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Polaris 120 - page 1
Owner's Manual for Maintenance and Safety 2006 Owner's Manual for Maintenance and Safety 2006 ...
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Polaris 120 - page 2
For your nearest P olaris dealer , call 1-800-POL ARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone (763) 417-8650 F ax (763) 542-0599 Part No. 9919675 Printed in USA ...
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Polaris 120 - page 3
W ARNING W ARNING Read, understand, and follow all of the instructi ons and safety precautions in thi s manual and on all product labels. Failure to follow the safety precautions could resul t in serious injury or death. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive harm. PROPOS ...
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Polaris 120 - page 4
1 WELCO ME Thank you for purcha sing a Polaris veh icle, and welc ome to our world- wide family of Polaris owne rs. W e proudly produce a n exciting line of utility a nd re cre ational pr oducts. S Snowmobiles S All-te rra in vehicle s (A TVs) S RANGER utility vehicle s S V i ctory m ot orcycl es W e belie ve Polaris sets a standa rd of exce llence ...
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Polaris 120 - page 5
2 WELCO ME Dear Par ents: W e belie ve your c hildren should ha ve the opportunity to e njoy The W ay Out expe rience along with you. W e’ve provided this owner’ s manual to a ssist you and your childr en in lear ning about the saf e opera tion and care o f your new Polaris snowmobile. Please re view the infor mation in this manual with a ny ch ...
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Polaris 120 - page 6
3 WELCO ME Dear Chil dren: Before you ride your ne w Polaris snowmobile, t here a re some important things tha t you need to know . Y our pare nts and Polaris wa nt you to enjoy riding your new snowmobile , and that’ s why you need to rea d and under stand the informa tion in your owner ’ s m anua l. Ask your par ents to explain anything you do ...
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Polaris 120 - page 7
4 PO LA RIS an d PO LA RIS T HE W A Y OUT are registered tradem arks of Po laris Indus tr i es I nc. Copyri ght 2005 Pol a ri s Sa le s Inc . A ll inf orm at ion c onta i ned wi thi n thi s publi ca ti on i s bas e d on the la te s t produc t inf orma ti on at the t im e of publi ca ti on. Due to cons t ant imp rov emen ts in the design an d qu ali ...
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Polaris 120 - page 8
5 TABLE OF CONTENTS Introducti on 7 ............................... Important Notes for Owners and Drivers 8 ........... Preservation of the E nvironment 9 .................. V ehicle Identification N umbers 1 1 ................... Safety 12 .................................... YOUTH SECT ION 17 .......................... Know Y our Snowmobile 17 . ...
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Polaris 120 - page 9
6 ...
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Polaris 120 - page 10
7 INTRODUCTION After r eading this manual, store it in the snowmobile for conve nient ref ere nce. It should re main with the snowmobile when sold. n This manual conta ins the l ate st i nfor mation at the time of printing. W e rese rve the right to make product change s and improvements without notice. n The illustra tions and photos used in this ...
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Polaris 120 - page 11
8 INTRODUCTION Impor tant Notes for Owner s and Dr ivers P ARE NTS: Do not allow anyone under the age of six (6) to opera te this mach ine. Review the infor mation in this manual w ith any child who may b e operati ng th e snowm obi le. It is u p to yo u to t each any opera tor the proper and saf e way to ride a snowmobile. Y ou must set boundarie ...
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Polaris 120 - page 12
9 INTRODUCTION Pr eservation of the E nvironm ent T each your child t o drive thei r snowmobil e w ith consi deratio n for the protec tion and pre serva tion of the envir onment. Noise Level One of the most publicize d subjects with r egar d to snowmobiles is noise. The Socie ty of Automotive Engineers (SAE) , whic h is the standar d-setting body f ...
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Polaris 120 - page 13
10 INTRODUCTION Pr eservation of the E nvironm ent Environm ental Protection As part of the continuing environmenta l education ca mpaign, we are enc ouraging state a nd provincial gover nments acr oss the snowbelt to adopt rigorous sa fety tra ining programs whic h also enc ourage protec tion of our environme nt, wildlife a nd vegetation. Snowmobi ...
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Polaris 120 - page 14
11 INTRODUCTION V ehicle Identification N umber s The fra me vehicle identif ication number (VI N) and engine seria l number a re impor tant for mode l identifica tion when re gistering your vehi cle, wh en obt aini ng i nsuran ce, and wh en orderi ng repl acement parts. In the eve nt your vehicle is stolen, these numbers are e ssential to the re c ...
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Polaris 120 - page 15
12 SAFE TY W ARNING Failur e to follow the war nings in this manual c an result in sever e injury or death. Read and underst and the owner ’s manual and all warnings bef ore operat ing a Polaris snowmobile. Adult s must thor oughly explain t his infor mation t o all operat ors of the snowmobile. All operat ors m ust be at least s ix (6) y ears ol ...
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Polaris 120 - page 16
13 SAFE TY Maintenance Pr ogram As with all snowmobiles, caution must be obse rved to ensur e oper ator safe ty . Particula r cau tion must be take n to make sur e that the snowmobile is in e xcelle nt opera ting condition at a ll times. W e strongly re commend tha t the oper ator , as well as a n adult, chec k major and vi tal safet y components b ...
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Polaris 120 - page 17
14 SAFE TY Safety Decals Safet y and warn ing d ecals hav e been placed o n the veh icle for t he opera tor ’ s protection. Make sur e the opera tor understands the info rmat ion o n all decal s. If any decal beco mes illegible or comes of f, contact your P olari s deal er for a replacement . Any safety decal needi ng repl acemen t wil l be pro v ...
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Polaris 120 - page 18
15 SAFE TY The following signa l words and symbols appe ar thr oughout this manual a nd on your vehicle . Y our sa fety is involved w hen these wor ds and symbols are use d. Become f amiliar w ith their meanings bef ore rea ding the manual. The safety aler t sym bol , on y our vehicle or in this manual, alert s you to t he potent ial for pers onal ...
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Polaris 120 - page 19
16 YOU TH SECT IO N Know Y our S nowmobi le Befor e you have an adult start the engine f or you for the first time, let’ s lear n about the contr ols on your new ma chine. 1. Engine St op Switc h - When the engine is running, you can push this button down and the e ngine w ill stop. The stop sw itch must be in the UP position to start the engine ...
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Polaris 120 - page 20
17 YOU TH SECT IO N Know Y our S nowmobi le Always t ake your t humb off t he throt tle lev er when you squeez e the brake l ever . 6. Bra ke L ever - S queeze t he brak e lever t oward th e hand lebar t o make your snowmobile slow down or stop. 7. Ignit ion Swit ch - T he ignition switch ke y must be turne d ON befor e pulling on the recoil starte ...
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Polaris 120 - page 21
18 YOU TH SECT IO N Know Y our S nowmobi le Let’ s lear n more about the parts of your snowmobile before we ta lk about riding. 1 2 3 4 5 6 9 8 10 7 ...
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Polaris 120 - page 22
19 YOU TH SECT IO N Know Y our S nowmobi le 1. Hood - The hood covers the moving and hot parts of the engine and must be secure ly latche d before you ride the snowmobile. 2. Headlight - The he adlight is always on when the engine is running. It helps othe rs see you whe n you’re r iding during daylight, but it’ s not supposed to be strong e no ...
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Polaris 120 - page 23
20 YOU TH SECT IO N Know Y our S nowmobi le Let ’ s review th e th ree ways to st op you r sno wmo bi le: 1. Push the stop switc h down. 2. Pull off the tethe r strap. 3. T urn the key of f. 1 2 3 ...
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Polaris 120 - page 24
21 YOU TH SECT IO N Pre-Rid e Chec k Y ou’re almost re ady to ha ve an a dult start your snowmobile. Bef ore the snowmobile is starte d for the first time, you must do a PRE-RIDE CHECK. In f act, eve ry time you ride your snowmobile you must have an adul t hel p you check t hese t hin gs before st arti ng it . Let ’ s l earn about these things ...
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Polaris 120 - page 25
22 YOU TH SECT IO N Pre-Rid e Chec k Always have an adult put gas in your s nowmobile. Never t ry t o do it yourself . n Have an adult che ck the gas level to see if your snowmobile needs more. Childre n should neve r add their own gasoline . This must always be done by an adult. Before a nyone adds gasoline to your snowmobile they must r ead the i ...
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Polaris 120 - page 26
23 YOU TH SECT IO N Ridi ng Rules Now you’re rea dy to learn a bout driving your Polaris snowmobile. There a re some things you can do and there are some things you must never do. Rules ar e very important when you’r e driving a snowmobile. Adults have r iding rules, too. The rules he lp keep us saf e when we ride. Y ou mus t be at leas t si x ...
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Polaris 120 - page 27
24 YOU TH SECT IO N Ridi ng Rules " Always wear the right kind of clothing when you’r e riding your snowmobile. Y ou’ll need a good helmet w ith a fac e shield or goggles. W ea r a warm jacke t and snowpants. Make sure your cloth- ing fits prope rly . If it’ s too small, it could kee p you from moving easily . If it’ s too big, it coul ...
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Polaris 120 - page 28
25 YOU TH SECT IO N Ridi ng Rules " Always drive your snow mobile while sitting down. Kee p both hands on the ha ndlebar s and keep both f eet on the r unning boards. " Neve r follow anothe r snowmobile too closely . Always allow lots of time an d space to stop your snowmobile. " Ride your snowmobile only where you know it’ s safe ...
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Polaris 120 - page 29
26 YOU TH SECT IO N Ridi ng Rules Lear n how to ride sa fely a nd corre ctly . Lea rn how to use your hands and ar ms as signals. Read a nd understand your Owner ’ s Manual. Left T urn Right T urn Stop ...
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Polaris 120 - page 30
27 ADULT SECTION Pre-Rid e Chec k It’ s up to you, the adult, to t each your child th e proper a nd safe way to ride a snowmobile. Y ou must set boundaries and a dhere to them, keep ing your child’ s safety for emost in your mind. Neve r allow your child to opera te this machine without adult superv ision. W ARNING T each t he operator s to per ...
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Polaris 120 - page 31
28 ADULT SECTION Pre-Rid e Chec k Befor e St arti ng The Engine n Re ad a nd Unde rs tand Y our Owner’ s M anua l Read and make sure the ope rators understa nd the Owner ’ s Manual comple tely befor e allowing anyone to opera te this snowmobile. It’ s also a good ide a to re view it per iodically to r einforc e the inf ormation. It’ s very ...
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Polaris 120 - page 32
29 ADULT SECTION Pre-Rid e Chec k n Check t hro ttl e safety sw itch T est the throttle saf ety switch system on a daily basis befor e the machine is used. While se ated in a normal riding position, and with the engine idling, hold the throttle leve r pin stationary by exe rting pressur e on the pivot pin in the dire ction shown in the illustration ...
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Polaris 120 - page 33
30 ADULT SECTION Pre-Rid e Chec k n Check en gi ne st op swi tch T est the engine stop switch befor e each us e of t he sn owmo bil e. T o stop the engine in an e mer gency , push down on the stop switch (A) . This will ground out the ignition and br ing the engine to a quick stop. T o restar t the engine , the switch m u s tb ep u l l e du pt ot h ...
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Polaris 120 - page 34
31 ADULT SECTION Operation Warnings n Do n ot carry passen gers This snowmobile is designed for a single opera tor . n Do n ot op erate w ith i nt ake sil encer remo ved CAUTION If t he engine is operat ed with t he intake s ilencer rem oved, damage t o the engine may occur. Do not operat e the engine wit h the int ake silencer rem oved. n Stay cl ...
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Polaris 120 - page 35
32 ADULT SECTION Operation Warnings n Do not touch the engine a fte r it’ s been running W ARNING Hot com ponents c an cause ser ious burns t o skin. Do not t ouch engine and exhaust part s af ter t he engine has been running. n Disab led o perato rs W ARNING Safe oper ation of t his rider- activ e vehicle requir es good judgement and physic al s ...
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Polaris 120 - page 36
33 ADULT SECTION Operation Warnings n Check b rake lever t ravel Measu re th e clearance bet ween the l ever and brak e block. Inspe ction should be made with the lev er firmly de presse d. Distanc e A should be no more than 3/4 ″ (1.9 cm ). Exces siv e trav el i ndi cates a need t o adj us t th e brake cab le. Refer t o th e mechan ical brak e a ...
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Polaris 120 - page 37
34 ADULT SECTION Operation Warnings n Che ck s urr oundings to ver ify cle ar ope ra ting are a It’ s important to make sure the re’ s a clear ar ea all around the snowmobile, including an area c lear of bysta nders. Some sidewa ys movement is possible when sta rting out, and debr is may be thrown by the t rack. T each th e operato r to check t ...
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Polaris 120 - page 38
35 ADULT SECTION Operation Warnings n Stop engine be fore a tte mpt ing a djustm ents W ARNING The s nowmobile engine compar tment cont ains mov ing parts . Shields and guar ds have been prov ided for saf ety , but it is st ill possible to car elessly get y our hands or fingers int o a moving chain or a r otating s haft . F or this r eason never at ...
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Polaris 120 - page 39
36 ADULT SECTION Operation Warnings n Know limita tions of ma chine a nd skills of driv er The opera tor should be aware that ther e are state a nd local laws governing snowmobile opera tion and that the se laws should be followe d. They have bee n establishe d for the pr otection o f all snowmobile rider s. Most state s off er a snowmobile safe ty ...
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Polaris 120 - page 40
37 ADULT SECTION Operation Warnings W ire fences are a s eriou s hazard . T each your child to a lways be on the a lert for fences. S ing le st rands are es pecial ly dang erous , s ince t here can b e a great distance betwe en posts. Guy wires on utility poles a re a lso dif ficu lt to distinguis h. T each your child to reduce sp eed when trav eli ...
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Polaris 120 - page 41
38 ADULT SECTION Operation Warnings Windchill/T emperatur e Charts The following inf ormation is provide d to help you deter mine when temper ature s become danger ous for r iding. WIND CHILL CHART ( ° F) Wind Speed in MPH Act ual Therm ometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2 0 -25 -30 -35 -40 -4 5 Equivalent T emperat ure ( ...
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Polaris 120 - page 42
39 ADULT SECTION Operation Warnings Windchill/T emperatur e Charts WIND CHILL CHART ( ° C) Wind Speed in KPH Act ual Therm ometer Reading ( ° C) 5 2 -1 -4 -7 -10 -13 -16 -1 9 -22 -25 -28 -31 -3 4 -37 -40 -43 -46 Equivalent T emperat ure ( ° C) Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -3 1 -34 -37 -40 -43 -4 6 8 3 0 - -7 -1 1 -14 -18 -22 -25 ...
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Polaris 120 - page 43
40 ADULT SECTION Operation Warnings Cold Weather Dr ive -A way Whe never the ma chine ha s been parke d for some length of time, espec ially overnight, alway s shake loose the skis and tra ck for the opera tor befor e attempting to put the machine into motion. The throttle will re quire some pre ssure to move the machine . T each t he opera tor not ...
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Polaris 120 - page 44
41 ADULT SECTION Operation Warnings Snow and Ice Build - Up Snow and ice buildup in the under hood are a ca n interf ere with the st eering. W ARNING Befor e allowing your c hild to driv e the mac hine, be sur e that ice and snow are not int erfer ing with t he steer ing. Manually t urn t he skis t o the left and right . I f difficult y is encount ...
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Polaris 120 - page 45
42 ADULT SECTION Operation Warnings Driving on Ice It is dangerous to opera te on ice or under slipper y conditions. If ice or slippery conditions ar e unavoidable , use extreme ca ution and opera te at speed s no fas ter th an a walk. N ever att empt an ab rupt ch ange of direct io n on a s li ppery s urface. T he chance o f “spi n-out ” in cr ...
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Polaris 120 - page 46
43 ADULT SECTION Operation Warnings Driving Downhill Whe n riding downhill, the opera tor must kee p the spee d at a minimum. It is importa nt to apply just enough throttle to keep the clutc h engage d while desc ending the hill. This will allow use of the engine ’ s compre ssion to help slow the machine , and kee p the snowmobile f rom rolling f ...
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Polaris 120 - page 47
44 ADULT SECTION Com ponent Identification 1. Hood 8. Rear Suspension 2. Headlight 9. Nosepa n 3. W indshield 10. T railing Ar m 4. Handlebar 1 1. Skis 5. S ea t 12. F ront Bumper 6. S torage ( under seat) 13. R ear Bumpe r 7. T aillight 14. Snow Flap 15. T ra ck 2 1 3 4 5,6 7 15 9 10 11 12 14 13 8 ...
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Polaris 120 - page 48
45 ADULT SECTION Com ponent Identification 1. St op Switch 2. T ether Strap 3. Throttle Control 4. Reco il S tart er Handl e 5. Hood Hold-Down 6. Choke B utton 7. Gas Cap 8. Ignition Switch 9. Console 10. Brak e Lever 1 1. T ether Switc h 10 8 11 6 3 1 4 7 9 2 5 5 ...
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Polaris 120 - page 49
46 ADULT SECTION Br eak-In Period Engi ne Br eak - In The brea k-in period for your new snowmobile is define d as the first ten hours of opera tion, or the time it takes to use the first two tanks full of gasoline. No single ac tion on your part is as impor tant as a pr oper brea k-in pe riod. Care ful trea tment of a new engine will r esult in mor ...
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Polaris 120 - page 50
47 ADULT SECTION Br eak-In Period CAUTION Mixing br ands or using a non- recomm ended oil may caus e serious engine damage. We r ecommend t he use of Polaris Prem ium 4 All Season Synthet ic oil. Never s ubstit ute or mix oil brands. Checking Engine Oil Befo re c hecking o r ref illing engine oil, be sure the engine is stopped and the vehic le is p ...
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Polaris 120 - page 51
48 ADULT SECTION Operation Fuel When refuel in g, u se eith er leaded o r unlead ed gaso li ne wit h a minimum pump octane number of 87=( R+ M)/2 octane. Fuel Safety W ARNING Gas oline is highly flam ma ble and ex plosiv e under c er tain condit ions. Always ex ercise ex trem e caution whenev er handling gasoline. Always r efuel wit h the engine st ...
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Polaris 120 - page 52
49 ADULT SECTION Operation Speed/Per formance Regulation Adults have the re sponsibility for t eachi ng chi ldren t he prop er and safe way to ride a snowmobile. Please set boundar ies and adhere to them, keep ing your child’ s safety fo remost in your mind. Never allow a c hild to operate this mac hine without adult supervision. Under certai n c ...
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Polaris 120 - page 53
50 ADULT SECTION Operation Sta rting the E ngine Never sta rt the snowmobile without che cking all components to be sure of prope r opera tion. Refer to the Pre -Ride Check be ginning on page 27. Star ting a Cold E ngine 1. T urn the ke y to ON. 2. P ull the e ngine stop switch (shut- of f switch) up to the RUN position. 3. Pull the choke leve r co ...
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Polaris 120 - page 54
51 ADULT SECTION Operation Em er gency S topping Pr ocedur es The following cha rt lists methods for stopping the engine in the eve nt of an em ergency . SYSTEM WHA T I T DOES THROTTLE CONDITIO N Engine Stop Switc h Interr upts ign ition circuit All Ignitio n Sw itch Interr upts ig nition circuit All T ether Sw itch Interr upts ig nition circuit Al ...
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Polaris 120 - page 55
52 ADULT SECTION Operation Pre - Ride W arm - Up Always war m up the engine, drive tr ain and tra ck befor e opera ting the snowmobile. W ith the snowmobile sec urely suppor ted by the re ar bumper with a minimum clea ranc e of 4 ″ (10 cm) from the ground, use the following pr ocedure to proper ly warm up the snowmobile . W ARNING A loose t rack ...
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Polaris 120 - page 56
53 ADULT SECTION Em ission C ontrol Infor m ation Em ission Con trol Label Y our snowmobile is equippe d at the time of sale with an emission control inf ormation (ECI ) label a nd a fac tory-insta lled emissions infor mation hang ta g. These ite ms are re quired by U .S. Environmenta l Protec tion Agency r egulations. The ECI label is per manently ...
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Polaris 120 - page 57
54 ADULT SECTION Maintenance Polaris R ecommended Mainten ance Pr ogram Pl ease read and fol lo w the reco mm ended mai nt enance p rogram illustrate d on the follow ing pages to maintain the perf ormanc e and relia bility of your Polar is snowmobile. Rec ord mainte nance and se rvice in the Mainte nance Log b eginning on page 93. The P olari s Rec ...
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Polaris 120 - page 58
55 ADULT SECTION Maintenance Care ful periodic mainte nance will help kee p your vehicle in the safe st, most relia ble condition. In spection, adjustme nt and lubrica tion of important c omponents ar e expla ined in the following c hart and in the mainte nance se ction of this manual. Ser vice and a djustments are c ritica l. If you’r e not fami ...
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Polaris 120 - page 59
56 ADULT SECTION Maintenance ITEM DAIL Y WEEK L Y O R BEFORE EXTEN DED PERIO D OF OPER A TIO N 50 HRS 100 HRS 150 HRS SEE PA G E Check tr ack alignment X 71 Che ck driv e ch ain ten sion X 62 Check and ti ghten any l oose suspensi on mounti ng bolt s X 79 T ight en ski s addle and spi ndle bo lts if loo se X 76 Check fr ont and rear limi ter str ap ...
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Polaris 120 - page 60
57 ADULT SECTION Maintenance Spa rk P lugs A new e ngine ca n cause tempora ry spark plug f ouling even though the heat ra nge is proper , due to the preserva tive which has bee n added during asse mbly of the e ngine to comba t rust and cor rosion. A void prolonged idle speed s, as plug fouling and ca rboniza tion will result. CAUTION Using non-r ...
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Polaris 120 - page 61
58 ADULT SECTION Maintenance Spa rk P lugs Spark Plug R emoval and R eplacement 1. Remove the spark plug cap. 2. Using the special wre nch provide d in the tool pouch, rotate the spark plug c ounterc lockwise to remove . 3. Reverse the proce dure for spar k plug installa tion. T orque to 12-14 ft. lbs. (16-19 Nm) . Fuel V alve/Fu el Lines The fuel ...
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Polaris 120 - page 62
59 ADULT SECTION Maintenance Car bur etor Proper c arbur etor adjustme nt is cr itical, since a mixture too lea n (too much a ir , too little fue l) will re sult in overhe ating of the combustion cha mber ca using pre- ignition of the fue l. This results in piston burning, bearing fa ilure, or complete e ngine failur e. A lean mixture ca n be the r ...
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Polaris 120 - page 63
60 ADULT SECTION Maintenance Throttl e Cable Lubr icat ion W ith the engine of f, lubrica te the throttle cabl e occasi onal ly . T urn t he han dleb ars to the lef t and lubric ate libe rally with Po laris A ll S eason Greas e. Choke /Cabl e Lubric ation Lubrica te the choke slide and cable s occasional ly as shown. Operat e the choke intermitte n ...
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Polaris 120 - page 64
61 ADULT SECTION Maintenance Brake A djustment If excess iv e brake l ever t o brak e blo ck clearan ce is ev id ent, t he brak e cab le should be adjusted. If prope r adjustment ca nnot be achieve d by using the following methods, check the brake ba nd for exce ssive wear . Y our snowmobile dea ler can install a new bra ke band when nece ssary . W ...
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Polaris 120 - page 65
62 ADULT SECTION Maintenance Chain T en sioner Inspec t the chain. The cha in s hould have 1 ″ of de flection as shown. If not, loosen the nut on the cha in tensioner (A) a nd raise until 1 ″ (B) of defle ction is attaine d. T ighte n nut to 15-18 ft. lbs. (20-24 Nm). Whe n the cha in comes w ithin 1/8 ″ (C) of the muf fler mount bra cket (D) ...
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Polaris 120 - page 66
63 ADULT SECTION Maintenance Lubri cation NOT E: Driveline nois e is norm al and inherent in a c hain drive system such a s this machi ne use s. T o ensure long life of the snowmobile ’ s driveline, lubricate a s follows: S Lubrica te Point A ever y 15 hours of oper ation with a sma ll amount of Pol aris P remi um All S easo n Grease. S Lubrica t ...
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Polaris 120 - page 67
64 ADULT SECTION Maintenance Oil Level Mainta in the oil leve l betwee n the safe ma rks (A) on the dipstick. Oil Chang e Change the oil af ter the initial 20 hours of operatio n and again after each 50 hours. W ashing Y our Snowm obile Keeping your snowmobile cle an w ill not only improve its appe ara nce but it can a lso extend the life of var io ...
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Polaris 120 - page 68
65 ADULT SECTION Maintenance Controls and L inkage All bushings, spindle shafts, and tie r od ends should be c oated w ith a light coa t of oil or g rea se. Thro ttle and brake contr ols and c able s should be lubric ated with Polar is Premium All Season Gr ease . Force a small amount of lubrica nt down the ca ble. Bearings T o preve nt corrosion w ...
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Polaris 120 - page 69
66 ADULT SECTION Maintenance Engi ne Proper of f-season pr epar ation of the e ngine and f uel system is vital to the pre vention of r ust and cor rosion forma tion on prec ision engine parts during stor age. W ithout proper stor age, jet re striction c an ca use lea n conditions and very poor slow spee d driving quality . When pr epar ing your sno ...
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Polaris 120 - page 70
67 ADULT SECTION Maintenance Car buretor P rotection During Off - Season Stor age When pr epar ing your snowmobile for of f-sea son storage we recomm end t hat yo u add a fuel con dit io ner/s tabi li zer or Prem ium Carbon Clea n (2871326) to the f uel tank. Follow the instruc tions on the can . Run the engine f or five minutes to get additives th ...
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Polaris 120 - page 71
68 ADULT SECTION Maintenance T ranspor ting the S nowmobi le Whe never the snowmobile is tra nsported the follow ing measure s should be taken: 1. T urn the fuel valve of f. 2. Be sure the fuel ca p is installe d corre ctly . 3. Always tie the snowmobile to the transporting unit secur ely using suitable str aps. NOT E: Transportat ion to and f rom ...
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Polaris 120 - page 72
69 ADULT SECTION Maintenance W ARNING Y our snowmobile is propelled by a revolv ing trac k, whic h must be part ially exposed for pr oper operation. Serious injuries m ay be caused by t he operat or ’s hands, f eet or c lothing becom ing entangled in t he trac k. B e alert. Always s it proper ly on t he seat. T rack a nd Suspensi on Under norma l ...
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Polaris 120 - page 73
70 ADULT SECTION Maintenance T rack Adjustment If the tra ck need s adjustment: 1. Loosen rear idle r shaft bolt (D). 2. T igh ten or l oos en the track ad jus ti ng screws (E ) as necessary t o provide equa l adjustment on both sides of the trac k. 3. Repeat measure ment on the other side of the track. NOT E: Check m ore fr equently when t he mach ...
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Polaris 120 - page 74
71 ADULT SECTION Maintenance T rack Alignment A periodic c heck should be made to see that the tra ck is center ed and running eve nly on the slide rails. Misalignme nt will ca use exc essive wea r to the tr ack a nd slide r ail. W ARNING When per form ing the f ollowing checks and adjust ments , st ay clear of all mov ing parts t o avoid serious p ...
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Polaris 120 - page 75
72 ADULT SECTION Maintenance T rack W arm U p Whe n storing your snowmobile outside overnight, it is rec ommended tha t the trac k be warmed up pr ior to driving the snowmobile. This re duces dr ive clut ch wear . T o warm u p the track , safe ly support the rear of the snowmobile of f the ground, start the engine an d abruptly engage the clutch . ...
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Polaris 120 - page 76
73 ADULT SECTION Maintenance T rack Inspection W ARNING Inspec ting t he trac k while the engine is running c an result in serious personal injur y if t he tr ack should being t o move. Never inspect t he trac k with t he engine running Using a hoist or jack stand, safe ly lift and support the rea r of the snowmobile off the ground. Rotate the tra ...
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Polaris 120 - page 77
74 ADULT SECTION Maintenance Slider Replacement The 120 snowmobile uses XTRA Lite style slide r . When an y area of t he sl id er is worn to 7/16 ″ (1.1 cm ), it should be repl aced. This wi ll save we ar on other vital compone nts. T h es l i d er a i li sd e s i g n e d t o opera te in conditions with adequa te snow cover to provide suf fic ien ...
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Polaris 120 - page 78
75 ADULT SECTION Maintenance T rack Lubr ica tion T r ack f ailure , loss of vehicle contr ol and bra king ability ca n result f rom ext ended us e of thi s vehi cle on s urfaces pro vi din g marginal l ubri cati on bet ween the sl id er and track g uid e clip s. E xamp les of m arginal lubrica tion would include la kes without snow c over , icy tr ...
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Polaris 120 - page 79
76 ADULT SECTION Maintenance Steer ing Insp ection and Adjustment The ste ering a ssembly of the mach ine should be checke d periodic ally for loose nuts and bolts. Se e A,B,C,D,E, F , a nd G in illustra tion at right. W ith handlebar s in straight ahe ad position and me asuring from the straight edge of the ski s, t he m easurem ent betwee n the s ...
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Polaris 120 - page 80
77 ADULT SECTION Maintenance Handlebar Adjustment 6. S lide the handleb ar pad upward t o access t he adj ust er bolts. If a dditional room is requir ed, unzip one of the handleba r pad z ippers and r oll the pad to the side. 7. T o adjust, remove the upper flange nut and car riage bolt. 8. Loosen the lower flange nut only enough so the br acke t c ...
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Polaris 120 - page 81
78 ADULT SECTION Maintenance Ski S kags The s kag (A) i s a repl aceable b ar atta ched to the underside of the ski. The purpose of the skag is to assist in tur ning the snowmobile and to preven t the weari ng away of th e ski caus ed by cont act wi th roads and other ba re ter rain. W e recom mend th at s kags b e checked once a we ek to mainta in ...
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Polaris 120 - page 82
79 ADULT SECTION Maintenance Sus pension Lubr icati on T o maintain r ider comf ort and to re tard w ear of the pivot shaf ts, the suspension pivot shaf ts should be lubrica ted with Polar is Premium All Season G rea se seve ral times dur ing the sea son and aga in befor e sum mer s torag e each year . The ri din g charact erist ics of t he snowmob ...
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Polaris 120 - page 83
80 ADULT SECTION Maintenance Sus pension Com ponents Suspension Lubric ation points ar e indica ted by a L . 1. Front Limiter Strap 8. Ra il Bumper 2. T or sion Spring Sleeves 9. T orque Arm 3. T orsion Spring 10. Rail 4. Carri er Wheel 1 1. Sl id er 5. Rear Limite r Strap 12. T oe Gua rd 6. S pacer 13. Id ler Wheel 7. Adjuster Bolts 4 6 2 1 5 12 1 ...
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Polaris 120 - page 84
81 ADULT SECTION Accessor ies Maintenance Items and Accessories The tools and ma intenanc e items me ntioned in this book, as well a s a long l ine of o ther P olaris access ori es, are avail able at your P olaris deal er . Pa int Codes Colo r Descri pti on Polaris “P” No. Raw Mater ial No. Indy Red P293 8520297 Indy Black P067 8520246 Paints c ...
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Polaris 120 - page 85
82 SPECIFICA TION S Jetting Chart Engi ne Serial # up to 0502779 Ambi ent T emperat ur e Belo w -30 _ F (-34 _ C) -30 _ to -10 _ F (-34 _ to -23 _ C) -10 _ to +10 _ F -23 _ to -12 _ C +10 _ to +30 _ F -12 _ to -1 _ C +3 0 _ to +50 _ F -1 _ to +10 _ C Abov e +50 _ F Abov e +10 _ C Altitude in Meters ( F ) 0-600 (0-2000) 75 72.5 72.5 72.5 70 70 M e t ...
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Polaris 120 - page 86
83 SPECIFICA TION S Ca pa cities a nd Dimen sion s Body St yle Mi ni Indy Ri ders/W eight 1/ 150 lbs. (68 kg) m aximum Eng ine Oil .6 qt s. ( .57 l ) Dry W eight (est .) 147. 5 lbs. (67 kg) Fue l T an k .5 ga l. (1.9 l) Hei ght 31 in. (78. 7 cm) Lengt h 75 in. (190. 5 cm) Ski Ce nter Dista nce 30 i n. (76. 2 cm) Wid th 34 in. ( 86.4 cm) Brake T yp ...
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Polaris 120 - page 87
84 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2871281 Premi um 4 Synt hetic 0W - 40 Engine Oi l ( 4-Cycl e)( qt. ) Gearcase / T r ansmi ssion Lubri cants 2873602 Premi um Synthet ic Gearcase Lubri cant (qt .) 2871653 Premi um Fr ont Gear case Lube (8 oz. ) 2871654 Pre mium D rive H ub F luid (8 oz .) Grease / Speci alized Lubri cants ...
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Polaris 120 - page 88
85 WARRANTY Ser vice A nd W arr anty Infor ma tion Obtaining Service and W ar ranty Assistance Read and unde rstand the servic e data an d the P olar is warra nty informa tion containe d in this manual. Contact your Pola ris deale r for replacem ent part s, serv ice or warran ty . Y our deal er receives frequ ent updates on c hanges, modific ations ...
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Polaris 120 - page 89
86 WARRANTY Li mit ed Warran ty Pola ri s Sa le s I nc. , 2100 Highw ay 55, Me dina , MN 55340, provi des a O NE YEAR LIM- ITED W ARRANTY on all c omponent s of the Pol a ri s snowmobi le a ga ins t def ec ts i n ma te ri al or wor kma nshi p. This wa r ra nty cove rs t he pa rt s and la bor cha r ge s for r epa i r or replacem ent o f d efective p ...
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Polaris 120 - page 90
87 WARRANTY Limita tions of warrantie s and remedi es ALL IMPLI ED W ARRANTIES (IN CLUDING BUT NOT LIMI TED TO THE I M- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TICU- LAR PURPOSE) ARE LIMI TED IN DURA TION T O THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIM S ALL EXPRESS W AR- RA NT IES N OT S T A T ED IN T HIS W ...
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Polaris 120 - page 91
88 WARRANTY Conditions and Ex clus ions In or de r t o qual if y for warr a nty , the product must ha ve be en pr oper ly s e t up a nd te st e d by a Po laris Dealer (if ap p licable). F ailure o f an y d ealer to p erfo rm th e requ ired v eh icle Pre - - De li ver y Inspe c ti on, per for m all a ppli c abl e se rvi c e bull et ins a nd have the ...
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Polaris 120 - page 92
89 WARRANTY Pol ari s Second Y ear E ngine Ser vic e Contr act Sec ond Y ea r Engine Servi ce Contr ac t i s s ta nda rd on a ll eli gibl e ne w a nd unuse d snow mobil es that were Snow Chec ked t hrough a n a uthor iz ed Pol a ri s de al e r dur ing t he Ma rc h/Apr il Snow Che ck promot ion. The f re e Sec ond Y ear Engi ne Se rvi ce Cont ra c t ...
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Polaris 120 - page 93
90 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THIS VEHI CLE IF IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. Th is po licy do es not app ly to v ehicles that hav e received aut ho rization fo r e xpor t fr om Pola ri s Indus ...
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Polaris 120 - page 94
91 WARRANTY Snow mobil e Engine E mi ssions Li mite d W ar ra nty Th is sno w mo bile en gin e emissio n s limited warran ty is in ad ditio n to th e Po laris standard li mi te d war ra nty for s nowmobi le s . Pola ri s Indus tr ie s I nc. wa rr ant s t hat at the ti me i t is fi rs t purc ha se d, thi s em is si ons- - ce r ti fi ed snowm obil e ...
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Polaris 120 - page 95
92 WARRANTY Snow mobil e Engine E mi ssions Li mite d W ar ra nty Some st a te s do not a ll ow li mi ta ti ons on how long an impl ie d wa rr ant y las t s, so the above limitatio n may n ot app ly if it is incon sistent with th e contro lling state law . Th is limited war- ra nty e xc lude s f a il ure s not ca us ed by a def ec t in mat er ia l ...
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Polaris 120 - page 96
93 MAINTENANCE LOG Present thi s sect ion of your m anual to your deal er each time your snowmobile is service d. This will provide you and future owner s with an accurate l og of mai nt enance and serv ices p erformed o n the snowmobile. DA TE HOURS T ECHNICIAN SER VICE PERFO RMED / COMMENTS 50 100 150 ...
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Polaris 120 - page 97
94 MAINTENANCE LOG DA TE MILES (K M) TECHNICI AN SERVICE PERFORMED / CO MMENTS ...
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Polaris 120 - page 98
95 MAINTENANCE LOG DA TE MILES (K M) TECHNICI AN SERVICE PERFORMED / CO MMENTS ...
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Polaris 120 - page 99
96 INDEX A Accessories 81 ..................... Auto C hain T ensioner 62 ............. B Brake A djustm ent 61 ................ Brake L ever T ravel 60 ............... Break-In P eriod 46-47 .............. C Carburetor 59 ..................... Carburetor P rotecti on 67 ............. Checki ng Engine O il 47 ............. Choke and C able L ubrica ...
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