 7041844 067 LH 7041845 067 RH Torsion spring diameter in mm 406 SLED DIMENSIONS Width in cm 34 86 Length in cm 75 191 Height in cm 31 79 Est dry weight lb kg 147 67 ELECTRICAL Ignition timing 23 3600 Spark plug gap in mm 028 70 Spark plug NGK BR6ES Voltage regulator output 50w 3600 ...

Page 15: ...r N A Rear Type Mini Travel in cm 6 9 17 5 Front Track Shock Rear Shock N A Track WxLxLug in cm 10x69x 79 25 4x175 3x2 JETTING Altitude meters feet Ambient Temperature 30 F 34 C 30 F to 10 F 34 C to 23 C 10 F to 10 F 23 C to 12 C 10 F to 30 F 12 C to 1 C 30 F to 50 F 1 C to 10 C 50 F 10 C 0 600 0 2000 75 72 5 72 5 72 5 70 70 600 1200 2000 4000 75 72 5 72 5 72 5 70 70 1200 1800 4000 6000 72 5 70 70...

Page 16: ...DECAL 2 3 VIN NUMBER DESIGNATION 2 4 PUBLICATION PART NUMBERS 2 4 MISC PUBLICATIONS 2 4 2007 SERVICE PUBLICATIONS 2 4 GENERAL REFERENCE 2 6 STANDARD BOLT TORQUE SPECIFICATION 2 6 2 STROKE GASOLINE OIL PRE MIX 2 6 GASOLINE VOLATILITY 2 6 SAE TAP DRILL SIZES 2 7 METRIC TAP DRILL SIZES 2 7 DECIMAL EQUIVALENTS 2 7 MEASUREMENT CONVERSION CHART 2 8 PISTON WASH SPARK PLUG READING 2 8 GLOSSARY OF TERMS 2 ...

Page 17: ... links Production setting is designated in the shaded areas JETTING Jetting chart is called out in the Jetting table ABBREVEATIONS The following chart explains the abbreviations that are used throughout this section ABBREVIATION MEANING PTO Power Take Off MAG Magneto RTA Rear Torque Arm FTA Front Torque Arm cc cubic centimeters RPM Revolutions Per Minuet PERC Polaris Electric Reverse Control ft lb...

Page 18: ...5 RMK N 166 RMK P Performance S Switchback T Touring U Utility Touring Limited 1A 121 F C OHV 4 Cycle Fuji 3A 340 F C Piston Port 4B 488 L C Piston Port 4C 440 EV L C Piston Port 5B 544 F C Cylinder Reed 5C 500 EV L C Case Reed 2 Cyl Liberty 6F 600 EV L C Case Reed HP 2 Cyl Liberty 6H 600 EV L C Case Reed SDI 2 Cyl Liberty 7E 750 2 Cyl FS Webber 7F 750 Turbo2 Cyl FS Webber 7H 755 EV SDI Case Reed ...

Page 19: ... 9920437 9920439 9920445 9920446 9916508 9920444 Trail RMK S07NJ5BS 9920449 9920450 9920451 9920452 9919882 9920444 Supersport EDGE S07NP5BS 9920437 9920440 9920445 9920446 9916508 9920444 500 XCSP S07NP5CS 9920437 9920441 9920447 9920448 9916508 9920444 Indy 340 Touring S07NT3AS 9920449 9920453 9920454 9920455 9916508 9920444 Trail Touring Deluxe S07NT5BS 9920449 9920456 9920457 9920458 9916508 9...

Page 20: ...S6HS 9920464 9920495 9920496 9920497 9916508 9920463 600 SDI IQ Switchback F S07PS6HSA 9920464 9920495 9920496 9920497 9916508 9920463 FST IQ Switchback S07PS7FS 9920468 9920498 9920499 9920500 9916508 9920463 600 SDI IQ Touring S07PT6HS 9920464 9920501 9920502 9920503 9916508 9920463 FS IQ Touring S07PT7ES 9920468 9920504 9920505 9920506 9916508 9920472 FST IQ Touring S07PT7FS 9920468 9920507 992...

Page 21: ...vice stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area When the weather is very cold gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly If summer blend fuel is being used in the winter little or no vaporization will occur Droplets will form causing flooding ...

Page 22: ...49 61 64 9531 31 32 9688 25 mm 9843 63 64 9844 1 1 0 Thread Size Drill Size Thread Size Drill Size 0 80 3 64 1 2 13 27 64 1 64 53 1 2 20 29 64 1 72 53 9 16 12 31 64 2 56 51 9 16 18 33 64 2 64 50 5 8 11 17 32 3 48 5 64 5 8 18 37 64 3 56 45 3 4 10 21 32 4 40 43 3 4 16 11 16 4 48 42 7 8 9 49 64 5 40 38 7 8 14 13 16 5 44 37 1 8 7 8 6 32 36 1 12 59 64 6 40 33 1 1 8 7 63 64 8 32 29 1 1 8 12 1 3 64 8 36 ...

Page 23: ...straight as it moves along the clutch face Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close and grip the drive belt Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially ...

Page 24: ...on meters OD Outside diameter Ohm The unit of electrical resistance opposing current flow oz Ounce ounces Piston Clearance Total distance between piston and cylinder wall psi Pounds per square inch PTO Power take off qt Quart quarts Regulator Voltage regulator Regulates battery charging system output at approx 14 5 DCV as engine RPM increases Reservoir Tank The fill tank in the liquid cooling syst...

Page 25: ...2 10 GENERAL ...

Page 26: ...2 11 GENERAL 2 ...

Page 27: ...2 12 GENERAL ...

Page 28: ...NGS 3 8 TRACK ALIGNMENT 3 8 TRACK TENSION 3 8 REAR IDLER WHEELS 3 9 TRACK WARM UP 3 9 SPARK PLUG 3 9 SPARK PLUG SELECTION 3 9 STEERING SYSTEM 3 10 STEERING INSPECTION 3 10 STEERING ADJUSTMENT 3 10 FUEL VALVE FUEL LINES 3 11 3 11 CARBURETOR 3 11 GENERAL CARBURETOR INFORMATION 3 11 CARBURETOR ADJUSTMENTS 3 11 ELECTRICAL 3 11 ELECTRICAL CONNECTIONS 3 11 EXHAUST 3 11 EXHAUST INSPECTION 3 11 CLEANING 3...

Page 29: ...3 2 MAINTENANCE TRANSPORTING TOWING 3 12 TRANSPORTING 3 12 TOWING 3 12 ...

Page 30: ...le from your Polaris dealer ITEM PRE RIDE FREQUENCY MILES KM PRE SEASO N 150 240 500 240 1000 1600 2000 3200 CLUTCH Clutch Alignment Offset without belt I I I Drive Belt Condition I I I I I Clutches disassemble C C C Belt Tension I I I I Clutch Sheaves I I I I ENGINE COOLING Engine Mounts I I I I Heat Exchangers I I I I I Recoil Rope I I I I I Engine Torque Stop I I I I Cylinder Head Bolts I I I C...

Page 31: ... Switch and Strap I I I I I I CHASSIS Ski Toe Alignment I I I Suspension Mounting Bolts I I I I I I Steering Fasteners I I I I C Rear Suspension Fasteners I I I I I Suspension Shock Oil I I I I Cooling Fins and Shroud I I I I Drive Shaft Bearing L L L I Jackshaft Bearings L L L I Skags Wear Bars I I I I I I Ski Saddle Spindle Bolts I I I I I I Drive Chain Tension I I I I I Hood Straps I I I I I I ...

Page 32: ...871423 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 gun kit complete with grease and adaptors is available to lubricate all fittings on Polaris snowmobiles Order PN 2871312 THROTTLE CABLE LUBRICATION With the engine off lubricate the throttle cable occasio...

Page 33: ...ed the dipstick 5 Clean the dipstick with a lint free cloth 6 Insert the clean dipstick and screw into place completely 7 Remove the dipstick and observe the oil level marking 8 Maintain the oil level between the safe marks on the dipstick CHAIN TENSIONER CHAIN TENSIONER INSPECTION Inspect the chain when the chain comes within 1 8 of the muffler mount bracket A on the chassis the chain has been st...

Page 34: ...e is adequate freedom of movement for positive brake operation Also make sure that all floating parts move freely and that all parts are mounted securely Tighten hardware as required 6 Tighten the adjuster jam nut and slide the rubber protectors back onto the adjuster 7 The brake band is adjusted correctly when there is 1 4 3 8 6 10mm brake lever free play and clearance between the brake lever 2 a...

Page 35: ...from the center of the rear idler wheel 2 The deflection 3 at this point with this amount of weight should measure 3 4 between the bottom of hi fax and the inside of the track NOTE Measure from where the weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide 4 If the track needs adjustment 5 Loosen rear idler shaft bolt 2 6 Tighten or lo...

Page 36: ...ume 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 manner This selection however could cause the customer who normally operates the engine under medium or light duty to have spark plug failure NOTE Incorrect fuel mixture can often cause a spark plug to ap...

Page 37: ... ignition output 1 Measure gap with a wire gauge and adjust to specifications by bending side electrode carefully 2 Coat spark plug threads with a small amount of anti seize compound 3 Install spark plug and torque to specification STEERING SYSTEM The steering systems on Polaris snowmobiles can be adjusted with ski toe alignment Improper toe alignment can cause erratic steering STEERING INSPECTION...

Page 38: ...aust system for wear or damage To inspect allow 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 CLEANING AIR FILTER NOTE Do not operate a machine with the intake filters removed in the summer This may cause carburetor intaking debris resulting poor fuel economy o...

Page 39: ...ack connector blocks with Nyogel grease and reconnect Replace worn or frayed electrical wire and connectors CARBURETOR THROTTLE BODY Fog engine with Polaris Fogging Oil aerosol type according to directions on can FUEL SYSTEM Treat the fuel system with Polaris Carbon Clean If Polaris Carbon Clean is not used fuel tank fuel lines and carburetor should be completely drained of gasoline CORROSION To p...

Page 40: ...AL 4 12 REMOVAL 4 12 ENGINE INSTALLATION 4 14 INSTALLING THE ENGINE 4 14 ENGINE COMPONENTS 4 16 CYLINDER CRANKCASE 4 16 MAIN BEARING COVER 4 16 CRANKSHAFT 4 16 CONNECTING ROD AND PISTON 4 16 PISTON RINGS 4 17 CAMSHAFT 4 17 VALVE ARRANGEMENT 4 17 CYLINDER HEAD 4 17 GOVERNOR SYSTEM 4 17 COOLING SYSTEM 4 17 LUBRICATION 4 18 IGNITION SYSTEM 4 18 DECOMPRESSION SYSTEM 4 18 CARBURETOR 4 18 AIR FILTER 4 1...

Page 41: ...2 CLUTCH SERVICE 4 32 FUEL TANK 4 33 FUEL TANK REMOVAL 4 33 FUEL TANK INSTALLATION 4 33 TROUBLE SHOOTING 4 33 FUEL SYSTEM 4 33 IGNITION SYSTEM 4 33 COMPRESSION SYSTEM 4 33 ENGINE MISFIRES 4 34 ENGINE STOPS 4 34 ENGINE OVER HEATS 4 34 ENGINE KNOCKS 4 34 ENGINE BACKFIRES THROUGH CARBURETOR 4 34 ...

Page 42: ...d sequence indicated in this manual tighten evenly to the specified torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them If the condition of any gasket or O Ring is in question replace it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks Some procedures will req...

Page 43: ...SPECIFICATIONS ENGINE TORQUE SPECIFICATIONS NOTE STD in the following table is the parts dimension from brand new engine parts Limit shows the maximum allowance for the parts to be used on the engine If the measurement exceeds beyond the limit the parts need to be replaced and or repaired APPLICATION TORQUE FT LB TORQUE NM Connecting Rod 6 5 8 3 9 11 Main Bearing Cover 6 7 8 9 5 Cylinder Head 3 st...

Page 44: ...4 5 ENGINE CARBURETOR CLUTCH 4 CLEARANCE DATA LIMITS CYLINDER HEAD ...

Page 45: ...4 6 ENGINE CARBURETOR CLUTCH CYLINDER PISTON Out of Round Cylinder Taper ...

Page 46: ...4 7 ENGINE CARBURETOR CLUTCH 4 ...

Page 47: ...4 8 ENGINE CARBURETOR CLUTCH CONNECTING ROD ...

Page 48: ...4 9 ENGINE CARBURETOR CLUTCH 4 CAM SHAFT VALVES ...

Page 49: ...4 10 ENGINE CARBURETOR CLUTCH 45q seat ...

Page 50: ...enance Remarks Change Crankcase Oil Removes any foreign material Maintenance Remarks Change crankcase oil Removes any foreign material Check and clean spark plug If wore or damaged replace Chain Tension Inspection Inspect and adjust tension Maintenance Remarks Clean fuel filter inside fuel tank Inspect cooling system and remove dirt and debris Remove blower housing and clean up between fins and ho...

Page 51: ...aust gasket E Raised edge on gasket faces exhaust pipe side 4 Remove nut F retaining brake band G Pull cable H out from housing Remove band G 5 Disconnect throttle cable at holder H using a screw driver to loosen set screw and remove cable bracket bolt Slide cable out and set aside 6 Disconnect choke cable from holder I and remove E clip from mount bracket Slide cable out and set aside A B C E F G...

Page 52: ... pliers and remove clutch bolt Slide clutch off drive shaft 14 Free recoil rope from chassis Be sure to tie knot in rope upon removal from handle or rope will retract inside recoil housing 15 Remove fuel line from fuel tank to carburetor Have container or shop cloth ready to catch any spilled fuel 16 Remove eight 8 motor mount bolts N Four are located at the base of the engine and protrude through...

Page 53: ...d tie a secure knot in recoil handle B 8 Insert choke cable through bracket and thread cable through lock barrel 9 Insert E clip B through bracket to secure cable 10 Pull choke knob on dash to choke closed 11 Move choke lever on carburetor to closed position full choke C 12 Tighten set screw on lock barrel 13 Choke cable is set when butterfly is completely closed with choke knob is fully extended ...

Page 54: ...fore installation and replace clutch if needed 18 Hold shoulder of clutch with adjustable pliers and torque bolt to 10 ft lb 14Nm 19 With new master link connect drive chain the slotted end can be positioned forward or rearward 20 Install brake band 21 Route cable through cable housing 22 The brake band is adjusted correctly when there is 1250 375 6 10mm brake lever free play and clearance between...

Page 55: ...der liner made of special cast iron is molded into the aluminum casting The crankcase has a mounting surface on the output shaft side where the main bearing cover is attached MAIN BEARING COVER The main bearing cover is an aluminum diecasting which is mounted on the output shaft side of the crankcase Remove the main bearing cover to inspect the inside of the engine CRANKSHAFT The crankshaft is for...

Page 56: ...is located on flywheel side of the cylinder head The hard alloy valve seats are molded in the cylinder head and stellite is fused to the exhaust valve face The cylinder baffle leads cooling air to the exhaust valve area for optimum cooling CYLINDER HEAD The cylinder head is an aluminum die casting which utilizes wedge type combustion chamber for the highest combustion efficiency GOVERNOR SYSTEM Th...

Page 57: ...SYSTEM An automatic decompression mechanism which opens the exhaust valve before the piston reaches compression top is assembled on the camshaft for easy starting CARBURETOR The carburetor has a float controlled fuel system The carburetor is calibrated carefully for good cold weather starting good acceleration low fuel consumption and sufficient output AIR FILTER There is no air filter element in ...

Page 58: ...4 19 ENGINE CARBURETOR CLUTCH 4 ENGINE COMPONENT LOCATIONS ...

Page 59: ...h washer solvent if necessary 5 Use the correct tools in the correct way ENGINE DESASSEMBLY 1 Drain oil as outlined in Chapter 2 NOTE To discharge oil quickly remove oil dipstick 2 Remove recoil 1 from blower housing 2 3 Remove blower housing 2 from engine 3 4 Remove the air box cover 5 Remove cleaner case 6 Unhook governor spring A from speed control lever B 7 Remove governor lever from governor ...

Page 60: ...seat 15 Remove spark plug from cylinder head 16 Remove rocker cover 8 and gasket 9 from cylinder head 10 17 Remove cylinder head from crankcase 18 Remove the cylinder head gasket 11 from the cylinder head 19 Remove push rods 12 20 Remove main bearing cover fastening bolts 21 Remove main bearing cover using plastic hammer 22 Remove cam shaft 13 from crankcase 23 Remove tappets 14 from crankcase 24 ...

Page 61: ...fore reassembly 4 Replace all the gaskets with new ones 5 Replace keys pins bolts nuts etc if necessary 6 Torque bolts and nuts to specification 7 Apply oil to rotating and sliding portions 8 Check and adjust clearances and end plays where specified in this manual ENGINE REASSEMBLY 1 Install crankshaft in crankcase wrapping the shaft with vinyl electrical tape to avoid damage to oil seal 2 Install...

Page 62: ... following manner Measure the depth A1 From mating surface to the inner race of the ball bearing Measure the height B1 From mating surface to the crank gear Following are available spacer shims CAUTION Incorrect valve timing will cause engine malfunction 3 In mm MM A1 0 3 B1 SIDE Clearances SIDE CLEARANCE 0 2 THICKNESS OF CRANKSHAFT SHIM mm required STD A1 0 012 B1 SIDE CLEARANCE inches SIDE CLEAR...

Page 63: ...d camshaft Carefully install cover guiding oil seal over shaft to avoid seal damage and to prevent spring from dislodging when installing the main bearing cover Tap the cover into place with a soft face hammer Tighten crankcase bolts to specification 11 Clean carbon and gum deposits from the valves seats ports and guides Inspect the valves valve seats and valve guides 12 Replace valves that are ba...

Page 64: ...en the rocker arm and valve stem end Tighten the lock nut under rocker arm NOTE Check and adjust valve clearance while engine is cold Check operation of valves by turning crankshaft Recheck valve clearance 20 Install rocker cover and new gasket 21 Install spark plug in cylinder head NGK BR6ES 22 Insert woodruff key in key way of crankshaft Wipe off grease and oil thoroughly from tapered portion of...

Page 65: ...g a screw driver and tighten lock bolt and nut 30 Install the air cleaner gasket and air cleaner case and tighten flange nuts 31 Install blower housing and recoil Insert the high tension lead from ignition coil into notch of blower housing so not to pinch the lead ENGINE BREAK IN An engine that has been completely overhauled by being fitted with new piston rings valves and connecting rod should be...

Page 66: ... valve slightly to release compression The release lever has a flyweight on one end and a crescent cam on the other end When the engine is cranked the crescent cam projects the camshaft cam profile and lifts up the tappet because the gravity force on the weight is larger than the centrifugal force on the weight When crank speed reaches a certain revolution the crescent cam is retracted into the ca...

Page 67: ...e valve maintains a constant fuel level during engine operation Fuel flows from the fuel tank into the float chamber through the needle valve When fuel rises to a specific level the float rises When its buoyancy and fuel pressure are balanced the needle valve shuts off the fuel thereby keeping the fuel at a predetermined level ...

Page 68: ...2 The springs 4 can be taken out by removing throttle stop screw 6 3 Remove the phillips head screw 2a and choke valve 10 Pull out choke shaft 9 4 When reassembling choke shaft make sure that the cutout in the choke valve faces the main air jet Meanwhile when reassembling set the rings 11 and 12 to the correct position 5 Remove pilot jet 8 using proper tools to avoid damage 6 When reassembling tig...

Page 69: ...ot float up Move reel clockwise and counterclockwise about one quarter circle several times until it moves smoothly 9 Lift up reel gradually and slowly pulling it away from the case 10 If spring in reel is close to popping up re perform previous steps ASSEMBLY 1 Apply grease to case as shown 2 Adjust position of inner end of spring which is set in reel The position of the end touches the rib of th...

Page 70: ...point about 50 cm from rope guide Keep rope slightly pulled so that rope will not be wound in 14 Lift your hand off reel gently while guiding rope through guide under pressure of spring until knob reaches rope guide 15 Test operation of recoil starter to see if rope recoils correctly and the ratchets project and retract properly Mount recoil starter to the engine 16 If spring escapes from reel whe...

Page 71: ...ber washer 3 3 Remove clutch weight holder snap ring 4 4 Separate the clutch parts and wash thoroughly in parts washer 5 Assemble clutch weights 5 and spring 6 6 Assemble clutch and install snap ring 4 7 Install grease seal fiber washer 3 8 Install drum 7 and snap ring 1 9 When clutch is installed and torqued to specification pump two 2 pumps initially of Polaris Premium All Season grease in fitti...

Page 72: ...ole Keep the choke open during this operation Dry the spark plug thoroughly screw it in to place torque to specification and try to start again IGNITION SYSTEM 1 Wires of the ignition coil and or spark plug disconnected 2 Ignition coil damaged or shorted 3 Spark plug cable wet or soaked with oil 4 Spark plug dirty or wet 5 Spark plug electrode gap incorrect 6 Spark plug electrode is connected or b...

Page 73: ...ing incorrect 3 Low grade gasoline used or engine is overloaded 4 Cooling air circulation restricted 5 Cooling air path misdirected causes loss of cooling efficiency 6 Cylinder head cooling fins clogged up with dirt 7 Engine operated in an enclosed space without sufficient cooling air 8 Exhaust system restricted or carbon deposits in combustion chamber 9 Engine running on low octane gasoline deton...

Page 74: ...USTMENT 5 3 ROD END PROCEDURE 5 3 ROD END ENGAGEMENT 5 3 TOE ADJUSTMENT 5 4 SKI SPINDLE BUSHING REMOVAL 5 5 SKI SPINDLE BUSHING INSTALLATION 5 5 SKAG REPLACEMENT 5 6 TIE ROD REPLACEMENT 5 6 RADIUS ROD REPLACEMENT 5 6 BODY 5 7 IFS SHOCK REPLACEMENT 5 7 TRAILING ARM REPLACEMENT 5 7 DECALS 5 8 TROUBLESHOOTING 5 8 ...

Page 75: ...he following torque values in the areas specified Refer to exploded views for torque values and orientation of components and fasteners Illustration depicts proper orientation of rod ends and bolts on steering components 16ft lb 21 7Nm 16ft lb 21 7Nm 16ft lb 21 7Nm 16ft lb 21 7Nm 16ft lb 21 7Nm 7 ft lb 9 5Nm 7 ft lb 9 5Nm ...

Page 76: ...er to steering exploded views at the beginning of this section Grease all fittings HANDLEBAR ADJUSTMENT Handlebars on the 2002 current 120 s can be adjusted to accommodate rider preference 1 Turn the fuel valve to the off position then remove the handlebar pad 2 Loosen the lower handlebar bolt Do not remove 3 Remove the top handlebar bolt from the current position 4 There are 3 positions to adjust...

Page 77: ... end jam nuts inner and outer and turn tie rod until equal measurements are achieved 4 Once you have skis in straight ahead position measure from the straight edge of the skis The measurement between the skis at point 3 should be 1 8 inches greater than point 4 as shown NOTE This measurement should be taken with the vehicle weight compressing the suspension 5 Once you have achieved the above measu...

Page 78: ...TALLATION 1 Grease spindle and bushings liberally with Polaris Premium All Season grease 2 Install spindle 1 through the top bushing 4 and then into the trailing arm 6 3 Place the bottom bushing 5 onto the spindle 4 Place the spindle spacer tube 9 onto the spindle and align the holes 5 Push roll pin 10 into spacer tube and press into the spindle NOTE The angled part of spacer tube faces forward 6 ...

Page 79: ... washer 4 3 Slide tie rod assembly 5 out through chassis 4 Slide in replacement tie rod assembly 5 Torque fasteners 2 4 to 16 ft lb 22 Nm RADIUS ROD REPLACEMENT This procedure is for either upper or lower radius rods 1 Lift and support front end of machine NOTE Be sure the machine is stable and solidly supported before proceeding Serious injury may result if machine tips or falls 2 Remove outer ra...

Page 80: ...o 17 ft lb 24Nm TRAILING ARM REPLACEMENT 1 Lift and support front end of machine 2 Remove ski spindle radius rods tie rod and shock as described previously See SKI SPINDLE BUSHING REMOVAL on page 5 5 3 Remove rear trailing arm bolt 1 Be sure not to lose rubber washer 2 4 Install trailing arm 3 and assemble in reverse order of disassembly Torque all bolts to specifications 5 Torque Trailing Arm Bol...

Page 81: ...e Perform this procedure in a well ventilated area away from gasoline of other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue PROBLEM POSSIBLE CAUSE SOLUTION Machine darts from side to side Incorrect ski toe alignment Loose or worn steering components or fasteners Cracked or broken skis or skags Adjust to correct toe alignment Tighten or...

Page 82: ...MENT 5 3 ROD END PROCEDURE 5 3 ROD END ENGAGEMENT 5 3 TOE ADJUSTMENT 5 4 SKI SPINDLE BUSHING REMOVAL 5 5 SKI SPINDLE BUSHING INSTALLATION 5 5 SKAG REPLACEMENT 5 6 TIE ROD REPLACEMENT 5 6 RADIUS ROD REPLACEMENT 5 6 BODY 5 7 IFS SHOCK REPLACEMENT 5 7 TRAILING ARM REPLACEMENT 5 7 DECALS 5 8 TROUBLESHOOTING 5 8 ...

Page 83: ... snow New rail sliders are best used in deep snow conditions Marginal snow or hard pack conditions are better suited to worn rail sliders or rail sliders which have been cured or broken in RAIL SLIDE REMOVAL 1 Remove suspension from machine 2 Remove front rail slider retaining bolt 1 3 Use a block of wood or a drift punch and hammer to drive rail slider 2 rearward off the slide rail 4 With the rai...

Page 84: ...SPENSION ITEMS DESCRIPTION DESCRIPTION DESCRIPTION 1 Torsion Spring 4 Toe Block 7 Track Adjuster 2 Front Limiter Strap 5 Idler Wheel 8 Torque Arm 3 Rail 6 Rear Idler Shaft 9 Carrier Wheel TORQUE TABLE TORQUE 10 15 17 FT LB 20 23Nm 11 100 in lb 11Nm 12 40 ft lb 54Nm 13 6 ft lb 8Nm 1 2 3 4 5 6 9 8 7 10 10 10 11 12 13 ...

Page 85: ...or similar material aside right of machine and tip sled on its side throttle side 4 Remove suspension mounting bolts 5 When all suspension bolts have been removed slide skid out and remove upper carrier wheels and shaft Remove one wheel and spacer and slide shaft out of limiter strap 6 Lift complete suspension skid out from track ...

Page 86: ...from rear sprocket guard Remove sprocket guard by pulling back toward rear of sled 2 Remove clutch guard exhaust and drive chain 3 Drive pin out from sprocket 4 Drive pin out of left side brake side drive sprocket Slide driver down shaft 5 Remove flangettes on both sides of driveshaft 6 Loosen 1 8 allen set screws on both drive shaft bearings Two 2 per bearing ...

Page 87: ...e shaft and left side bearing DRIVE SPROCKET DRIVESHAFT INSTALLATION 1 Insert track and drive shaft Make sure track is installed so it will turn in proper direction 2 Install LEFT side brake side bearing and flangette Tighten flangette to specification Do NOT tighten bearing set screws at this time 3 Set drive chain sprocket on drive shaft Do not replace pin at this time 4 Install RIGHT side throt...

Page 88: ...LLATION 1 Insert suspension skid into track The rear carrier wheels should be installed with circlip in toward center of sled 2 Install suspension mounting screws and torque to specification 3 Tip machine upright Install drive chain outlined in Chapter 2 4 Install drive sprocket guard and install five 5 rivets 5 Tighten and align track Ensure that driven sprocket is positioned against bearing 6 Ti...

Page 89: ...NOTES SUSPENSION 6 8 ...

Page 90: ... ENGINE ELECTRICAL DIAGRAM 7 3 THROTTLE 7 4 SPEED CONTROL ASSURANCE SWITCH ADJUSTMENT 7 4 SPEED CONTROL ASSURANCE REPLACEMENT 7 4 ELECTRICAL TESTING 7 4 REV LIMITER REGULATOR TESTING 7 4 SPEED CONTROL ASSURANCE TESTING 7 4 OPEN CIRCUIT RUN 7 4 AUXILIARY SHUT OFF 7 4 120 WIRING DIAGRAM 7 5 ...

Page 91: ...which will bypass the current I1 and abruptly shut off the current I2 because the power transistor is turned off This sudden current change generates a high voltage on the secondary side of the ignition coil and which sparks the spark plug At higher engine speed rotation of the flywheel generates the current I1 As this current flows through the base terminal of the power transistor it is activated...

Page 92: ...7 3 ELECTRICAL 7 ENGINE ELECTRICAL DIAGRAM Ignition Coil Flywheel Charge Coil Sparkplug Sparkplug Cap ...

Page 93: ...ack wires at the throttle With the throttle depressed blue to black should be an open circuit With the throttle untouched blue to black should show continuity SPEED CONTROL ASSURANCE TESTING With engine idling hold the throttle pivot and open the throttle slightly The engine should stop running If it does not stop running check for continuity between the black and brown wires from the throttle ass...

Page 94: ...7 5 ELECTRICAL 7 120 WIRING DIAGRAM ...

Page 95: ...NOTES ELECTRICAL 7 6 ...

Page 96: ...Drive Shaft Installation 6 6 Removal 6 5 Drive Sprocket Installation 6 6 Removal 6 5 E Electrical Connections 3 11 Engine Assembly 4 22 4 26 Precautions 4 22 Engine Break In 4 26 Engine Compartment Locations 4 19 Engine Components 4 16 Air Filter 4 18 Camshaft 4 17 Carburetor 4 18 Connecting Rod 4 16 Cooling System 4 17 Crankshaft 4 16 Cylinder Crank Case 4 16 Cylinder Head 4 17 Decompression Syst...

Page 97: ... 9 2 12 Specification 2001 120 XCR 1 10 Specification 2002 120 XC SP 1 10 Specification 2005 PRO X 120 1 6 Specification 2006 PRO X 120 1 4 Specification 2007 Dragon 120 1 2 Specifications 1 2 2000 120 XCR 1 12 2002 120 XC SP 2001 120 XCR 1 10 2004 120 PRO X 2003 120 XC SP 1 8 2005 120 PRO X 1 6 2006 120 PRO X 1 4 2007 120 1 2 Speed Control Assurance Switch Adjustment 7 4 Replacement 7 4 Testing 7...

Page 98: ...sporting 3 12 Troubleshooting Compression System 4 33 Engine Backfires 4 34 Engine Knocks 4 34 Engine Misfires 4 34 Engine Over Heats 4 34 Engine Stops 4 34 Front Suspension 5 8 Fuel System 4 33 Ignition System 4 33 Steering 5 8 Tunnel Decal 2 3 W Warnings 4 3 Wiring Diagram 7 5 ...

Page 99: ...IX 4 ...

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