Polaris 120 Pro X manual

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W ARNING W ARNING Read, understand, and follow al l of the instructions and safety precautions in thi s manual and on all product labels. Failure to follow t he safety precautions could result in serious inj ury or death. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive harm. PROPO[...]

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2 Copyri ght 2004 Pola r is Sa l es I nc . Al l inf or ma ti on c onta i ned wi t hin t hi s publ i ca t ion i s bas e d on the l a te s t produc t i nfor ma t ion at t he ti me of publ ic ati on. Due to cons tant imp rov emen ts in the design an d qu ality o f pr oduc ti on compone nts , s ome mi nor discrep an cies m ay result betw een the actual[...]

3 TABLE OF CONTENTS Wel com e 4 .................................. Introducti on 5 ............................... Important Notes for Owners and Drivers 6 ........... Preservation of the E nvironment 7 .................. V ehicl e Identificati on Numbers 9 .................... Safety 10 .................................... YOUTH SECT IO N 13 .....[...]

4 WELC OME Dear Par ents: W e belie ve your c hildre n should have the opportunity to enjoy The W ay Out expe rienc e along with you. W e’ve provided this owner’ s manual to a ssist you and your ch ildren in lea rning about the safe opera tion and car e of your new Polaris snowmobile. Please re view the informa tion in this manual with a ny chi[...]

5 INTRODUCTION After r eading this manual, store it in the snowmobile for conve nient ref ere nce . It should remain with the snowmobile when sold. n This manual conta ins the latest information at the time of printing. W e rese rve the right to make product cha nges and improveme nts without notice. n The illustra tions and photos used in this ma [...]

6 INTRODUCTION Impor tant Notes for Ow ners and Dr iver s P ARENT S: Do not allow anyone unde r the age of six (6) to operate this mach ine. Revie w the infor mation in this manua l with any c hild who may b e operati ng t he snow mob ile. It i s up t o you t o teach any opera tor the proper and saf e way to ride a snowmobile. Y ou must set boundar[...]

7 INTRODUCTION Pr eservation of the E nvironm ent T each your child to dri ve their s nowmobile w i th considerat ion for the protec tion and pr eser vation of the environme nt. Noise Level One of the most publicize d subjects w ith rega rd to snowmobiles is noise. The Society of Automotive Engine ers (SAE) , which is the standar d-se tting body fo[...]

8 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 provincia l governme nts across the snowbelt to adopt rigorous sa fety tr aining progr ams which a lso encour age protec tion of our environme nt, wildlife and vege tation. Snowmobi[...]

9 INTRODUCTION V ehicl e Identification N umber s The fra me vehicle ide ntifica tion number (VIN) and e ngine serial number a re impor tant for model identific ation whe n re gistering your vehi cle, when o btai ni ng in suran ce, and wh en orderi ng repl acement parts. In the eve nt your vehicle is stolen, these numbe rs are e ssential to the re [...]

10 SAFE TY W ARNING Failur e to follow the war nings in this manual can r esult i n severe injury or death. Read and unders tand t he owner ’s manual and all warnings bef ore operat ing a Polaris snowmobile. Adult s mus t thoroughly explain t his inf ormat ion to all operat ors of t he snowmobile. All operat ors m ust be at least s ix (6) y ears [...]

11 SAFE TY Maintenance Pr ogram As with all snowmobiles, caution must be obse rve d to ensure ope rator safe ty . Partic ular c aution must be taken to make sure tha t the snowmobile is in e xce llent oper ating c ondition at all time s. W e strongly re comme nd that the ope rator , as well a s an adult, ch eck ma jor and vi tal safet y components [...]

12 SAFE TY Safety Decals Safet y and warni ng d ecals hav e been placed o n the veh icl e for the opera tor ’ s protec tion. Make sure the oper ator under stands the info rmat ion o n all d ecals. If any d ecal becom es illegible or c omes of f, contact your P olari s deal er for a replacement . Any safety decal needi ng repl acemen t wil l be pr[...]

13 SAFE TY The following signa l words and symbols a ppear throughout this manual a nd on your vehic le. Y our sa fety is involve d when the se words and symbols are use d. Become f amilia r with their mea nings befor e rea ding the manual. The safety aler t sy mbol , on y our vehicle or in this manual, alert s you to t he potent ial f or personal [...]

14 YOU TH SECT IO N Know Y our S nowm obile Befor e you have an adult star t the engine for you for the first time, let’ s lear n about the c ontrols on your ne w mach ine. 1. Engine St op Switc h - When the e ngine is running, you ca n push this button down and the e ngine w ill stop. The stop sw itch must be in the UP position to start the engi[...]

15 YOU TH SECT IO N Know Y our S nowm obile Always tak e your t humb off t he throt tle lev er when you s queeze 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 c h - The ignition sw itch ke y must be turne d ON befor e pulling on the recoil star [...]

16 YOU TH SECT IO N Know Y our S nowm obile Let’ s lear n more about the parts of your snowmobile befor e we talk about riding. 1 2 3 4 5 6 9 8 10 7[...]

17 YOU TH SECT IO N Know Y our S nowm obile 1. Hood - The hood covers the moving and hot parts of t he engine and must be secure ly latche d befor e you ride the snowmobile. 2. Headlight - The he adlight is always on when the engine is running. It helps other s see you when you’ re r iding during daylight, but it’ s not supposed to be str ong e[...]

18 YOU TH SECT IO N Know Y our S nowm obile Let ’ s review t he t hree w ays to st op you r sn ow mob il e: 1. Push the stop switch dow n. 2. Pull of f the tethe r strap. 3. T urn the key of f. 1 2 3[...]

19 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 . Before the snowmobile is starte d for the first time, you must do a PRE-RIDE CHECK. In fa ct, ever y time you ride your snowmobile you must have an adul t hel p you ch eck thes e thin gs befo re start ing i t. Let ’ s learn about these things n[...]

20 YOU TH SECT IO N Pre-Rid e Chec k Always have an adult put gas in your snowmobile. Nev er tr y to do it yours elf. n Have an adult che ck the gas leve l to see if your snowmobile nee ds more. Childre n should never add their own gasoline . This must always be done by an adult. Before anyone a dds gasoline to your snowmobile they must r ead the i[...]

21 YOU TH SECT IO N Ridi ng Rules Now you’re ready to lear n about driving your Pola ris snowmobile. There a re some things you can do and there ar e some things you must never do. Rules are ve ry important when you’r e driving a snowmobile. Adults have r iding rules, too. The rules he lp keep us sa fe whe n we ride. Y ou mus t be at leas t si [...]

22 YOU TH SECT IO N Ridi ng Rules " Always wear the right kind of clothing when you’re riding your snowmobile. Y ou’ll need a good he lmet with a fac e shie ld or goggles. W ear a wa rm jacket and snowpants. Make sur e your cloth- ing fits prope rly . If it’ s too small, it could keep you f rom moving easily . If it’ s too big, it coul[...]

23 YOU TH SECT IO N Ridi ng Rules " Always drive your snow mobile while sitting down. Keep both hands on the ha ndlebar s and kee p both fe et on the running boa rds. " Neve r follow anothe r snowmobile too close ly . Alwa ys allow lots of time an d space to stop your snowmobile. " Ride your snowmobile only where you know it’ s saf[...]

24 YOU TH SECT IO N Ridi ng Rules Lear n how to ride sa fe ly and cor rec tly . Lea rn how to use your hands and ar ms as signals. Read a nd understa nd your Owner’ s Manual. Left T urn Right T urn Stop[...]

25 ADULT SECTION Pre-Rid e Chec k It’ s up to you, t he adult, to teach your chi ld the proper and safe way to ride a snowmobile. Y ou must set boundaries and adhe re to them, keeping your child’ s safe ty fore most in your mind. Never allow your child to opera te this machine w ithout adult supervision. W ARNING T each t he operator s to per f[...]

26 ADULT SECTION Pre-Rid e Chec k Befor e S tar ting The Engi ne n Re ad a nd Unde r sta nd Y our Owner’ s M anua l Read and make sure the oper ators under stand the Owner ’ s Manual comple tely befo re allowing anyone to oper ate this snowmobile. It’ s also a good ide a to re view it pe riodica lly to re inforc e the inf orma tion. It’ s v[...]

27 ADULT SECTION Pre-Rid e Chec k n Check t hro ttl e safety sw itch T est the throttle sa fety switc h system on a daily basis befor e the machine is used. While se ate d in a normal riding position, and with the engine idling, hold the throttle leve r pin stationar y by exe rting pre ssure on the pivot pin in the dire ction show n in the illustra[...]

28 ADULT SECTION Pre-Rid e Chec k n Check en gi ne st op swi tch T est the engine stop switch bef ore each us e of t he sn owmo bi le. T o stop the engine in an emer genc y , push down on the stop switch (A) . This will ground out the ignition and bring the engine to a quick stop. T o resta rt the engine, the switch m u s tb ep u l l e du pt ot h e[...]

29 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 silenc er remov ed. n Stay cl[...]

30 ADULT SECTION Operation Warnings n Do not touch the engine a ft er it’ s bee n running W ARNING Hot com ponents can caus e serious bur ns to s kin. Do not t ouch engine and exhaust part s af ter t he engine has been running. n Disab led o perat ors W ARNING Safe oper ation of t his rider- activ e vehicle requir es good judgement and physic al [...]

31 ADULT SECTION Operation Warnings n Check b rake lever t ravel Measu re th e clearance betw een the l ever and brak e block. Inspec tion 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 si ve trav el i ndi cates a need t o adj us t th e brake cab le. Refer t o t he mech anical brak e a[...]

32 ADULT SECTION Operation Warnings n Che ck s urr oundings to ve rif y cle ar ope r ating ar e a It’ s important to make sure the re ’ s a clea r are a 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 thr own by the t rack. T each th e operat or to ch[...]

33 ADULT SECTION Operation Warnings n Stop engine be for e att em pting adjus tm ents W ARNING The s nowmobile engine compar tment cont ains mov ing parts . Shields and guar ds have been prov ided for s afet y , but it is st ill possible t o careles sly get your hands or f ingers int o a moving chain or a r otat ing shaft . F or t his reason nev er[...]

34 ADULT SECTION Operation Warnings n Know limita tions of m ac hine and sk ills of driv er The opera tor should be aware tha t there are sta te and local laws governing snowmobile operation and tha t these la ws should be followe d. They have been esta blished for the pro tection of all snowmobile rider s. Most state s of fer a snowmobile sa fety [...]

35 ADULT SECTION Operation Warnings W i re fences are a s erio us h azard. T each your child to a lways be on the aler t for fences. S in gle s tran ds are es pecial ly dang erous , s ince t here can b e a great distance between posts. Guy wire s on utility poles a re a lso dif f icult to distinguis h. T each your child to reduce sp eed when trav e[...]

36 ADULT SECTION Operation Warnings Windchill/T emper ature Charts The following informa tion is provide d as a guide to determine wha t temper ature s are danger ous when riding your snowmobile . WIND CHILL CHAR T ( ° F) Est i- m a t e d Actual Ther mometer Reading ( ° F) mate d Wind Speed i n M P H 50 40 30 20 10 0 -10 -20 -3 0 -4 0 -5 0 -6 0 i[...]

37 ADULT SECTION Operation Warnings WIND CHILL CHAR T ( ° C) Est i- m a t e d Actual Ther mometer Reading ( ° C) ma t e d Wind S p e e d 5 0 -5 -10 -15 -2 0 -25 -3 0 -35 -40 S pee d in KPH Equivalent T emperature ( ° C) 0 5 0 -5 -10 -15 -2 0 -25 -3 0 -35 -40 10 1 -4 -1 1 -16 -22 -2 7 -33 -3 8 -45 -50 20 -4 -9 -17 -23 -29 -3 6 -42 -4 8 -54 -61 30[...]

38 ADULT SECTION Operation Warnings Cold Weather Dr ive - A way Whe neve r the machine h as been par ked for some le ngth of time, espec ially overn ight, alwa ys shake loose the skis and track for the opera tor bef ore atte mpting to put the machine into motion. The throttle will re quire some pre ssure to move the mac hine. T each the opera tor n[...]

39 ADULT SECTION Operation Warnings Snow and Ice Build - Up Snow and ice buildup in the under hood are a c an inter fer e 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 the skis t o the left and ri ght. If diff icult y is encount[...]

40 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 unavoida ble, use extreme c aution and oper ate a t speed s no fast er than a wal k. Never att emp t an abrup t chang e of direct io n on a s li ppery surface. T he chance o f “spi n-out ” in cr[...]

41 ADULT SECTION Operation Warnings Driving Downhill Whe n riding downhill, the oper ator must ke ep the spe ed a t a minimum. It is importa nt to apply just enough throttle to keep the clutc h enga ged while desc ending the hill. This will allow use of the engine ’ s compr ession to help slow the mac hine, and ke ep the snowmobile f rom rolling [...]

42 ADULT SECTION Com ponent Identification 1. Hood 8. Rear Suspension 2. Headlight 9. Nosepan 3. W indshield 10. T railing Arm 4. Handleba r 1 1. S kis 5. Seat 12. Front Bumper 6. Storage (unde r seat) 13. Rear Bumper 7. T aillight 14. Snow Flap 15. T rack 2 1 3 4 5,6 7 15 9 10 11 12 14 13 8[...]

43 ADULT SECTION Com ponent Identification 1. Stop Switch 2. T ethe r Strap 3. Thro ttle Control 4. R ecoi l S tart er Handl e 5. Hood Hold-Down 6. Choke Button 7. Gas Cap 8. Ignition Switc h 9. Console 10. Brak e Lever 1 1. T ethe r Switch 10 8 11 6 3 1 4 7 9 2 5 5[...]

44 ADULT SECTION Br eak-In Per iod 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 a ction on your pa rt is as impor tant as a pr oper brea k-in pe riod. Care ful tre atme nt of a new e ngine will r esult in [...]

45 ADULT SECTION Br eak-In Per iod CAUTION Mixing br ands or using a non- recomm ended oil may c ause serious engine damage. We recomm end the use of P olaris Prem ium 4 All Seas on Synt hetic oil. Never subst itut e or mix oil brands. Checking Engin e Oil Befo re c hec king or r efilling e ngine oil, be sure the engine is stopped and the vehic le [...]

46 ADULT SECTION Operation Fuel When refuel in g, us e 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 fla mm able a nd explos iv e under c er ta in conditi ons. Always exerc ise ext reme caut ion whenever handling gas oline. Always ref uel with t he engine [...]

47 ADULT SECTION Operation Speed/Per form ance Regulation Adults have the re sponsibility for t eachin g chil dren t he proper and s afe way to ride a snowmobile. Please set boundarie s and adhere to them, keep ing your child’ s safety f ore most in your mind. Never a llow a c hild to operate this ma chine without adult superv ision. Under certai[...]

48 ADULT SECTION Operation Sta rti ng the Engine Never sta rt the snowmobile without checking all compone nts to be sure of prope r opera tion. Refer to the Pre -Ride Chec k beginning on page 25. Star ting a Cold E ngine 1. T urn the key to O N. 2. Pull the engine stop switc h (shut-of f switch) up to the RUN position. 3. Pull the choke lever c omp[...]

49 ADULT SECTION Operation Em er gency S topping P r ocedur es The following cha rt lists methods for stopping the engine in the event of an em ergency . SYSTEM WHA T IT DOES THROTTLE CONDITIO N Engine Stop Switc h Interr upts ig nition circuit All Ignitio n Sw itch Interr upts ig nition circuit All T ether Sw itch Interr upts ig nition circuit All[...]

50 ADULT SECTION Operation Pre - Ride W arm -Up Always war m up the engine, drive train and tr ack be fore opera ting the snowmobile. W ith the snowmobile sec ure ly supported b y the re ar bumper with a minimum clea ra nce of 4 ″ (10 cm) f rom the ground, use the following pr ocedur e to prope rly war m up the snowmobile. W ARNING A loose t rack[...]

51 ADULT SECTION Maintenance Polaris R ecommended Maintenance Program Y our Polaris snowmobile has bee n engine ere d and manuf acture d by skilled Polaris personne l to the highest degre e of perf ormanc e and relia bility possible. In or der to ma intain this level of qua lity , your mach ine must have regula r servic e and mainte nanc e inspecti[...]

52 ADULT SECTION Maintenance Care ful periodic ma intenanc e will help keep your vehic le in the safest, most relia ble condition. In spection, adjustme nt and lubr ication of important c omponents ar e expla ined in the f ollowing char t and in the mainte nance se ction of this manual. Ser vice a nd adjustments ar e cr itica l. If you’re not fa [...]

53 ADULT SECTION Maintenance ITEM DAIL Y WEEKL Y OR BEFORE EXTEND ED PERIO D OF OPER A TIO N 50 HRS 100 HRS 150 HRS SEE PA G E Check tr ack ali gnment X 69 Che ck driv e ch ain ten sio n X 60 Check and ti ghten any l oose suspensi on mount ing bol ts X 77 T i ghten ski saddle and spi ndle bo lts if loo se X 74 Check fr ont and rear limit er str ap [...]

54 ADULT SECTION Mai ntenanc e Present thi s sect ion of your m anual to your dealer 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 s ervices p erformed o n the snowmobile. 50 Hou r Init ial M aint enance In spect ion Auth orized P ol aris S ervici ng Deal er Serv icin g T[...]

55 ADULT SECTION Maintenance Spa rk P lugs A new e ngine c an ca use te mporar y spark plug f ouling even though the heat ra nge is proper , due to the prese rvative w hich has bee n added during asse mbly of the e ngine to c ombat rust an d corr osion. A void prolonged idle speed s, as plug fouling and c arboniz ation will r esult. CAUTION Using n[...]

56 ADULT SECTION Maintenance Spa rk P lugs Spark Plug R emoval an d Replacem ent 1. Remove the spark plug ca p. 2. Using the spec ial wrenc h provided in the tool pouc h, rotate the spark plug c ounterc lockwise to re move. 3. Rever se the procedur e for spar k plug installation. T orque to 12-14 ft. lbs. (16-19 Nm). Fuel V alve/Fuel Lin es The fue[...]

57 ADULT SECTION Maintenance Car bur etor Proper c ar buretor a djustment is critic al, since a mixture too lean (too much a ir , too little fue l) will r esult in over hea ting of the c ombustion cha mber c ausing pre -ignition of the fue l. This results in piston burning, bearing fa ilure , or complete engine fa ilure. A lea n mixture ca n be the[...]

58 ADULT SECTION Maintenance Throttl e Cabl e Lubri cation W ith the engine of f, lubricate the thr ottle cable o ccasi onal ly . Turn the h andl ebars to the lef t and lubric ate liber ally with Po laris Al l Seas on Grease. Choke /Ca ble Lubr icati on Lubrica te the choke slide and ca bles occasional ly as shown. Operat e the choke intermitte ntl[...]

59 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 wea r . Y our snowmobile dea ler ca n install a new brake band when nec essar y .[...]

60 ADULT SECTION Maintenance Chain T en sioner Inspec t the chain. The cha in should have 1 ″ of de flec tion as shown. If not, loosen the nut on the cha in tensione r (A) a nd ra ise until 1 ″ (B) of defle ction is atta ined. T ighten nut to 15-18 ft. lbs. (20-24 Nm). Whe n the c hain co mes within 1/8 ″ ( C) of the muf fler mount bra cket ([...]

61 ADULT SECTION Maintenance Lubri cati on NOT E: Driveline nois e is norm al and inherent in a c hain drive system such as this machi ne uses. T o ensure long life of the snow mobile’ s drive line, lubricate a s follows: S Lubrica te Point A ever y 15 hours of ope ration w ith a small a mount of Pol aris P remi um Al l Seaso n Grease. S Lubrica [...]

62 ADULT SECTION Maintenance Oil Level Mainta in the oil leve l betwe en 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 Snow mobi le Keeping your snowmobile cle an w ill not only impr ove its a ppea ranc e but it can a lso extend the life of va[...]

63 ADULT SECTION Maintenance Controls and L inkage All bushings, spindle shafts, and tie r od ends should be coate d with a light coa t of oil or grea se. Thr ottle a nd bra ke c ontrols a nd ca bles should be lubric ated with Pola ris Premium All Sea son Grea se. Force a small amount of lubrica nt down the c able. Bearings T o pre vent cor rosion [...]

64 ADULT SECTION Maintenance Engi ne Proper of f-sea son prepa ration o f the engine and fuel system is vital to the pre vention of rust and co rrosion f ormation on pr ecision e ngine parts during stor age. W ithout proper stora ge, jet re striction c an c ause le an c onditions and very poor slow spee d driving quality . When pr epar ing your sno[...]

65 ADULT SECTION Maintenance Car buretor P rotection During Off - Season Storage When pr epa ring your snowmobile for of f-season stor age w e 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[...]

66 ADULT SECTION Maintenance T ra nspor ting the Snow mobi le Whe neve r the snowmobile is transpor ted the following mea sures should be taken: 1. T urn the fuel valve off . 2. Be sure the f uel cap is installe d corre ctly . 3. Alwa ys tie the snowmobile to the transporting unit secur ely using suitable str aps. NOT E: Transportat ion to and f ro[...]

67 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. Ser ious injuries may be caused by the oper ator ’ s hands, f eet or c lothing bec oming entangled in t he trac k. Be alert . A lways sit proper ly on the s eat. T ra ck and S uspensi on Under norma [...]

68 ADULT SECTION Maintenance T rack Adjustment If the tra ck nee ds adjustment: 1. Loosen rea r idler shaf t bolt (D). 2. Tight en or loo sen th e track adj ust ing s crews (E) as neces sary to provide equa l adjustment on both s ides of the trac k. 3. Repea t measure ment on the other side of the track. NOT E: Check m ore f requently when the m ac[...]

69 ADULT SECTION Maintenance T rack Alignment A periodic c hec k should be made to see that the track is ce ntere d and running eve nly on the slide rails. Misalignmen t will ca use exc essive wea r to the trac k an d slide ra il. 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 [...]

70 ADULT SECTION Maintenance T rack W arm Up When stor ing your snowmobile outside overnight, it is rec ommende d that the tra ck be warmed up pr ior to driving the snowmobile. This reduc es 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 and abruptly e ngage the clutch . A[...]

71 ADULT SECTION Maintenance T rack Inspection W ARNING Inspec ting t he tr ack while t he engine is running can r esult in serious personal injur y if t he tr ack should being t o mov e. Never inspect t he trac k with t he engine running Using a hoist or jac kstand, safe ly lift and suppor t the rea r of the snowmobile of f the ground. Rotate the [...]

72 ADULT SECTION Maintenance Hi - Fax Replacement The 120 PRO X uses XTRA Lit e st yl e Hi-F ax. When any are a of the Hi-Fax is worn to 7/16 ″ (1.1 cm), it should be replaced . T his wi ll sav e wear on other vital compone nts. T h es l i d er a i li sd e s i g n e dt o opera te in conditions with adequa te snow cover to provide suf fic ient lub[...]

73 ADULT SECTION Maintenance T ra ck Lubr icati on T rack f ailur e, loss of vehic le c ontrol and br aking a bility ca n result f rom exten ded us e of thi s vehi cle on s urfaces pro vid ing m arginal l ubr icati on betwee n hi-f ax and tr ac k guide clips. Example s of mar ginal lubrication would include la kes without snow c over , icy trails a[...]

74 ADULT SECTION Maintenance Steering Inspection and Adjustment The ste er ing assembly of the mach ine should be check ed 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 handleba rs in stra ight ahe ad position and me asur ing from the straight edge of the ski s, t he m easurem ent betwee n the s[...]

75 ADULT SECTION Maintenance Handlebar Adjustment 6. Slide the handlebar pa d upward t o access t he adj ust er bolts. If additiona l room is requir ed, unzip one of the handleba r pad z ipper s and roll the pad to the side. 7. T o adjust, remove the upper flange nut and ca rriag e bolt. 8. Loosen the lower flange nut only enough so the br ac ket c[...]

76 ADULT SECTION Maintenance Ski S kags The s kag (A) i s a repl aceable b ar atta ched to the under side 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 con tact wi th road s and other ba re ter ra in. W e recomm end th at sk ags b e checked once a week to ma inta[...]

77 ADULT SECTION Maintenance Sus pension Lubr ic ation T o mainta in rider comfort and to r etar d wea r of the pivot shafts, the suspension pivot shaf ts should be lubric ated with Pola ris Premium All Season G rea se se vera l times during the season a nd aga in befo re sum mer s torag e each year . Th e ridi ng ch aracteri sti cs o f the snowmob[...]

78 ADULT SECTION Maintenance Suspe nsion C ompone nts Suspension Lubric ation points ar e indica ted by a L . 1. Front Limite r Stra p 8. Rail Bumpe r 2. T orsion Spring Sleeve s 9. T orque Ar m 3. T orsion Spring 10. Rail 4. C arrier Wh eel 1 1. Hi-fax 5. Rea r Limiter Stra p 12. T oe Gua rd 6. S pacer 13. Idler Wh eel 7. Adjuste r Bolts 4 6 2 1 5[...]

79 ADULT SECTION Accessor ies Maintenance Items and Accessories The tools and ma intena nce items mentione d in this book, as well as a long l ine of o ther P olari s access ori es, are availabl e at your Po laris deal er . Pa int Code s Colo r Descri pti on Polaris “P” No. Raw Mater ial No. Indy Red P293 8520297 Indy Black P067 8520246 Paints [...]

80 SPECIFICA TION S Jetting Chart Ambient T emperature Below -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 Above +50 _ F Above +10 _ C Altitude in Meters ( F t ) 0-600 (0-2000) 75 72.5 72.5 72.5 70 70 M e t e r s (Feet ) 600-1200 (2000 - - 4[...]

81 SPECIFICA TION S Ca pa cities a nd D imen sion s Body St yle Mi ni Indy Ri ders/ W eight 1/150 lbs . ( 68 kg) maxi mum 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 Distan ce 30 in. (76.2 cm) Wid th 34 in. ( 86.4 cm ) Brake T y[...]

82 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2871281 Premi um 4 Synt heti c 0W -40 E ngine Oi l ( 4- Cycle) (qt .) Gearcase / T ransmi ssion Lubri cant s 2873602 Premi um Synthet ic Gear case Lubricant ( qt. ) 2871653 Premi um Fr ont G earcase Lube ( 8 oz.) 2871654 Pre mium D rive H ub F luid (8 o z.) Grease / Speci ali zed Lubrican[...]

83 WARRANTY Ser vice A nd W arr anty Infor mati on Obtaining Ser vice and W ar ranty Assistance Read and unde rstand the ser vice da ta and the Polaris war ranty informa tion containe d in this manual. Contact your Polaris dea ler f or replacem ent part s, serv ice or warran ty . Y our d ealer recei ves frequ ent updates on c hange s, modifications[...]

84 WARRANTY Li mit ed Warran ty Pola r is S al e s Inc . , 2100 Highwa y 55, Medi na , MN 55340, provi de s a ONE YEAR LIM - ITED W ARRANTY on all c ompone nts of t he Pola ris s nowmobi le a ga ins t de fe c ts i n ma te r ia l or wor kma nshi p. This w ar r a nty cove r s the pa r ts a nd la bor cha r ges f or re pa ir or replacem ent o f defecti[...]

85 WARRANTY Limita tions of warrantie s and remedi es ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LI MITED T O THE IM- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TI CU- LAR PURPOSE) ARE LIMI TED I N DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W AR- RA NT IES N OT S T A TE D IN TH IS [...]

86 WARRANTY Conditions and Exc lusi ons In or de r t o qua li f y for wa r ra nty , the pr oduc t m ust ha ve bee n pr ope rl y s et up a nd te ste d by a Po laris Dealer (if ap plicab le). F ailure o f any dealer to p erform th e req uired v eh icle Pre - - De li ve ry Ins pe ct i on, per f orm a ll a ppl ic a ble s e rvi c e bull e t ins a nd hav[...]

87 WARRANTY Pol ar is Se cond Y ear E ngine S er vice C ontr act Sec ond Y e ar Engi ne Ser vi ce Cont r ac t is s t anda r d on al l e li gibl e ne w a nd unuse d snow mobil e s tha t we re Snow Che c ke d thr ough a n aut hor iz e d Pola r is de a le r duri ng t he Ma rc h/ Apr il Snow Chec k promot ion. The f re e Se c ond Y e ar Engi ne Se rvi [...]

88 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 THI S VEHICLE I F 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 au tho rizatio n for e xpor t fr om Pola r is I nd[...]

89 INDEX A- B Accessories 79 ..................... Auto C hain T ensioner 60 ............. Brake A djustm ent 59 ................ Brake L ever T ravel 58 ............... Break-In P eriod 44-45 .............. C Carburetor 57 ..................... Carburetor P rotection 65 ............. Checki ng Engine O il 45 ............. Choke and C able L ubrica[...]